DAS Aviation Expands Heat Exchanger Service for Cessna Business Jets with Reliable Two-Week Turnaround

DAS Aviation expands its heat exchanger inspection, repair and overhaul service to help Cessna business-jet operators reduce downtime and avoid costly replacements. The program delivers an average two-week turnaround while restoring every unit to original manufacturer specifications, giving operators a fast, dependable path back to service.

"Heat exchangers operate in one of the harshest environments on the aircraft, facing both structural and thermal stress," says 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."

DAS begins each project with a comprehensive incoming inspection to assess both internal structural and external physical condition. Pressure testing and defect evaluation determine whether a unit remains serviceable and what corrective action is required. Common findings include fin damage, surface oxidation and corrosion, structural cracking, and general wear from time in service. Repairs are then matched to findings—minor local repairs for small, isolated defects or complete overhauls when damage is more extensive—including re-core services that replace the core assembly. Finished units move to the paint shop for final finishing before returning to service.

Typical repair or overhaul turnaround is approximately two weeks, helping operators keep aircraft available for both scheduled maintenance and AOG needs. When even a short turnaround isn't fast enough, DAS maintains flat-rate exchange units in stock and ready to ship, providing an immediate option to return aircraft to service. Whatever the requirement, DAS has a solution.

A new DAS video offers a behind-the-scenes look at the process, demonstrating how technicians remove old welds from the end caps, fit new cores using a precision jig to ensure alignment, complete welding, and perform a leak check to verify seal integrity. The video also highlights the operational realities the heat exchangers face—particularly extreme heat at the bottom—which wears down the coils and degrades the aluminum fins, sometimes leading to leaks. When functioning properly, the units deliver pressurized and conditioned hot or cold air to the cabin.

With over a decade of hands-on experience, DAS has completed a substantial volume of repairs and overhauls backed by deep, proven, in-house expertise. Its team routinely services units on Cessna Citation 560XL aircraft and supports a wide range of the broader Cessna business-jet fleet, including 680 series models. 

"Our customers expect fast, dependable turn times," Rietschel adds. "By standardizing our evaluation and repair workflow and adhering to OEM specifications, we deliver consistent quality across the Cessna fleet."

DAS Aviation's heat exchanger services are available now for scheduled maintenance and AOG support.

For quotes, availability, or to watch the repair video, visit https://dasaviation.com.