An engineering team from Arizona endured bone-chillingly cold temperatures in the summer and even created their own ice storms to make the Apache helicopter of the future more reliable in cold weather.

The Airframe Integrated Product Team at the Rotorcraft site in Mesa, Ariz., reached a milestone in late 2008 by completing engine nose gearbox fairing anti-icing testing at the NASA Glenn Icing Research Wind Tunnel in Cleveland, Ohio.

The engine nose gear box fairing is a fiberglass shell that covers the gearbox between the engine and transmission.

It is required to meet anti-icing standards to prevent ice from forming on the fairing and being ingested into the engine, potentially creating a dangerous situation.

Because there is a new transmission and engine nose gearbox going on Block III Apaches, the ENGB fairing design was modified and the need for anti-ice qualification resulted,” said Test Team Lead Laura Buck, an aerothermal engineer. The team’s efforts in preparing for the tests conducted in August 2008 spanned nearly three years. The test team included over 20 Boeing teammates. Seven participated in the test, along with representatives from Goodrich, the ENGB fairing supplier, NASA Glenn, and the U.S. Army. Using a full-scale mock-up representing ¼ of the Apache helicopter, various aircraft speeds in - 5 to -20 Celsius temperatures with different water droplet sizes for ice, the team proved the ENGB fairing anti-ice system was reliable and durable, and most importantly, will protect the Apache engines in an icing situation. “Successful test results confirmed the anti-icing performance of a new engine nose gearbox fairing that will be used in Block III Apaches, the helicopters of the future,” said Tim Lynch, Airframe Block III IPT Lead

“Testing also showed the improved durability and reliability of the new heater technology used by Goodrich in the ENGB fairing verses the legacy fairings,” said Senior Engineer Nick Rodriguez, Airframe Center section lead. “The team’s success is due to the planning, coordination and good communication between the Airframe IPT, the U.S. government, our suppliers and the NASA Glenn team,” Lynch said.

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