1POPA Convention 2016 June 18, 2016
EC/Utility AircraftPilatus Aircraft CertificationDietmar BretscherDirector Utility Aircraft
Pilatus Aircraft Ltd, Stans
POPA Convention 2016
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POPA Convention 2016Pilatus Aircraft Certification
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Utility Aircraft
• Application to the Certifying Authority followed by agreement on Programme and Certification Basis
• Definition of the Type Design / Aircraft Design Completion• Showing of Compliance to the agreed Certification Basis
Means of compliance include:
• Verification of Compliance - independentActivity performed by Compliance Verification Engineers (CVE)
• Declaration of compliance and application to the Certifying Authority (EASA) for a Type Certificate – approval
Type CertificationSummary of Activities
Statements, Design Reviews, Calculations & Analysis, Safety Assessments, Human Factors Assessment, Equipment Qualification/Vendor Data, Tests Results
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Utility Aircraft
1. Summary of Activities
Type CertificationSummary of Activities
Definition of Change / Aircraft
Design
Testing(lab/rig, ground/flight)
Build Showing Compliance
Compliance Verification
Declaration of Compliance
witnessing
Approved Design Data
Approval (Type Certificate)
Agreement of ProgrammeCertification Basis
Deliver
Au
tho
riti
es
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Utility Aircraft
1. Certification Rules
2. Certification Process
3. Foreign Country Validations
4. Pilatus Examples
TOPICS
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Utility Aircraft
Abbreviations
EASA European Aviation Safety Agency CS Certification Specification
FAA Federal Aviation Administration (USA) FAR Federal Aviation Regulation
TC Transport Canada
FOCA Federal Office of Civil Aviation (Switzerland)
CVE Certification Verification Engineer (Pilatus)
AFM Airplane Flight Manual POH Pilot Operating Handbook
AMM Airplane Maintenance Manual SB Service Bulletin
SRM Structural Repair Manual SADD Statement of Approved Design Data
IPC Illustrated Parts Catalogue SL Service Letter
VFR Visual Flight Rules IFR Instrument Flight Rules
DO Design Organization PO Production Organization
DAS Design Assurance System
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1. Certification Rules
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Utility Aircraft
1. Pilatus Aircraft Ltd : Privileges and Obligations• Design Organization (DO) & Production Organization (PO)
2. Certification Basis• Airworthiness Standards• Additional requirements, clarifications or accepted deviations
by the certifying or validating authorities3. Environment Protection (noise and aircraft engine emissions)4. Operational Suitability Data (OSD)
• Pilatus Objectives and Requirements (… fit for purpose …)• Design Principles, Best Practice, Experience, …• Customer Requirements and Expectations, “Brand”, …
Certification Rules1.
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Utility Aircraft
Pilatus Aircraft Ltd – Privileges1.1Design Organization
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Utility Aircraft
• Each holder of a type certificate shall comply with:• 21A.3 Failures, Malfunctions and Defects• 21A.3B Airworthiness Directives• 21A.4 Coordination between design and production• 21A.55 Record keeping• 21A.57 Manuals• 21A.61 Instructions for continued airworthiness• 21A.14 Demonstration of capability
• These obligations are overviewed by EASA (FOCA) in the frame of the annual DO Approval Surveillance Audit.
