The 'Number 1' Maintenance SME Recognized by Overseas Helicopter Companies

[Asia Economy Yang Nak-gyu, Military Specialist Reporter] The International Institute for Strategic Studies (IISS) in the UK evaluated global military power last year and ranked South Korea's helicopter force as the 4th largest in the world. The United States holds the top spot with about 3,900 helicopters, followed by China with around 1,000, and Russia operating about 800. South Korea currently possesses over 500 helicopters, including attack helicopters such as the AH-64E Apache Guardian and AH-1S/F Cobra, utility helicopters like the UH-60P and Surion, and large transport helicopters such as the CH-47D Chinook. Given the large number of helicopters, maintenance is essential. To assess the maintenance capabilities of domestic defense companies, we visited UI Helicopter located in Yesan, Chungnam, on the 6th.

Upon entering the company’s headquarters, the vast site area of 115,702㎡ (35,000 pyeong) immediately suggested that this was an aviation maintenance facility. The company handles maintenance not only for civilian helicopters used by the Fire Agency and Police Agency but also for the Army’s main attack helicopter, the Cobra (AH-1). The buildings are organized according to helicopter size.

Inside the civilian helicopter maintenance building, red and blue helicopters were disassembled to the point where their shapes were barely recognizable. The markings on the helicopter bodies indicated they belonged to the Busan Fire Helicopter, Police Helicopter, and Jeonnam Fire Helicopter. These aircraft require overhaul maintenance after a certain number of flight hours. Overhaul maintenance involves completely disassembling the aircraft to inspect, repair, and replace parts.

Im Seong-ui, CEO of UI Helicopter, said, "Overhaul maintenance is not just simple maintenance but is at the level of reassembly." He added, "We are certified by Bell and have the capability to maintain over 30 types of helicopters from nine companies worldwide."

Moving to the adjacent maintenance building, a painting operation was underway on a 4-meter-long Cobra helicopter blade (rotor blade). Since the blade spins at speeds of 200 km/h, even tiny dust particles can cause scratches. Repeated scratches can affect flight performance. The painting process involves four types of paint, including stealth paint to evade enemy radar and paint that repels lightning, taking more than 14 hours. Because the blade is sensitive to weight and balance, the paint must be applied evenly. This is a core technology and the reason UI Helicopter is the only company in Korea capable of blade maintenance.

UI Helicopter plans to domestically produce the blade connection device (CUFF) for the UH-60 transport helicopters used by the military. Previously, to replace the connection device, it had to be sent directly to the manufacturer, taking 18 months and costing 120 million KRW per unit for repairs. However, with domestic production expected to be completed by April next year, replacement time will be reduced to 6 months and repair costs to 90 million KRW, making it more affordable. This will also increase aircraft operational rates for the military. The company emphasized that after starting with the UH-60, it will soon domestically produce parts for other helicopter models.

Lee Jong-cheol, Head of Quality and Safety, said, "The Forest Service mainly requests maintenance for helicopters during wildfire prevention periods, and the Coast Guard during typhoon seasons," adding, "We can guarantee maintenance periods with both domestic technology and maintenance expertise."

In the next building, overhaul maintenance of a transmission was in progress. The transmission transfers power from the helicopter engine to the blades. On the workbench lay a disassembled transmission from a Cobra attack helicopter, with over 500 parts. Each part undergoes non-destructive testing using ultrasound. Afterwards, parts are either replaced or repaired. Outside the factory, the overhauled transmission looked like a brand-new product just unwrapped from its packaging.

Leaving the factory, there was a sense of anticipation that the vast factory grounds would soon be filled with helicopters. The technological capabilities of domestic small and medium enterprises seemed more than sufficient.