AD/DA40/9 Upper Wing Skin-to-Main Spar Adhesive Joint (Cth)

AIRWORTHINESS DIRECTIVE

For the reasons set out in the background section, the CASA delegate whose signature appears below issues the following Airworthiness Directive (AD) under subregulation 39.001(1) of CASR 1998.  The AD requires that the action set out in the requirement section (being action that the delegate considers necessary to correct the unsafe condition) be taken in relation to the aircraft or aeronautical product mentioned in the applicability section: (a) in the circumstances mentioned in the requirement section; and (b) in accordance with the instructions set out in the requirement section; and (c) at the time mentioned in the compliance section.

Diamond DA40 Series Aeroplanes

AD/DA40/9 Upper Wing Skin-to-Main Spar Adhesive Joint 2/2009

Applicability:

Model DA 40 aircraft, serial numbers 40.377, 40.420, 40.422, 40.644 through 40.693, 40.695 through 40.842, 40.844, 40.846 through 40.887, 40.889 through 40.912, 40.915 through 40.917, 40.919 through 40.929, 40.931, 40.932, 40.934 through 40.940, 40.944 through 40.949, 40.951 through 40.953, 40.955 through 40.957, 40.961, 40.964, and 40.971.

Requirement:

1.    Inspect the adhesive joint between the wing main spar caps and the upper wing skin in accordance with the instructions of Diamond Aircraft Industries GmbH MSB-40-060 / MSB-F4-016 dated 20 October 2008, or later EASA approved revision.

2.    Report the results to Diamond Aircraft Industries in accordance with the instructions of Diamond Aircraft Industries GmbH MSB-40-060 / MSB-F4-016 dated 20 October 2008, or later EASA approved revision.

When voids are detected that exceed the criteria of the Requirement document, before further flight, contact Diamond Aircraft Industries for approved repair instructions and accomplish the repair accordingly.

Note:  EASA AD 2008-0224 refers.

Compliance:

1.    Within 100 flight hours or 3 months after 12 February 2009, whichever occurs first.

2.    Within 30 days after the inspection is accomplished.

This Airworthiness Directive becomes effective on 12 February 2009.

Background: A number of wings manufactured by Diamond Industries Inc. in Canada have been found to exhibit voids in the adhesive joint between the main spar caps and the upper wing skins.  The available information indicates wings with voids continue to meet the certification design limits, provided the voids are within established criteria.  However, to detect any wings that may have voids exceeding these criteria, Diamond has issued a mandatory service bulletin that describes instructions for inspection of the aircraft that had these wings installed during manufacture.  Aircraft that have voids within the inspection criteria may continue to operate without restriction, pending the outcome of ongoing investigations.  Aircraft that have voids exceeding the inspection criteria must be repaired.

David Punshon
Delegate of the Civil Aviation Safety Authority

18 December 2008