Pilatus Aircraft Ltd – Obligations1.1as a Type Certificate holder
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Utility Aircraft
Pilatus Aircraft Ltd 1.1Design Organization Approval
SCOPE
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Utility Aircraft
Pilatus Aircraft Ltd1.1Production Organization
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Pilatus Aircraft Ltd1.1Production Organization Approval
SCOPE
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Utility Aircraft
• Airworthiness Standards• Normal, Utility, Acrobatic, and Commuter Category Airplanes
• FAA : FAR 23 (current : Amendment 23-62, 31 January 2012)• EASA : CS 23 (current : Amendment 4, 15 July 2015)
• Additional Requirements, Clarifications or accepted Deviations(Certification Basis, Special Conditions, Exemptions, Equivalent Safety Findings)
• Certification Review Item (CRI), Issue Paper (IP),Compliance Question Form (CQF), Certification Action Item (CAI)
• Certification Basis : defined a dedicated CRI/IP
Certification Basis1.2
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Utility Aircraft
• Examples (see Type-Certificate Data Sheets)• PC-12 : application in 1986 / Type Certificate issued in 1994
• FAR 23 (Amdt. 23-1 to -42 / 62) and 22 CRIs & 2 CQFs• PC-24 : application in 2012 / Type Certificate planned for 2017
• CS 23 (Amdt. 1 to 3) and approx. 91 CRI’s
• Application until Certificationfor new aircraft and significant major change• no change of certification basis if below 3 years if longer then newer airworthiness standard (if available) applies
Certification Basis1.2Pilatus Examples
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Utility Aircraft
• https://www.easa.europa.eu/system/files/dfu/CS-23%20Amdt%203.pdf• hhttp://rgl.faa.gov/Regulatory_and_Guidance_Library/rgFAR.nsf/MainFrame?OpenFrameSet
• Subpart A – General (§§ 23.1 – 23.3)• Subpart B – Flight (§§ 23.21 – 23.255)• Subpart C – Structure (§§ 23.301 – 23.575)• Subpart D – Design and Construction (§§ 23.601 – 23.871)• Subpart E – Powerplant (§§ 23.901 – 23.1203)• Subpart F – Equipment (§§ 23.1301 – 23.1461)• Subpart G– Operating Limitations and Information (§§ 23.1501 – 23.1589)
Certification Basis1.2Airworthiness Standards – Subparts
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Utility Aircraft
Certification Basis1.2Airworthiness Standards – Example FAR 23 (Amdt. 23-1 to 62)
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Utility Aircraft
• Example : PC-12/47E• Type-Certificate
Data Sheet (TCDS)
Certification Basis1.2Additional Requirements, Clarifications or accepted Deviations
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2. Aircraft Certification Process
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Utility Aircraft
1. Development and Certification of a new Aircraft (Type Design)
2. Change to (existing) Type Design• Minor existing rules apply, no involvement of authorities• Major existing rules apply, authorities are involved and approve
• Significant latest rules apply• Substantial new Type Certificate
3. Documents and Approved Design Data
Aircraft Certification Process2.
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Development and Certification of a new Aircraft
2.1
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• Minor• existing rules apply, no involvement of authorities
• Major• existing rules apply, authorities are involved and approve• Master Certification Program (agreement with authorities)• Significant
• latest rules apply• requires update of Certification Rules (at least for the change)
• Substantial• new Type Certificate
Change to (existing) Type Design2.2Levels / Classification
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Change to (existing) Type Design2.2Pilatus DO Process
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Utility Aircraft
• Certification Compliance List (CCL)• For each rule (FAR/CS paragraph; CRI, IP, CQF,
CAI) a compliance statement is required• Detailed substation is provided in Engineering
Reports (reference)• Engineering Change (EC)
• For each change a top level description is provided
• Lists all affected parts and drawings• Lists affected rules with compliance statement
and substantiation/Engineering Report
Engineering Report• Show compliance to
the Certification Basis by detailed substantiation
• Contain test results, analysis, calculations, human factors and safety assessments, …
Documents2.3
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Utility Aircraft
• Original PC-12 Certification Compliance List of 1994• FAR 23.903 (Example)• Signed by Pilatus• Approved by FOCA
• without PilatusDesign Organization Approval
Documents2.3Certification Compliance List
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Utility Aircraft
• Summary Engineering Report for PC-12 NG (2008)• Signed by Pilatus• Approved by Pilatus CVE’s
• with PilatusDesign Organization Approval
Documents2.3Certification Compliance List
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Utility Aircraft
• Summary Engineering Report for PC-12 NG (2008)
• Updated Certification Compliance List
• FAR 23.903 (Example)
Documents2.3Certification Compliance List
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Utility Aircraft
Documents2.3Engineering Report: Structural Analysis
Load Cases• Global Finite Element Model (GFEM) of the PC-12
Required to calculate loads and stresses
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Utility Aircraft
Documents2.3Engineering Report: Structural Analysis
• Flutter Model PC-12 (based on GFEM)
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Documents2.3Engineering Report: Structural Analysis
• Static Wing Structural Test (original)
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Documents2.3Engineering Report: Safety Assessments
Severity(or effect of the failure
condition)
Probability of occurrenceAcceptable
Not acceptable
Class II(PC-6)
Class III(PC-12)
Class IV(PC-24)
CAT High Potential for loss of the aircraft, multiple fatalities.
