Exhaust System Catalog

Hartzell Aviation (QAA) leverages our extensive experience servicing single, twin, turbocharged, radial, and turbine aircraft exhaust systems. With our specialized knowledge and superior customer service, we’ll swiftly get you back in the air when you need it most! 

Explore our comprehensive exhaust catalog below, and if you don’t find what you’re looking for, feel free to give us a call for customized solutions.

Quality Materials & Certified Craftsmanship 

Each component we handle is crafted with precision and the highest quality materials. We use 321 stainless steel for all sheets and tubes, and most of our exhaust parts are produced using stamped pieces identical to the Original Equipment Manufacturer’s (OEM) specifications. This effectively avoids the pitfalls of lesser, pieced-together alternatives. Naturally, all welds undergo internal purging to maintain the highest standards of integrity.

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OEM vs PMA

Federal Aviation Administration – Parts Manufacturer Approval (FAA-PMA) may serve the same function as OEM parts, but their quality doesn’t measure up. Poor design in some PMA parts can lead to a shorter service life. For example, the construction differences between the units shown below could result in a severe exhaust failure. OEM parts are made with two formed shells, and the aftermarket PMA parts use fillet-welded tubes. The originally formed tooling, though costly, ensures that the load is carried through the parent material rather than relying on welded joints.

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The Pull-Through Method

We also use a technique called the ‘Pull Through’ method for aircraft exhaust systems. This involves cutting a smaller hole rather than a standard-sized one. A lip is then extruded to elevate the weld away from the shoulder area, which is prone to cracking. This technique results in a much stronger joint between exhaust components.

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Cessna 300-400 Pull through Airworthiness Directive (AD) 2000-01-16

The photo displays the difference between a part with (right) and without (left) a pull-through. The part on the left shows a crack adjacent to the weld.

We use rigid weld fixtures to guarantee a precise fit during installation. Where possible, wire bails are added to outlets to prevent blockages, offering an additional layer of reliability. Afterward, each unit undergoes a leak test and a final quality control inspection by certified welding technicians to meet the stringent Aeropace Welding Standard (AWS) D17.1. The inspection process is critical to avoid carbon monoxide poisoning, loss of power, or fire and requires thorough review. LearnHartzell Aviation’s best practices and how to inspect your aircraft exhaust system and parts.

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New and Overhauled Aircraft Exhaust Parts

Our technicians, with an impressive 319 years of combined welding experience, are the backbone of our operations. The fact that two of our original employees from 1987 are still part of the team is a testament to our commitment to excellence. Whether your project is large or small, simple or complex, we offer expert solutions for all your aircraft exhaust needs, ensuring you can trust us with your aircraft.Hartzell Aviationholds a Class I, II unlimited FAA repair station certificate and European Aviation Safety Agency (EASA) approval. Learn more aboutHartzell Aviation’s overhaul services and process from start to finish.

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Special Services – Twin Cessna Exhaust Airworthiness Directive Compliance (AD 2000-01-16)

Hartzell Aviation is authorized to fulfill the overhaul requirements of “Paragraph G” under Title 14, Section 43 of the Code of Regulation. Paragraph G sets the standards and procedures necessary for the maintenance, repair, and overhaul of aircraft exhaust systems as outlined by regulatory authorities. These guidelines ensure that all work meets specific safety and quality criteria We recommend replacing all exhaust components during engine overhauls. AtHartzell Aviation, we restore exhaust components to like-new condition using OEM materials and processes. Our exhaust systems are designed to surpass the 2500-hour inspection interval between changes. However, due to the challenges of removing some configurations, we advise replacing them during engine changes for optimal removal.

Twin Cessna Exhaust AD 2000-01-16

Many components in these exhaust systems can be manufactured from stainless steel, Inconel, or a combination of both. According to the Cessna Maintenance Manual, exhaust systems made of stainless steel, partial steel, or those with unknown or repaired materials must undergo ultrasonic inspection every 500 hours of use time. This inspection is crucial for detecting any potential issues or wear and tear, especially for slip joints, turbo inlet wyes, and aft exhaust elbows. AD 2000-01-16 does not waive this ultrasonic inspection requirement or mandate using Inconel parts.

