Category Archive: News

What Will Succeed the UH-60 Black Hawk?

Which Helicopter Will Be the New Black Hawk?

The Sikorsky UH-60 Black Hawk has been the gold standard in military combat helicopters since it was first deployed in 1979. Now, as the Black Hawk nears retirement, two airframes have emerged as potential replacements.

Almost half a century old, the Black Hawk has been employed by almost 30 militaries worldwide. Bill Fell, who is a Sikorsky test pilot as well as an army veteran helicopter pilot, has been building Black Hawks for almost 50 years. In his opinion, the Black Hawk is “the greatest helicopter the world has ever known.”

The helo that replaces the Black Hawk will be chosen by the Future Long-Range Assault Aircraft (FLRAA) Program. The winning helicopter will be selected in 2022 and deployed in 2030. Industry insiders agree that the Black Hawk will be hard to beat. Here are the two top candidates as of today:

Bell V-280 Valor

The Bell V-280 resembles the V-22 Osprey. It’s a bit smaller and flaunts a V-tail. Instead of one large rotor assembly, like the Black Hawk, the V-280 tilts two large prop-rotors on each wingtip, like the Osprey. A tilt-rotor aircraft, the Valor behaves like an airplane while flying forward and like a twin-rotor helicopter in vertical takeoff.

Sikorsky-Boeing SB-1 Defiant

Sikorsky-Boeing, a client of Aerospace Manufacturing, has created what it calls a compound helicopter. This helo boasts “stacked, counter-rotating main rotors, a pusher propeller, and aircraft-like rudders” that equip the pusher propeller with strong forward thrust. That, in turn, reduces the need to tilt the primary rotor for forward flight.

The Defiant’s counter-rotating main rotors supply additional lift while delivering a smooth, steady ride. Aviation experts say the SB-1 has “speed, climb, take-off/landing advantages over normal helicopters.”

These designs meet the Army’s demand for a “multi-mission VTOL aircraft that flies much faster and farther than the workhorse Black Hawk.” The Army wants the new model to reach speeds of 230 knots (265 mph) or more. That’s 33.3 percent faster than the 159-knot (183 mph) twin-engine Black Hawk.

SB-1 Defiant or V-280 Valor?

Both helicopters have racked up extensive flying time, and both have showcased their talents in public displays. They differ from the UH-60 in the way they fly.

The Valor’s tilt rotor and the Defiant’s pusher propeller give pilots the ability to control thrust on multiple axes simultaneously. That confers agility that the UH-60 cannot achieve.

 

Procure Aerospace Fasteners from AMI

AMI is an AS9100 and ISO:9001 accredited, vertically integrated manufacturer of high strength, close tolerance aerospace pins, bolts, threaded rods, studs, screws and built-to-print specials.

Our clientele includes industry leading OEMs like Boeing, Bombardier, DLA, General Electric, Lockheed Martin, and Sikorsky.

We are a Philips Screw licensee that specializes in both large and small runs. Whether you need a prototype or large runs for your assembly line, you can rely on AMI for rapid delivery and short lead-times.

Search our expansive inventory or launch your Custom Quote today!

 

Aerospace Manufacturing Maintains Positive Outlook for 2020, 2021, and Beyond

Small and medium-sized enterprises (SMEs) worldwide are feeling the sting of COVID-19. These firms, which are the bread and butter of the aviation industry, are seeing demand for their products diminish by the day.

Many SMEs are finding it increasingly difficult to remain optimistic while wondering if they can stay above the water for the remainder of 2020.

Even with the help of governments and the easing up of lockdowns and work-at-home orders, reopening a business can be costly. For SMEs, the lifting of restrictions can drain dwindling reserves even more.

Sanitized work stations, marking tape on factory floors and social distancing can get things up and running on the supply side. On the demand side, many SMEs are wondering whether they will still have customers once production resumes.

According to the German trade association BDLI, Airbus needs a production level of at least 50 percent of what was originally projected for 2020. If that’s not accomplished, “an entire domestic manufacturing infrastructure that has flourished alongside the European airframer over more than 40 years could collapse.”

The situation is not much different in other countries where Airbus is part of a “complex global supply chain for both big aircraft manufacturers.”

