Hope Aero continues to be the country’s leading propeller systems service facility. We support the newest high tech composite propellers, military and vintage aircraft propellers. We consistently hold ourselves to higher standards and work to tighter tolerances than required by manufacturers’ specifications, and we apply our own additional requirements based on experience to the standards we meet. We set-match propeller blades for performance and reliability.
Metal Propellers – Aluminum & Steel Blades
After disassembly of the propeller and the blades are removed from the hub, they are thoroughly cleaned prior to initial assessment. Ninety-five percent of blades are dimensionally inspected using the Aeroscan machine to confirm that they are within minimum dimensions (width and thickness) through the full length of the blade to confirm that there is enough material left to go through the overhaul process. A water jet machine is used to blast the lead ballast out of the balance hole. Blades are then stripped for further visual inspection and dimensional inspection of the shank and bore. Bent blades are returned to shape, and any erosion damage and corrosion is removed from the blade by sanding using our state-of-the-art system with dust collection. Blades are dimensionally checked again for minimum widths and thicknesses.
Blade Set Matching: Blades may track within each other in a set; however, due to thrust bending, most blades require correction to their face alignment to bring it back to manufacturers’ limits. Blades are twisted and straightened as required to adjust face alignment and angles to within manufacturers’ tolerances. After face alignment and angles are corrected, trailing edges are filed as required to match edge alignment. After edge alignment is matched, leading edges are filed to match as a set. This unique attention to detail during the overhaul process can add a couple of extra hours of labour to the process, but for the owner, the passengers and the aircraft itself, however, the benefit of set-matching is a noticeably smoother propeller operation and, ultimately, a better passenger & pilot experience. Blades are final processed through the Aeroscan machine for recording of final airfoil dimensions.
Hamilton Standard blade thrust washers are ground as required and magnetic-particle inspected. Blades are further inspected by optical comparator, etching, borescope inspection, liquid penetrant inspection, eddy current inspection, and ultrasonic inspection as required. Blades are cold rolled, polished, shot peened, alodined, and anodized as required before being painted. Finished blades are primed, painted, statically balanced and inspected prior to installation assembly.
Composite Blade Propellers
After disassembly of the propeller and the blades are removed from the hub blades processing begin with a thorough visual inspection and damage assessment – including an internal fibre-optic borescope inspection to determine serviceability. Protective coatings are removed as required. Fibreglass, carbon fibre and foam repairs are carried out. Delaminations are repaired using lay-up vacuum bag repair process. Leading edge heating devices and erosion protectors are replaced as required. Blades are sanded as required using our state-of-the-art system with dust collection. They are inspected by tap test, optical comparator, etching, liquid penetrant inspection, eddy current inspection, magnetic particle inspection and ultrasonic inspection as needs dictate. Blade shanks are cold rolled, shot peened and alodined as required. Finished blades are then primed, painted, statically balanced and inspected prior to installation assembly.
Fixed Pitch Propellers – Aluminum and Natural Composite (Wooden)
Propellers begin with a thorough visual inspection and dimensional assessment to determine serviceability. Protective coatings are removed as required. Fibreglass, carbon fibre repairs are carried out. Delaminations of wooden propellers are repaired IAW OEM accepted procedures. Blades are sanded as required using our state-of-the-art system with dust collection. They are then further inspected by tap test, etching, liquid penetrant inspection, eddy current inspection, magnetic particle inspection and ultrasonic inspection as needs dictate. Metal blades are shot peened and alodined as required. Finished propellers are then primed, painted, statically balanced and final inspected.
Hope Aero is proud to have forged close relationships with the world’s leading propeller manufacturers and continues to invest in achieving the highest levels of authorized service status. These critical service relationships are dependent on initial OEM training programs as well as regular factory service meetings. We must also pass rigorous OEM quality audits of our process and facility, confirming our attention to quality and detail meets their standards as well as our own. It always does.
Below are some of our key affiliations and service status capabilities:
- Avia – Disassembly at Hope Aero, repair at Avia, and reassembly at Hope Aero
- Hamilton Sundstrand (Standard) – Factory-trained for all repair and overhaul processes
- Hartzell Propeller – Hartzell-recommended and -approved service and deicer facility
- Hoffman Propeller – Distributor and Approved Service Station
- McCauley Propeller Systems – Authorized Service Station and Distributor
- MT Propeller – Authorized Distributor, Repair and Overhaul facility
- Sensenich Propeller – Authorized Dealer and Repair Shop
- Goodrich Corporation – Authorized Deicer Sales