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During the research described in A. Logbook Entries and B. Aircraft Records, owners may discover that STCs are installed on their airplane. In some cases, an STC can affect the continued airworthiness of the airplane. If it does, you should see this reflected with changes to the airplane’s Instructions for Continued Airworthiness (ICA). Unfortunately, this does not always happen. Therefore, it is always in the owner’s best interest to consider additional maintenance or inspection requirements for incorporated STCs that do not provide specific instructions for continued airworthiness.
During the records research, the owner should be aware of certain factors that may have significant impact on the condition of an aging airplane. You should adjust the way an individual airplane is inspected according to what the research reveals about the airplane's history. The research should answer several questions.
An airplane spends far more time on the ground than it does in the air. Therefore, the environment it is exposed to while on the ground plays a significant role in how it ages.
Has the airplane been hangared? How much of its time has been outside? If the airplane has spent much of its time outside, then there may be additional wear on seals, hoses, and moving parts exposed to the extremes of temperature and moisture. The likelihood of corrosion would be higher for an airplane not hangared.
Where has the airplane been geographically? If it has been located in coastal areas, even for a few years, corrosion is probably a concern. (The Florida coast seems to be especially severe.) Corrosion degradation is not limited to structure; it can also cause problems with electrical connectors, etc. Corrosion is more of a concern if the airplane has not been hangared. If it has spent most of its time outside in areas where it gets very cold or very hot, this will take an additional toll. Deterioration of electrical components, hoses, seals, and lubrication is faster when subjected to temperature extremes.
Has the airplane been inactive or in storage for a long period of time? Airplane inactivity has a more severe impact than regular use. The same issues of material deterioration, lubrication, and part wear due to lack of movement can lead to accelerated aging.
Has the airplane been used in a special usage role? A significant amount of time flying at low levels (for example, pipeline patrol or aerial survey) exposes the airframe to more frequent and higher gust loads. This in turn causes additional metal fatigue damage to the wings, empennage, and associated structure. Mountain flying is also a harsher gust environment and therefore more damaging. Operating the airplane with consistently heavy loads or for very short flights also induces additional fatigue damage. Any operation in aerobatic or high-g maneuvers is damaging.
Unfortunately, metal fatigue damage is not “healing.” Severe usage early in an airplane’s life is just as damaging as similar usage to an old airplane. Just because the airplane was new when it flew in severe operations, unseen and undetected damage to the metal still occurred and will remain. This can manifest itself in a higher likelihood of cracking later in the airplane’s life. (Wood and composite structures don’t sustain fatigue damage the same as metal, but repeated loads still have long-term damaging effects.)
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Best Practices Guide for Maintaining Aging General Aviation Airplanes(6)