SMEs have been pressured to borrow money to purchase scarce raw materials and to finance cutting-edge automation technologies to comply with accelerated ramp-up schedules. Now, they are watching their end markets disappear because of extended stay-at-home guidelines and travel restrictions.

These companies are justifiably concerned about whether demand for their products will resume within the foreseeable future, if at all.

There is also worry about the total combined Airbus and Boeing output in 2020 and 2021. Will it be sufficient to achieve the 50 percent of 2019’s output which BDLI says is needed by member companies to remain up and running?

First-tier suppliers like AeroSystems and GE Aviation have slashed their workforces. Lost jobs threaten both production and supply. Many SMEs work with a single manufacturer for whom they customize their work and on whom they rely for the lion’s share of their income.

Outstanding customer payments for deliveries made before the current crisis combined with government assistance can help SMEs to hang on, at least for the short term. Meanwhile, the fate of these companies is being determined by a virus that will decide when and where people can fly.

Challenges notwithstanding, AMI has a positive outlook for 2020, 2021 and beyond.

As an essential business and an SME, Aerospace Manufacturing is maintaining production output with contingencies in place to prevent the introduction of or the spread of the virus on our production floor.

We are continuing to partner with other aerospace and aviation companies. Our manufacturing capabilities range from our Phillips-Licensed head and recess configuration product line to standard and custom manufacturing with built-to-print specials.

Aerospace Manufacturing also owns and operates a warehouse where we maintain a large stock of inventory for AOG with rapid turnaround and delivery times.

 

Procure Aerospace Fasteners from AMI

AMI is an AS9100 and ISO:9001 accredited, vertically integrated manufacturer of high strength, close tolerance aerospace pins, bolts, threaded rods, studs, screws and built-to-print specials.

Our clientele includes industry leading OEMs like Boeing, Bombardier, DLA, General Electric, Lockheed Martin, and Sikorsky.

We are a Philips Screw licensee that specializes in both large and small runs. Whether you need a prototype or large runs for your assembly line, you can rely on AMI for rapid delivery and short lead-times.

Search our expansive inventory or launch your Custom Quote today!

The Impact of COVID-19 on Airline Maintenance Schedules

Commercial airplanes cannot simply be parked on a runway to wait out the pandemic. Whether it’s fine-tuning an aircraft’s flight-control system, maintaining safe and effective brakes, or getting rid of nesting birds, planes need lots of time and attention, even while grounded.

Humidity can corrode parts while damaging a plane’s interior. Some planes must be filled with gas just to keep tanks lubricated and prevent the aircraft from rocking in the wind.

In Abu Dhabi, maintenance engineers at Etihad Airways PJSC work 24/7 to keep grounded planes in good condition. Their work includes firing up aircraft, running engines, and protecting high-tech components from penetration by dust and dirt.

Even so, all but the most essential equipment servicing is being deferred to balance expenses against income. The extent to which these measures continue depends on the duration of the current crisis and the pace of economic recovery.

Given the current uncertainty, total lost airline revenue is difficult to predict. In late February of 2020, it was roughly $29 billion. In mid-April, it was $314 billion. That’s 55 percent less revenue in 2020 than in 2019 so far.

How airline companies handle maintenance affects not just the fleets in question. It also impacts suppliers all the way down the supply line. When planes are parked and nonessential maintenance is deferred, all aftermarket sectors feel the crunch. As demand for air travel resumes, some areas will recover faster than others.

For green time engines, MRO services may be placed on hold indefinitely. According to Dietmar Focke, head of engine services at Lufthansa Technik, the longer the crisis continues, the longer it will take to restore aircraft operations to pre-COVID-19 levels and the bigger the impact on airline service providers will be.

Focke believes that the effects of COVID-19 on the airline industry could extend through 2021 or longer. Accordingly, MRO requests could shift further out into the future depending on the pace of recovery.

High-end maintenance jobs like engine overhauls are being postponed while mobile repairs, spare engines and on-wing services are likely to be employed instead. This won’t necessarily help MRO providers, but it can benefit engine lessors such as Engine Lease Finance, FTAI Aviation and Willis Lease Finance.

