2010-06 · NASA ASRS report 892108
A Lathe Machinist reports their machine shop was recently informed they had been manufacturing repair bushings for a main landing gear secondary strut and main gear trailing arm assemblies with the wrong material for three years.
On an Air Carrier's Regional Jet main gear; I used the incorrect revision of the Air Carrier's bshing blueprints to manufacture repair bushings. Details as follow: main gear secondary strut bushing IPC 32-10-04 (Illustrated Parts Catalog) item 390; Carrier's Engineering blueprint parts equivalent and interchangeable list; this bushing is a -17. The -17 bushing was manufactured per engineering blueprint and the material specification calls out using S-4640 material. On the [current] engineering blueprint revision; material was changed to manufacture the -17 bushing with 17-4PH material. Not aware of the blueprint change; we continued to manufacture the -17 bushing with the wrong material from [revision issue date] to date found.The Air Carrier's Regional jet main gear trailing arm assemblies part number #2309- XXXX; 2309-YYYY; 2309-ZZZZ; and 2309-XYZA bushings found in IPC 32-10-01; item 40; with PN #2309- per engineering blueprint parts equivalent and interchangeable list; this bushing is a -5. The -5 bushing was manufactured using 17-4PH material in the shop. The -5 bushing should have been S-4640 material. But on [our] engineering revision 'E' dated May 2010 the material called out changed to 304SS to be used. Not aware of the material requirements we manufactured the -5 bushing with the wrong material until found.Air Carrier's Regional Jet main gear trailing arm assemblies PN # 2309-AAAA; 2309-BBBB; and 2309-CCCC and bushings IPC 32-10-01; item 120; PN # 2309-DDDD; per Air Carrier's engineering blueprint parts equivalent and interchangeable list; this bushing is a -3. The -3 bushing was manufactured in shop using 15-5 PH material. The -5 bushing should have been S-4640 material. On Air Carrier's Engineering Revision 'E' dated May 2010 the material calls out for 15-5 PH.
Reporter stated he is a Machinists by trade and installs the shop manufactured bushings into the main landing gear secondary struts and trailing arm assembly for numerous type aircraft. The bushings are first rough-cut from stock material by a computerized numerical controlled (CNC) lathe to form the bushings; approximately 20-25 are made at one time.Reporter stated when the main landing gear secondary strut or main gear trailing arm assemblies are ready for bushing installation; the Machinist will re-check the inside diameter holes (bore) of the strut or trailing arms and then use the manual lathe to machine the bushing to the exact size for each specific hole. The manual lathe is used to machine the bushing outside diameter including the hat thickness or flange thickness. The -17-4PH is a hardened steel material and the 304SS is stainless steel.Reporter also stated when he receives the Bushings for installation; they have already been Cadmium Plated (CAD); so he does not know what the Bushing material is actually made of at that time. But; when he does install each bushing; he must verify he is using the specific sealant each Carrier requires; for the Main Gear bushings he installs; even though the Main Gears may be the same type.
Source: NASA Aviation Safety Reporting System (public domain). Reports are voluntary submissions and are not verified by NASA.
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