Extremely Improbable
<10-7
per flight hour<10-8
per flight hour<10-9
per flight hour
More than Extremely Improbable
HAZLarge Reduction in functional capabilities or safety margins that can cause serious or fatal injuries.
Extremely Remote
<10-6
per flight hour<10-7
per flight hour<10-7
per flight hour
More than Extremely Remote
MAJ
Significant reduction in functional capabilities or safety margins that will cause physical discomfort or a significant increase in workload, possible injuries or fatalities.
Remote <10-5
per flight hour<10-5
per flight hour<10-5
per flight hour More than remote
MIN
Slight reduction in functional capabilities or safety margins that will cause an increase in workload or require use of emergency procedures.
Probable <10-3
per flight hour<10-3
per flight hour<10-3
per flight hourMore than probable
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Utility Aircraft
• Parts List and Drawings (incl. processes and tests)• how to build an aircraft
• AFM/POH, AMM, IPC, SB• how to operate, maintain
and modify an aircraft• SRM, SADD
• how repair an aircraft
• SL, …• for information
Documents2.3Approved Design Data
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3. Foreign Country Validations
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Utility Aircraft
• Development and Certification of a new Aircraft (Type Design);Change to (existing) Type Design• Prime Certifying Authority is EASA (was FOCA until 2006)
• Validation required by foreign country in order to register the aircraft in that country• Always for new Type Designs; some countries require validations of all
major changes• Some countries define additional requirements, clarifications or accepted
deviations (new certification basis)• Change to Type Design (initially by EASA, validation by foreign country)• Certain options have to be installed (from factory or by SB)
Foreign Country Validations3.Process
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Utility Aircraft
• Agencies covering several countries• EASA : European Aviation Safety Agency
Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxemburg, Malta, Norway, Poland, Portugal, Slovak Republic, Slovenia, Spain, Sweden, Switzerland, The Netherlands, United Kingdom
• CIS : Commonwealth of Independent StatesArmenia, Azerbaijan, Belarus, Georgia, Kazakhstan, Kyrgyzstan, Moldova, Russia, Tajikistan, Turkmenistan, Ukraine, Uzbekistan
• Level of Involvement• Full evaluation including dedicated certification basis (new requirements)• …• Acceptance of other countries Type Certification
Foreign Country Validations3Level of Involvement
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Utility Aircraft
Foreign Country Validations3.PC-12
• Including• EASA• CIS
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4. PC-12 Examples
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Utility Aircraft
1. PC-12 Certification Steps• FOCA, FAA, EASA• PC-12 (basic, IFR, 4’100 kg MTOW, FIKI)
PC-12/45PC-12/47PC-12/47E
Change to Type Design2. IPECO Crew Seat (PC-12/47)3. PC-12 NG (PC-12/47E)4. PC-12 Model 2016
PC-12 Examples4.