Engine lessors should see improvement once commercial airlines resume service. Lessors should also benefit when backed-up engine overhauls are again taking place.

Prior to the crisis, the impressive reliability of narrowbody turbofan airplanes led to stretched ratios of active to spare engines. As a result, there is now little room for deferred engine maintenance.

 

Procure Aerospace Fasteners from AMI

AMI is an AS9100 and ISO:9001 accredited, vertically integrated manufacturer of high strength, close tolerance aerospace pins, bolts, threaded rods, studs, screws and built-to-print specials.

Our clientele includes industry leading OEMs like Boeing, Bombardier, DLA, General Electric, Lockheed Martin, and Sikorsky.

We are a Philips Screw licensee that specializes in both large and small runs. Whether you need a prototype or large runs for your assembly line, you can rely on AMI for rapid delivery and short lead-times.

Search our expansive inventory or launch your Custom Quote today!

Coronavirus Aboard Ballistic Missile Submarines and Aircraft Carriers

Coronavirus seems to be everywhere lately, even aboard nuclear-powered aircraft carriers and ballistic missile submarines. To date, the virus has turned up on Russian, Dutch and American warships and effectively removed these heavy hitters from the game.

Navies worldwide are testing their sailors for coronavirus. Many sailors are testing positive. Infected crew members are being quarantined and ships are being locked down and sent home. Deep underwater, other submarine crews may know nothing of the virus at all.

Fourteen ballistic missile submarines comprise the U.S. fleet. Eight or nine subs are typically out on patrol at any given time. Four or five are stationed and under “hard alert.” They are ready to deploy at a moment’s notice. Once deployed, they may be gone for 90 days at a time.

A former French Navy commander believes that his country’s submarine crews have probably not been told about the current pandemic. The commander added that strategic nuclear submarine crews may spend over two months on underwater patrol. They are kept in the dark about current world events to help them stay focused on the business of nuclear deterrence.

In Russia, the cruise missile submarine Orel has been locked down following a visit from an infected civilian. A Dutch ballistic missile submarine has reported that eight sailors out of 58 have tested positive for coronavirus. The Dutch submarine is presently headed home to the Netherlands early.

Sailors on two U.S. Navy nuclear-powered aircraft carriers have tested positive for coronavirus. Two cases were detected aboard the USS Ronald Reagan which is currently stationed in Japan.

Aboard the USS Theodore Roosevelt, the virus was detected after the nuclear aircraft carrier had visited Vietnam. It was ordered to dock in Guam and have the ship’s personnel tested for the virus. As many as 200 sailors aboard the USS Theodore Roosevelt have now tested positive for COVID-19. That’s roughly three to five percent of the total crew.

Captain Brett Crozier, the ship’s captain, wrote to the San Francisco Chronicle in protest. He said that his warship was ill-equipped to quarantine so many sailors. He appealed to his commanding officers to remove the infected sailors instead. Crozier said that “Keeping over 4,000 young men and women on board the TR is an unnecessary risk and breaks faith with those Sailors entrusted to our care.”

On the other hand, it must be asked whether it is practical to completely evacuate a nuclear aircraft carrier with munitions, planes and a nuclear power plant on board.

Procure Aerospace Fasteners from AMI

AMI is an AS9100 and ISO:9001 accredited, vertically integrated manufacturer of high strength, close tolerance aerospace pins, bolts, threaded rods, studs, screws and built-to-print specials.

Our clientele includes industry leading OEMs like Boeing, Bombardier, DLA, General Electric, Lockheed Martin, and Sikorsky.

We are a Philips Screw licensee that specializes in both large and small runs. Whether you need a prototype or large runs for your assembly line, you can rely on AMI for rapid delivery and short lead-times.

Search our expansive inventory or launch your Custom Quote today!

 

A Deep Dive into the Lockheed Martin F-16 Production Development

Aerospace Manufacturing has been following the Lockheed Martin F-16 Fighting Falcon program.  Here’s what you need to know.

The F-16 is the most successful multipurpose fighter jet presently in service. The 3,000 jets fly in 25 countries. The F-16 Block 70/72 is the latest and most technically advanced configuration of the F-16.

