V2500 fan cowl

Replacing the original carbon fiber honeycomb part with a durable integral milled aluminum structure successfully eliminates problems of the V2500 fan cowl.

The issue

After about ten years, the fan cowlings on the IAE V2500 typically exhibit structural damage to the composite materials. In particular, delamination between the sandwich core and the top layer due to the entrapment of water can be quite extensive, causing considerable problems and significant repair costs. In order to avoid the cost of an original replacement part, ARC^® decided to try a new approach which entails replacing the composite structure with an aluminum substitute.

Our solution

No longer manufactured as a sandwich, the new part is a milled aluminum structure, consisting of a thin outer skin with stiffening ribs. The resulting weight is virtually identical to that of the OEM structure. Moreover, the cowling is fully interchangeable with the conventional part. There are no compatibility problems.

Significantly reduced cost

Compared with the price of an original replacement part, the cost is reduced by 50 percent. Moreover, the Lufthansa Technik part will be less expensive to since any repairs that may be required can still be carried out on-wing, thus avoiding the need for an elaborate bonding tool and autoclave. The new structure is evaluated and in the Lufthansa fleet.