General Status and Prospective of SHM from the Standpoint of an End-User

Agenda

Lufthansa Technik Group: An Overview LHT Aircraft Engineering: What we do Airplane Health Management Overview Structural Health Monitoring Concepts Testcase Floor Structure Corrosion Lessons Learned

General Status and Prospective of SHM from the Standpoint of an End-User 28.10.2011, Page 2 Copyright Lufthansa Technik AG. All rights reserved. Subject to restrictions and disclaimer on last page.

Lufthansa Technik Group: An Overview

750 customers worldwide 2.055 aircraft under exclusive contracts 2.392 engines under contract 500 jetliners under Total Technical Support TTS 1.700 aircraft inspections per day 32 subsidiaries and affiliates worldwide 60 line maintenance stations with Lufthansa Technik staff worldwide 6.3 billion Euros in revenue* 26.000 employees worldwide*
*Lufthansa Technik AG and all companies of Lufthansa Technik Group in 2010. General Status and Prospective of SHM from the Standpoint of an End-User 28.10.2011, Page 3 Copyright Lufthansa Technik AG. All rights reserved. Subject to restrictions and disclaimer on last page.

LHT Aircraft Engineering: What we do

Engine Engine Services Services

Aircraft Aircraft Component Component Services Services

Aircraft Aircraft Maintenance Maintenance Services Services

Aircraft AircraftBase Base Maintenance Maintenance

Landing LandingGear Gear Services Services

VIP VIP& & Executive ExecutiveJet Jet Solutions Solutions

Maintenance Program (MS) Modifications (ADs, SBs)

PLAN

ACT Operator
Change Maintenance System

LHT LHT Aircraft Aircraft

Engineering

DO MRO Provider
e.g. Line Maintenance Base Maintenance

CHECK
Reliability Monitoring
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Airplane Health Management Overview

Wha t abo ut st ructu res?

Flight Data Analysis

Maintenance Computer FDE / nonFDE Fault s

Engine Condition Monitoring

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Structural Health Monitoring Concepts

30% - 50% of all scheduled maintenance tasks are driven by the structures program Scheduled maintenance tasks are static with regard to airplane flight cycles, flight hours or calendar time SHM Concept Structural Usage Parameter - Monitoring of load, stress and strain - Calculate and monitor fatigue life (flexible inspections) SHM Concept Impact Detection - Future task for composite airplanes SHM Concept Hotspot Monitoring - Monitoring of cracks, corrosion, etc. - Replace existing maintenance tasks by dedicated sensors
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Structural Health Monitoring Concepts Hotspot Monitoring

Crack
Technical requirements: - Sensor must cover each possible failure mode, i.e. fatigue cracking, corrosion, accidental damage, - Sensor must meet certification specifications - Sensor and hardware must work reliable for 30 years, 120.000 flight hours, 75.000 flights - Sensors must not trigger false alerts Economical requirements: - Existing maintenance task must impose a high economic burden (i.e. time consuming access) - Low finding rate, otherwise necessary repairs will require previously avoided access - Additional maintenance requirements for sensor system, added weight etc. must be valued against possible savings

Surface Corrosion

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Testcase Floor Structure Corrosion

Wet Areas require more frequent inspections for corrosion than Dry Areas are difficult to access due to installed galleys/lavatories/moisture barriers have a moderate finding rate at specific locations Costs* for corrosion monitoring of floor structure in wet areas: 737 Fleet ~100.000 US$/year, 747 Fleet ~200.000 US$/year
* Labour costs only, additional Operator costs for extended ground times not included
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Testcase Floor Structure Corrosion

Within AISHA II the consortium developed a moisture detection sensor LHT installed 2 sensor prototypes in a B737 forward galley area in April 2011 Initial results show that sensors work as desired Sensor won The Most Practical SHM Solution for Aerospace Award during the 8th International Workshop on Structural Health Monitoring at Stanford University Installation of 12 more test-sensors in B747 galley areas ongoing

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Lessons Learned

There is no reason anyone would want a computer in their home.

Ken Olson, CEO of Digital Equipment Corp. 1977

For a good solution you need one person with a big problem and a second person with a great idea.
Peter Heer, Lufthansa Technik 2011

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Thank you for your attention.

Copyright Lufthansa Technik AG. All rights reserved. The information contained in this presentation is proprietary to Lufthansa Technik AG and is disclosed in confidence. The presentation and the information contained herein shall be kept strictly confidential and shall not be used, disclosed to others or reproduced without the express written consent of Lufthansa Technik AG. Nothing contained in this publication shall constitute any warranty, guarantee or liability for Lufthansa Technik AG, from its subsidiaries affiliates General Status and Prospective of SHM the Standpointand of an End-Userbut is for information purposes only. Accordingly, Lufthansa Technik AG 28.10.2011, Page 11 its subsidiaries and affiliates neither expressly nor conclusively accept responsibility or liability for the actuality, accuracy and Copyright Lufthansa Technik AG. All and rights reserved. completeness of the statements information contained in this publication.
Subject to restrictions and disclaimer on last page.