It boasts new abilities extracted from the F-16V configuration. The new flyer has a structural life that exceeds previous F-16 models by 50 percent. The new avionics architecture lengthens the structural life of the plane even more.

Production started on the F-16 on November 11, 2019 in Greenville, South Carolina. Production startup dovetails perfectly with the rapidly growing market for F-16s all over the world.

The work is generating an abundance of jobs in the Greenville area that are supported by suppliers in 41 states. In addition to structural and capability upgrades, new production guarantees that the international F-16 fleet will be in service until 2016 or longer.

The F-16 Block 70/72 has other upgraded capabilities such as Advanced Active Electronically Scanned Array Radar. The new plane comes equipped with high-tech software that wasn’t available with earlier versions of the plane.

Additional features include advanced datalink, targeting pod and weapons. The F-16 is fitted with precision GPS navigation in addition to the Automatic Ground Collision Avoidance System (Auto GCAS).

With almost 40 years of F-16 weapon integration experience, no other company can compare with Lockheed Martin. In conjunction with the U.S. Air Force and foreign military sales customers, the company has certified over 3,300 carriage and release configurations for over 180 weapon and store types.

Lockheed Martin’s experience as a weapons integrator has equipped the F-16 to become one of the most versatile multi-role fighter jets in history. As an F-16 Original Equipment Manufacturer (OEM), Lockheed Martin can design, engineer, integrate and sustain an F-16 weapons system that’s customized to meet your needs.

 

Procure Aerospace Fasteners from AMI

AMI is an AS9100 and ISO:9001 accredited, vertically integrated manufacturer of high strength, close tolerance aerospace pins, bolts, threaded rods, studs, screws and built-to-print specials.

Our clientele includes industry leading OEMs like Boeing, Bombardier, DLA, General Electric, Lockheed Martin, and Sikorsky.

We are a Philips Screw licensee that specializes in both large and small runs. Whether you need a prototype or large runs for your assembly line, you can rely on AMI for rapid delivery and short lead-times.

Search our expansive inventory or launch your Custom Quote today!

Flight Testing for Boeing 777X is Now Underway!

On January 25, 2020, fight testing for the Boeing 777X began. The first plane took to the skies from Paine Field. The 777X incorporates innovations from the 787 Dreamliner. Hailed as the “flight experience of the future,” the plane features custom architecture and a roomy, comfortable cabin. The company is now moving forward with flight testing and is preparing for the first 777X deliveries. The aircraft has so far flown four times and is presently stationed in Seattle’s Boeing Field.

Along with other tests, Boeing reports that the 777X will undergo avionics testing including stability control and low-speed aerodynamics. Three additional 777-9s on the Everett flight line will be joining the test fleet and plan to be flying by second quarter.

Flight-test programs generally include a few thousand hours of flight time and a small number of test airlines flying several times weekly. For example, Airbus A350-900 flight testing lasted for about 15 months. Five planes traveled about 2,600h.

However, because timelines for development programs and the certification process can be uncertain, the company declined to share detailed information at this time.

Michel Merluzeau, an aerospace analyst with Consultancy AIR said, “I really anticipate a fairly smooth ride. A very diligent and methodical and smooth ride.” He added that “The real area of focus will be the engines and flight control system.”

Aerospace consultant and former Boeing engineer Peter Lemme worked on several of Boeing’s commercial airline flight testing programs. Lemme says that because the 777X doesn’t have an ACAS system, the fly-by-wire system would address any unexpected issues with pitch.

Stretched fuselage allows the 777X to achieve a larger composite wing. The 777X boasts a longer wingspan, and its wings have folding tips that retract while the plane is landing.

The folding wing design reduces drag that collects on a plane’s wing tips. Less drag improves fuel efficiency for cheaper operation. The design also enables the 777-9 to carry about 30 more passengers.

About Aerospace Manufacturing

Aerospace Manufacturing is an AS9100 and ISO:9001 accredited, QSLM approved manufacturer of high strength, close tolerance aerospace fasteners that’s trusted by OEMs like Lockheed Martin, Boeing, NAVICP, Sikorsky, Bombardier and General Electric.

Our strategic location next to Newark Liberty International Airport (EWR) means same-day shipment is available on stock items and very short lead-times of one to four weeks can be met on most fasteners.