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Utility Aircraft
PC-12 Certification Steps4.1Basic Certification, Change to Type Design
23.12.05
14.12.05
/474740 kg
24.3.95
27.2.95
PC-124100 kg
13.7.94
PC-12IFR
15.7.94
30.3.94
PC-12BASICVFR
4000 kg
USFAA
SwissFOCA
EASA
28.7.95
29.6.95
PC-12Icing
31.7.96
4.6.96
/454500 kg
23.6.06 23.6.06 23.6.06
28.3.08
Part of EASA
/47EAPEX
28.3.08
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Utility Aircraft
PC-12 Certification Steps4.1Type Certification : EASA & FAA
Type-Certificate Data Sheet
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Utility Aircraft
• Vertical Structural Dynamic Test (60°) FAR § 23.592Simulation of Emergency Landing Condition at Stall Speed
• PC-12 : 19.0g / 0.050s 61kcas• PC-12/45 : 21.6g / 0.044s 65kcas• PC-12/47 : 22.9g / 0.042s 67kcasLumber spine loads (1500 lbs limit)
• Horizontal Head Injury Criteria (HIC) TestSimulation of Aircraft Overrun during Take Off and Landing Simulation of Emergency Landing without Landing Gear or on Non-Prepared Runways
• all : 26.0g / 0.050sHIC < 1000 (due to head impact)
IPECO Crew Seat (PC-12/47)4.2Dynamic Seat and Head Injury Criteria
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Utility Aircraft
IPECO Crew Seat (PC-12/47)
Vertical Structural Dynamic Test (60°)
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EC/Utility Aircraft
New IPECO pilot seat (PC-12/47)
Vertical Structural Dynamic Test (60°)
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Utility Aircraft
IPECO Crew Seat (PC-12/47)
Horizontal HIC Test
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EC/Utility Aircraft
New IPECO pilot seat (PC-12/47)
Horizontal HIC Test
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Utility Aircraft
Determine Impact Location by plotting the Head Trajectory in the Interior Drawing re-evaluation
with component changes
Component test (head dummy only)
IPECO Crew Seat (PC-12/47)4.2Determination of all Impact Locations
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Utility Aircraft
• Major Changes• Primus Apex and associated Components & Systems *)• ESIS (Electronic Standby Instrument System) *)• PGDS (Power Generation and Distribution System) *)• Engine (PT6A-67P)• Digital CPCS (Cabin Pressure Control System)• Digital ECS (Environmental Control System) Controller
Note *) : significant
• Several other minor changes were done as well
PC-12 NG (PC-12/47E) 4.3Changes to Type Design
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Utility Aircraft
• P02 : 2004 – 2006• 107 flying hrs
• MSN 545, 1001, 1002 :2006 – 2008• 776 flying hrs
PC-12 NG (PC-12/47E) 4.3Flying Hours
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Utility Aircraft
• Dedicated Engineering Reports per change
• Summary Reports for other subjects
PC-12 NG (PC-12/47E) 4.3Engineering Reports > 150
APEX
PGDS Engine CPCS ECS ESIS 23.1309
Structural Substantiation
Aerodynamic & Performance
Fuel
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Utility Aircraft
• Major Changes• Removal of Standby Compass• 5-blade Composite Propeller• Primus Apex Build 10
• Several other minor changes• External aerodynamic changes• Pax door• Removal of clock• …
PC-12 Model 2016 4.4Changes to Type Design
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Utility Aircraft
• Flight test program for Model 2016 (117.5 hrs)• 5-blade propeller & aerodynamic improvement: 68.5 flying hrs• APEX Build 10: 49.0 flying hrs
• Number of Engineering Reports updated or created (57):• Certification Programs: 3• Top Level Reports: 5• APEX Build 10: 15• 5-blade propeller: 15• Performance: 19
• Updated AFM/POH, AMM, IPC
PC-12 Model 2016 4.4Flying Hours / Engineering Reports
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Utility Aircraft
• L3 ESIS displays heading independently (and more reliably).• With the introduction of the L3 ESIS which provides an
independent display of magnetic heading, the centrepost mounted whisky compass is no longer needed.
