As the local CASA rep also in charge of the A400M I of course appreciate your overall positive remarks of the recent roll-out. Questions came up regarding possible engine challenges, which I explain here in more detail:
The first TP400-D4 engine run took place in October 2005 and the first engine and propeller run was performed in an out-door test facility in Istres (Southern France) in February 2006, successfully achieving a Contractual Milestone.
During the engine test programme, technical issues were discovered. The Power Gear Box suffered manufacturing quality issues, causing premature failure of the bearings while the Gear Box casing casting in Magnesium encountered quality problems. In August 2007, a High Pressure Compressor (HPC) failure occurred in a test engine. At the time of discovery of the HPC issue, the total engine test hours were close to 500 hours. The root cause of the HPC failure was identified in October 2007 and the engine test rig was modified to avoid unnecessary high-power surge. Engine test runs continued. The improved HPC will be installed on the test engine in August 2008 for testing and the production standard HPC will be available in October 2008. On 24 June 2008, engine test runs had accumulated 1550 hours, with 3 to 5 engines running simultaneously. All the necessary engine tests for MSN001 first flight clearance are scheduled to be completed by the end of July 2008, with a possibility of 1 month extension.
One TP400-D4 engine has been installed on a C-130 aircraft for flying test. The first successful engine ground run on the C-130 took place in early June 2008 and first flight of the engine is scheduled at end of July 2008.
All in all, once the aircraft is airborne and in operations no one will talk about engine casings anymore. I haven't given up hope yet Canada will someday take a serious look at the A400M.
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