We are a Philips Screw licensee that specializes in both large and small runs. Whether our customers need a prototype or large runs for their assembly line, they know they can rely on AMI for rapid delivery and short lead-times.

Search our Inventory or Launch Your Custom Quote today!

The F-35 Lightning can Finally Survive a Lightning Strike

Though 2020 has presented its fair share of challenges and disappointments, Lockheed Martin is slated to have a massive triumph by the end of the year. More specifically, they’re anticipating successful upgrades to their F-35 fighter jets, making them equipped to fly the friendly skies. Earlier this year, the Air Force discovered an issue with the Onboard Inert Gas Generation System. This system is designed to protect against lightning strikes. It does so by pumping fuel tanks with nitrogen-enriched air.

Unfortunately, maintainers in Utah noticed that one of the system’s tubes were damaged, effectively ruining its purpose. Eager to remedy the problem, the Defense Department and Lockheed have agreed to fix the OBIGGS before moving forward. According to Darren Sekiguchi, the vice president of F-35 production, their team will focus on strengthening the brackets within the tubes of the OBIGGS to ensure that they’re secure and less sensitive to movement. These modifications are already underway, and Sekiguchi is confident that the updated system will be ready for delivery by the end of the year.

While Lockheed has made productive efforts on this front, the Defense Department is now keen to implement changes in existing jets used by the Air Force. Sekiguchi maintains that administering any adjustments is contingent upon the service’s availability, stating that the reconstruction period could take years in the field. It’s not yet clear whether Lockheed will be financially responsible for these upgrades, but the F-35 Joint Program Office is doing all they can to oversee smooth, streamlined revisions. Until the F-35As have been reworked, they can’t fly within 25 miles of lighting or thunderstorms.

When these complications came to light in June, the F-35 Joint Program Office shared that 14 of the 24 models had damaged tubes. Not surprisingly, Lockheed immediately halted production, pausing deliveries so that they could validate these claims. Operations were stagnant for three weeks, subsequently resuming later that month. When Lockheed eventually resolves the OBIGGS issue, it’s presumed that they’ll have perfected F-35 production methods. With the COVID-19 pandemic, addressing the OBIGGS tube situation proved even more difficult.

From the end of May to the beginning of September, Lockheed underwent schedule changes. The 2,500 employees working on the F-35 in Texas were required to work two weeks, followed by a week off. In addition to keeping workers safe, Lockheed executives state that this slowdown was necessary to accommodate delays across the supply chain. Despite these shortcomings, Lockheed is still looking forward to introducing 121 F-35s within the next couple of months. This is 20 fewer jets than their initial forecast, but it’s an impressive feat, nonetheless.

During the summer, Lockheed encountered an onslaught of roadblocks. With that said, F-35 production slowed considerably, with the manufacturing team eking out about nine jets per month. Lockheed’s goal was to increase this number to 14, but some suppliers are still facing significant disruptions. As a result, Lockheed experienced losses in both daily routines and future assembly. Their European suppliers got hit the hardest, requiring Lockheed to get creative during times of despair.

Sekiguchi is happy to report that F-35 production is slowly but surely returning to business as usual. Even still, he does see the occasional setback with global suppliers. Fortunately, these hiccups pale in comparison to what they endured a few short months ago. Sekiguchi takes great solace in knowing that Lockheed is both willing to and capable of overcoming unprecedented obstacles. In the meantime, Sekiguchi is patiently awaiting the arrival of the new and improved F-35 fighter jets.

Procure Aerospace Fasteners from Aerospace Manufacturing (AMI)

AMI is an AS9100D:2016 and ISO: 9001:2015 accredited, vertically integrated manufacturer of high strength, close tolerance aerospace pins, bolts, threaded rods, studs, screws, and built-to-print specials. Our clientele includes industry-leading OEMs like Boeing, Bombardier, DLA, General Electric, Lockheed Martin, and Sikorsky.

We are a Philips Screw licensee that specializes in both large and small runs. Whether you need a prototype or large runs for your assembly line, you can rely on AMI for rapid delivery and short lead-times.

Search our expansive inventory or launch your Custom Quote today!

