Two-week turnaround aims to minimise aircraft downtime and reduce replacement costs
DAS Aviation has expanded its heat exchanger inspection, repair and overhaul capabilities for Cessna business jets, introducing a service programme designed to help operators reduce aircraft downtime while avoiding expensive component replacements.
The company said the programme offers an average turnaround time of approximately two weeks, restoring heat exchangers to original OEM specifications and enabling operators to return aircraft to service quickly for both scheduled maintenance and aircraft-on-ground (AOG) requirements.
“Heat exchangers operate in one of the harshest environments on the aircraft, facing both structural and thermal stress,” said Andrew Rietschel, New Product Development Engineer at DAS Aviation. “Our job is to return these units to a fully serviceable condition as quickly as possible, without altering the certified design.”
Each heat exchanger undergoes a comprehensive incoming inspection to assess its internal structural integrity and external condition. Pressure testing and detailed defect evaluations help determine serviceability and identify the appropriate repair strategy. Typical issues include fin damage, corrosion, oxidation, structural cracks and wear resulting from prolonged service.
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Depending on the condition of the unit, DAS Aviation performs either localized repairs for minor defects or complete overhauls, including re-core services that replace the core assembly. For operators requiring immediate component availability, the company also maintains a stock of flat-rate exchange units that can be shipped to support rapid return-to-service requirements.
According to DAS Aviation, its in-house team has accumulated more than a decade of experience in heat exchanger repairs and overhauls, with extensive support for the Cessna Citation 560XL as well as several aircraft in the Citation 680 family.
To showcase its maintenance capabilities, the company has also released a behind-the-scenes video demonstrating the repair and overhaul process. The video highlights key stages including removal of worn welds, installation and alignment of new cores using precision fixtures, welding, leak testing and final painting before the units are approved for service return.
The company noted that aircraft heat exchangers are continuously exposed to extreme operating temperatures, particularly around the lower sections of the assembly, where prolonged thermal stress can degrade aluminium fins and coils, eventually leading to leaks and reduced performance. Properly functioning heat exchangers are essential for delivering conditioned and pressurised air to the aircraft cabin.
“Our customers expect fast, dependable turn times,” Rietschel added. “By standardizing our evaluation and repair workflow and adhering to OEM specifications, we deliver consistent quality across the Cessna fleet.”
The expanded heat exchanger maintenance programme is now available for Cessna business jet operators seeking inspection, repair, overhaul and exchange support.