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Special Services – Radial Exhaust and Vintage Restorations

In addition to rebuilding and repairing older exhaust systems,Hartzell Aviationis the largest manufacturer of radial exhaust systems worldwide and produces new exhaust systems for out-of-production aircraft. Our radial exhausts are made for various aircraft, from the earliest Boeing still in flight to robust agricultural cropdusters and the latest aerial firefighting aircraft.

 

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Aircraft Exhaust Systems FAQs

Below you will find a series of industry frequently asked questions surrounding aircraft exhaust systems. Read on to find out more information or contact us today with your aircraft exhaust system question or request.

What is the role of the aircraft exhaust systems in general aviation models?

Aviation exhaust systems play a crucial role beyond expelling waste gases. They manage engine performance, reduce noise, assist in cabin heating, and optimize back pressure for efficient engine power.

What are the different aircraft exhaust components?

A typical aircraft exhaust system consists of an: 

  • Aircraft exhaust manifold
  • Aircraft exhaust stack 
  • Heat exchangers (mufflers)
  • Any additional components like augmenter tubes and wastegates in turbocharged systems
Why is regular maintenance crucial for aircraft exhaust systems?

Regular maintenance of an aircraft exhaust system ensures safety and performance. Inspections detect cracks, leaks, erosion, heat discoloration, excessive carbon build-up, and erosion or thinning of pipes. Early detection prevents catastrophic failures.

How do SOPs contribute to the safety and longevity of exhaust systems?

Standard Operating Procedures (SOPs) provide instructions for proper aircraft exhaust system operation, troubleshooting, emergency protocols, and maintenance. Following SOPs ensures safe system functionality and ensure you get the most out of your investment.

What Happens If You Don’t Inspect Your Aircraft Exhaust?

If you fail to inspect your aircraft exhaust system, it will lead to the complete failure of your aircraft’s engine and will hamper your airplane’s performance. Be sure to proactively inspect and service your aircraft exhaust system regularly!

Glossary of Terms

Below is a list of some common aircraft fuel system parts and terms.

Exhaust Manifolds: These are the first part of the system that collects hot gases from each of the engine’s cylinders. They’re like pipes that gather all the exhaust in one place before sending it through the rest of the system.

Muffler: After the manifold, the exhaust gases flow into the muffler. This part reduces engine noise. Similar to a car muffler, the aircraft muffler helps keep things quieter both inside and outside the plane.

Tailpipe: The tailpipe is the final stop for exhaust gases. It’s the part you can often see at the back of the plane that guides the gases out of the aircraft and into the air.

Heat Exchangers: Some aircraft exhaust systems include heat exchangers, which use the hot exhaust to warm up the cabin air. It’s an efficient way to keep passengers comfortable without using additional energy.

Turbochargers: In some planes, the exhaust system includes a turbocharger. This part uses the energy from the exhaust gases to compress the air going into the engine, which helps the engine produce more power — especially at higher altitudes where the air is thinner.

OEM Parts: These are parts made by the original equipment manufacturer.

PMA (Parts Manufacturer Approval) Parts: These are parts made by other companies but still approved by the FAA.

Additional Resources

The links below provide further information about aircraft exhaust systems and the value of quality service.

How to Inspect Aircraft Exhaust System Parts

https://hartzellaviation.com/blog/how-to-inspect-aircraft-exhaust-system-parts

Your Aircraft Exhaust System: Tips for Inspection and Maintenance

https://hartzellaviation.com/blog/maintaining-your-aircraft-exhaust-system-tips-for-inspection

Factors and Strategies To Maximize Your Aircraft Resale Value

https://hartzellaviation.com/blog/factors-and-strategies-to-maximize-your-aircraft-resale-value

Contact Us

For reliable and expertly crafted aircraft solutions, trust our team to deliver the quality your aircraft deserves, including compliant welding and restoration services. If you have any questions or need assistance, please contact us today. We’re here to help with all your aircraft needs, providing you with the peace of mind that your aircraft will receive quality treatment.

 

Contact Us

For reliable and expertly crafted aircraft solutions, trust our team to deliver the quality your aircraft deserves, including compliant welding and restoration services.