PC-12 Model 20164.4Removal of Standby Compass
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Utility Aircraft
Master Certification Programme
• Agreement with Certifying Authority regarding Programme and Certification Basis
major non-significant
• Signed by Pilatus• Verified by Pilatus• Accepted by EASA
PC-12 Model 20164.4Removal of Standby Compass
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Utility Aircraft
Pilatus Configuration Management
PC-12 Model 20164.4Removal of Standby Compass
Changed Drawingsand Parts Lists
Engineering Reports, Approvals, …
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Utility Aircraft
Major Change Approval Summary
• Signed and Verified by Pilatus
Pilatus to EASA
PC-12 Model 20164.4Removal of Standby Compass
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Utility Aircraft
EASA & FAA Approval
PC-12 Model 20164.4Removal of Standby Compass
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Utility Aircraft
• Propellers receive specific Type Certificate (FAR 35 / EASA CS-P) issued by FAA/EASA• Supplier Testing by Hartzell
• EASA/FAA have to validate the propeller Type Certificate
• Pilatus has to certify the new propeller as part of the Aircraft Type Certificate• Major Change• with EASA/FAA
PC-12 Model 20164.55-Blade Composite Propeller
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Utility Aircraft
• The applicant must demonstrate, by tests or analysis based on tests or experience on similar designs, that the propeller can withstand the impact of a 4-pound bird at the critical location(s) and critical flight condition(s) of a typical installation without causing a major or hazardous propeller effect.
• Test Condition• 4 lbs bird / Impact Location 8 inches from tip• NP = 1700 RPM / 1200 SHP / 76 KTASImpact Velocity = 392 kts & Impact Angle = 17.4 degreesConditions simulate take-off rotation, as the airplane accelerates into a advancing bird. Results in the bird hitting the blade at the highest angle (not cutting the bird).
5-Blade Composite Propeller 4.5Testing : FAR 35.36, Bird Impact
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Bird Impact Testing
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EC/Utility AircraftBird Impact Testing
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Lightning Testing
All Hartzell composite blades have successfully passed direct effects lightning tests to:
– 1,000,000 volts– 100,000 amps
Our propellers have been tested and include features and components that provide a level of protection for airframe electrical components from indirect lightning effects
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Deicer Testing
Hartzell designs, manufactures and certifies it’s own fluid anti-ice and electro-thermal deice systems
Impingement and accretion analysis is performed using LEWICE
Certification is accomplished using FAA approved analytical and convection testing capabilities− Thermal (IR) temperature measurements− Wind tunnel (600 ft/s) to verify deicer surface
temperatures at the applicable speed conditions
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Propeller Stress Testing
Dedicated test lab − Blade, Hub & component fatigue testing− Focused on testing propeller
components to comply with FAR Part 35 and 23 requirements
In-flight Vibration Testing− Accomplished by strain gaging
propeller and telemetry system− Perform propeller loads/stresses for all
unique aircraft/propeller installation
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Utility Aircraft
In-flight Vibration Testing on PC-12 (MSN 545)
PC-12 Model 20164.55-Blade Composite Propeller
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Utility Aircraft
Propeller Pressure Survey Testing
PC-12 Model 20164.55-Blade Composite Propeller
• Controlling oil pressure never drops to zero and never exceeds the maximum governing pressure
• Flyweights and spring act against the oil pressure
• Examples are from the 4-blade aluminum propeller testing on PC-12 P02 (1994)
• Same testing repeated with the 5-blade composite propeller on a similar application
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PC-12 Model 20164.55-Blade Composite Propeller
Propeller Pressure Survey (4-blade)
• max power:Vs Vmo Vs
5-blade composite propeller
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Utility Aircraft
Propeller Pressure Survey (4-blade)• max power: Vs Vmo Vs
PC-12 Model 20164.55-Blade Composite Propeller
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EC/Utility Aircraft