Notice Regarding COVID-19

Dear Valued Customers and Partners,

We recognize that with the constantly changing COVID-19 situation around the world, this is an unprecedented time for everyone. Our hearts and thoughts go out to each and every one of you.

We would like you to know you have our commitment to continue providing you with the products and services you depend on. For more than 30 years, Aerospace MFG (AMI) has focused on our mission to produce products and leverage service at unparalleled quality standards. This enduring mission guides us as we closely monitor, assess, and respond to this situation.

In response to the current situation, we’ve implemented our Business Continuity Plan — which examines all areas of business operations — and have taken actions to ensure continued service to our customers. Rest assured, we are prepared to serve you.

First and foremost, our plan ensures the health and safety of our employees, so we can continue to deliver and support the products you count on. At our facilities, this means:

  1. Increased workspace sanitization
  2. Instituting workplace and personal hygiene standards
  3. Staggered breaks and shifts
  4. Mandatory physical distancing
  5. Non-essential business travel is suspended. Additionally, we urge extreme caution regarding personal travel
  6. Meetings with visitors are suspended. We invite all clients and suppliers alike to hold teleconference meetings whenever possible
  7. Our plant is closed to any outside visitors, except for shipments

Nothing in this correspondence is, or is intended to be, understood or relied upon as direction or authority to deviate from any of terms and conditions of any purchase order.

Please refer to Centers for Disease Control (CDC) for additional information, updated recommended medical protocols and news regarding any announcements from state or federal authorities.
These precautionary measures have been taken to limit the potential spread of the virus, to support our employees in this challenging time, and to ensure we maintain our ability to serve you, our customers, for the long term. Our senior leadership team remains vigilant and is monitoring the situation in real-time and responding rapidly as conditions evolve.

Please be safe and stay healthy.

Aerospace MFG (AMI)

Travel Industry Braces for Cancellations Amid the Growing Coronavirus Panic

At first, it seemed like just another run-of-the-mill flu virus. However, it’s turning into something much bigger than that. The coronavirus could have a devastating effect on the travel industry and many other industries as well.

Travelers are not the only ones affected. Businesses are restricting or canceling employee travel as well as trade shows, conferences, conventions and major sporting events. The convention business is the livelihood of local hotels and restaurants, says Joe Schwieterman, a transportation professor at DePaul University. He believes that the cancellations could be the death of establishments already on the verge of collapse.

The curtailment of business travel in particular and travel spending in general could cost the travel industry $46.6 billion dollars every month. Travel spending could drop by 37 percent. The travel industry is already concerned about not turning a profit this year. Employees fear that layoffs are not far behind.

Delays in producing and distributing a virus test kit have created uncertainty. People don’t know if they have the virus or not. Concerns over where the virus is now and where it will go next is causing people to panic and cancel travel plans.

Scott Solombrino, Executive Director of the Global Business Travel Association, says, “What we’re trying to tell people and message people is, ‘Look, travel is still safe. Take the normal precautions you would take: Wash your hands, don’t be coughing on people, you know, try to be diligent while you’re traveling.’ But we don’t see any reason why people wouldn’t be traveling, certainly domestically.”

Media coverage about the virus has been upsetting for many travelers. Agencies are getting frantic calls from clients wondering if they should just cancel everything and stay home.

Tammy Levent, CEO of Elite Travel, says that clients are freaking out and calling her day and night. Levent says, “Travel agents have to become psychiatrists, OK? We have to become therapists for all these people who call in.”

United Airlines announced that it will waive change fees for domestic and international flights made between now and March 31. However, Levent cautions travelers that canceling or changing flights to destinations without travel restrictions will not excuse them from paying the fees they will be charged.

Many fliers are unconcerned about the coronavirus. Arriving in Los Angeles from Cologne, Germany, Adrian Schmetz, 34, believes that the media is overhyping and overplaying the danger of the virus. Schmetz adds, “It’s not going to affect my choice of travel at all.”

However, Los Angeles International Airport parking attendant Myla Maramba says that business is beginning to fall off. She fears a cut in hours or even layoffs. “It’s going to affect a lot of people’s livelihoods,” Maramba says.

