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VHA Shifts Priorities to 206 Main Blade Development
Van Horn Aviation recently shifted its development priorities to focus on the 206 main rotor blade program after the MD500 main blade flight test program was cut short by unexpected unavailability of the test aircraft.
From May through August 2013, VHA and MD Helicopters personnel prepared the loaned MD530F for flight test, installing strain gages and other instrumentation on the aircraft and the VHA composite main rotor blades. Following successful hover tests at the VHA facility in August, the instrumented MD530F returned to the MD Helicopters facility for forward flight tests. Over the next four months, the VHA flight test team achieved successful track and balancing of newly redesigned blades, high-g maneuvers, and forward flights to 130 kts.
VHA had expected to complete flight test testing on the loaned MD530F to FAA certification standards and bring the rotor blades to market early in 2014. However, MD Helicopters determined they had other priorities for the loaned aircraft and terminated the flight test program in early December.
This was the third round of flight testing since the program began in April 2011. VHA’s challenge was to replace the current metal symmetrical airfoil main rotor blades with a NASA-developed laminar flow composite airfoil while implementing minimal control system modifications. The MD500 series’ non-hydraulically boosted control system and tailored collective stick balance spring proved to be particularly sensitive to changes in main rotor blade design. During the VHA MD500 main rotor blade development program, VHA engineers completed several design modifications including trim tab alteration, root fitting changes and center of gravity (CG) adjustments.
The ability to fly the latest iteration of the VHA composite blades to 130 kts on a helicopter with a maximum cruise speed of 134 kts proved the success of the VHA design. The knowledge and experience gained from the MD530F flight test program will be carried over to the 206 main blade program. While the loss of the MD530F test ship forces refocusing of VHA priorities, VHA intends to resume certification testing of the MD500 series main and tail rotor blades after purchasing its own test helicopter in fourth quarter 2014.
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For 206L LongRanger operators flying P/N 20633000-101 serial numbers A007-A009 or A012-A104, we would like to remind you that these blades are subject to AD 2022-22-08, which requires recurring tap inspections every 400 flight hours or 2,400 engine starts, whichever comes first. You can learn more about the tap test requirements and procedure in our video . These blades are likely to develop a delamination in the area of the weight pocket on the lower surface of the blade. The AD further requires removing the blades from service if the delamination reaches 6 inches in length. However, extensive company testing indicates that all blades will likely achieve their full retirement life before that occurs. So long as the delamination is monitored and does not exceed the permitted length, the blades are entirely safe to fly with no adverse effects on aircraft behavior or performance. Operators are required to report their findings at every inspection interval to VHA for tracking using the form on the last page of Service Bulletin 33000-4 . Completed forms should be emailed to info@vanhornaviation.com . Providing this data helps to ensure all operators of these blades remain safe. All of the identified blades are likely to have delaminations, so if none are detected please contact us for assistance. In addition, this AD is considered an interim action and once sufficient data is gathered it may be updated to reduce the required frequency of inspection. Refer to AD 2022-22-08 and SB 33000-4 for further information.
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