Legacy V-Band clamps have remained essentially the same in turbocharged aircraft for some time now. Traditional V-Band clamps are subjected to extreme temperatures, vibration, and mechanical stress, which can lead to unnecessary wear and in-flight risks. Now, Hartzell is reimagining the part to be more robust, hoping to increase its reliability and performance with a new innovative design. 

With a recent airworthiness directive affecting more than 40,000 aircraft, operators throughout general aviation are facing a combination of aging clamp designs, supply chain shortages, and limited replacement options.

At EAA AirVenture 2025, SocialFlight Live! podcast host Jeff Simon spoke with Hartzell Engine Technologies president Keith Bagley about the scale of the problem and how a new V-Band design is aiming to eliminate the root cause of traditional clamp failures. 

Read on as we explore why these failures occur, how the current situation developed, and what the new clamp design could mean for aircraft owners and maintenance professionals.

The Industry Problem: Legacy V-Bands and Supply Chain Shortages

V-Bands are simple in appearance but play a critical role in securing high-temperature turbocharger and exhaust joints. Their placement in high-stress areas means that failure can lead to immediate and significant operational issues.

During the AirVenture conversation, Simon described the core issue clearly:

“There was an airworthiness directive for turbocharged engine exhaust systems where the V-Bands could fail, and it is almost grounding the industry because you cannot get the parts.”

Bagley went on to talk about the scale of the issue:

“There is this perfect storm of supply chain issues and the AD. There are over 40,000 aircraft in the field that are impacted by this and at risk of being grounded because parts are not available.”

This is made all the more difficult by the fact that many available replacement parts are the same legacy designs with the same documented failure modes that originally prompted regulatory attention.

Why Traditional V-Band Clamps Fail

Traditional V-Band clamps have been a persistent concern in aircraft maintenance due to their tendency to develop problems under the extreme heat and vibration found in turbocharged exhaust systems. Over time, technicians across the industry have identified a consistent set of failure modes that can compromise clamp integrity, leading to leaks, performance issues, or unexpected grounding. Understanding these common weaknesses is an important step in reducing risk and improving long-term reliability.

 

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1. Spot Weld Cracking

The airworthiness directive focuses heavily on the risk of cracking around spot welds. These welds act as stress concentration points that degrade under repeated heat cycles and vibration.

2. Rivet Fatigue

The new V-Band design eliminates rivets, addressing another weak point found in many older clamps. Traditional V-Bands can develop problems when rivets or latch mechanisms loosen or fatigue over time, compromising the clamp’s integrity in high-stress environments.

3. Heat and Vibration-Induced Distortion

Turbocharged aircraft components regularly cycle from ambient temperatures to extreme heat. This metal expansion and contraction can be a danger to operators and their aircraft, leading to:

• Band warping
• Stretching of t-bolts
• Latch misalignment
• Incomplete clamp seating
  
  

These issues can create exhaust leaks or complete clamp failure.

Hartzell’s Patent Pending Solution: A Weld-Free and Rivet-Free V-Band

 

In response to widespread frustration and safety concerns, Hartzell Engine Technologies developed a new, patent-pending V-Band design that eliminates the two most common failure points in legacy models.

According to Bagley, 

“We are under patent protection now on a unique and novel V-Band that eliminates spot welds. It is rivet-free as well.” 

This design directly addresses the structural weaknesses identified in traditional clamps.

Certification Testing Already Underway

 

The new V-Band is not simply a concept. It is already deep into testing and early field use. Bagley shared several important developments.

• Approximately 400 hours of engine testing are underway at the Hartzell facility.
• Two test programs have already been completed in OEM engine test cells.
• Two prototype V-Bands are currently flying on a customer aircraft.
• Internal testing indicates strong performance and durability.
  
  

Bagley summarized their confidence, “We have two V-Bands that are flying on a customer’s airplane right now. So we have high confidence in the capabilities.”

Installation and Inspection Will Remain Familiar

A significant benefit of the new design is that it does not require new tooling or new procedures. Mechanics will follow nearly identical steps to those used with existing clamps.

Bagley noted, “Installation is going to be very similar to the current V-Bands. It is install, torque check at 50 hours, and then fly it to TBO.” For maintenance teams, this means a simple transition to a stronger and more reliable product.

Why This Matters for the General Aviation Community

Historically, operators have faced repeated challenges related to:

• Long backorders
• Inconsistent availability of OEM hardware
• Overreliance on aging designs
• Limited trustworthy aftermarket options
  
  

Signia Aerospace is focused on long-term investment in the general aviation market by strengthening product support and ensuring that critical components remain available. Many smaller manufacturers have struggled with continuity and lacked clear paths to sustain their products, putting important parts at risk of disappearing from the market. 

Bringing these legacy products under a stable, well-resourced organization helps preserve them for the future. The new V-Band design reflects this commitment by offering a durable, long-term solution for the large number of aircraft affected by the current airworthiness directive.

With certification testing underway and early units already flying, this design represents an important step toward improving safety and stability across the turbocharged GA fleet.

Trust Hartzell Aviation to deliver the superior magnetos you need to fly with confidence and precision. We are proud to offer top-of-the-line magneto overhaul services, ensuring your aircraft’s ignition system operates at peak performance.

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