About Aerospace Manufacturing

Aerospace Manufacturing is an AS9100 and ISO:9001 accredited, QSLM approved manufacturer of high strength, close tolerance aerospace fasteners that’s trusted by OEMs like Lockheed Martin, Boeing, NAVICP, Sikorsky, Bombardier and General Electric.

Our strategic location next to Newark Liberty International Airport (EWR) means same-day shipment is available on stock items and very short lead-times of one to four weeks can be met on most fasteners.

We are a Philips Screw licensee that specializes in both large and small runs. Whether our customers need a prototype or large runs for their assembly line, they know they can rely on AMI for rapid delivery and short lead-times.

Search our Inventory or Launch Your Custom Quote today!

Here’s Why the SR-71 Was Actually Designed to Leak Fuel All Over the Tarmac

The SR-71’s Fuel Leakage: Accidental or Intentional?

Esteemed as one of the most advanced spy planes used in the Cold War, the SR-71 is hallmarked for its intense speed, pristine construction, and unrivaled flying capabilities. Designed by Lockheed Martin, the SR-71 was built in response to a CIA request. NASA and the United States Air Force were responsible for operating it, and this impressive aircraft first took flight in December of 1964. Dubbed the “Blackbird,” the SR-71 was crafted for long-range purposes, which allowed it to fly at incredibly high altitudes.

However, there was one design feature that many presumed was a mechanical flaw. When the Blackbird took to the sky, its airframe started leaking, leaving a trail of jet fuel on the tarmac. While many were concerned that this would render the plane useless, the Blackbird was designed to eject its specialized fuel. When developing the aircraft, engineers accounted for the temperature fluctuations that it would experience. More specifically, they realized that the plane’s components would heat up as the aircraft gained more speed.

This friction would inevitably prompt the plane’s body to expand, so they had to fit some pieces together loosely. The fuselage panels, in particular, were purposely positioned farther apart. These loose-fitting parts are what produced the leakage, but it was a necessary design quality to prevent overexpansion. As the SR-71 reached 2,200 miles per hour, the panels enlarged as expected. Fortunately, there was enough room between them to allow for this inflation.

The leakage was also attributed to the SR-71’s lack of a fuel bladder. With that said, when the plane took off, fuel managed to escape before the airframe could expand. Once again, this proved advantageous. With less fuel, the jet’s tires and brakes could release pressure, creating a safer, steadier, and reliable aviation journey. Though this temporary leakage was necessary, engineers knew that the Blackbird would need to be refueled while in the air.

Otherwise, the high temperatures would create fumes inside the fuel tanks. If neglected, this problem could induce an explosion. It’s for these reasons why aerial refueling was warranted. What’s more, without this vital characteristic, the SR-71 couldn’t fly more than 2,000 miles. Thanks to its refueling abilities, the Blackbird was able to travel more than 12,000 nautical miles.

Though the SR-71 heated up while it took flight, it cooled down while landing. As a result, the panels contracted, causing them to return to their original state. When this happened, the jet’s fuel leaked again. Due to this additional leakage, pilots had to be especially cautious when navigating the tarmac so that the plane wouldn’t slip. If the runway still had fuel on it from takeoff, taxiing the aircraft was even more challenging.

In fact, there was an intense situation that happened in Japan when pilots were landing the SR-71. Due to excess fuel on the tarmac, the pilots had to relinquish control as the plane approached the runway. In true heroic fashion, the ground crew rushed in, placing a chock in front of each wheel to secure the aircraft’s movements. Though the SR-71 lived a long and memorable life, NASA retired the Blackbird in 1999. The SR-71 was a tremendous example of aircraft engineering, and the plane’s quirky attributes will go down in aviation history.

Procure Aerospace Fasteners from AMI

AMI is an AS9100 and ISO:9001 accredited, vertically integrated manufacturer of high strength, close tolerance aerospace pins, bolts, threaded rods, studs, screws, and built-to-print specials. Our clientele includes industry-leading OEMs like Boeing, Bombardier, DLA, General Electric, Lockheed Martin, and Sikorsky.

We are a Philips Screw licensee that specializes in both large and small runs. Whether you need a prototype or large runs for your assembly line, you can rely on AMI for rapid delivery and short lead-times.

Search our expansive inventory or launch your Custom Quote today!