TASK 72-32-51-300-016 LP Rotor Center Shaft - Repair By Plasma Spraying The Bearing Journal, Repair-016 (VRS1280)

DMC:V2500-A0-72-32-5101-00A-609A-C|Issue No:002.00|Issue Date:2015-08-01

Export Control

EAR Export Classification: Not subject to the EAR per 15 C.F.R. Chapter 1, Part 734.3(b)(3), except for the following Service Bulletins which are currently published as EAR Export Classification 9E991: SBE70-0992, SBE72-0483, SBE72-0580, SBE72-0588, SBE72-0640, SBE73-0209, SBE80-0024 and SBE80-0025.

Copyright

© IAE International Aero Engines AG (2001, 2014 - 2021) The information contained in this document is the property of © IAE International Aero Engines AG and may not be copied or used for any purpose other than that for which it is supplied without the express written authority of © IAE International Aero Engines AG. (This does not preclude use by engine and aircraft operators for normal instructional, maintenance or overhaul purposes.).

Applicability

All

Common Information

TASK 72-32-51-300-016 LP Rotor Center Shaft - Repair By Plasma Spraying The Bearing Journal, Repair-016 (VRS1280)

Effectivity

FIG/ITEM

PART NO.

01-100

5R7016

Material of component

RR

DESCRIPTION

SYMBOL

MATERIAL

Rotor center shaft coating

Titanium alloy

tungsten carbide/cobalt

General

Price and availability

Refer to IAE

The practices and processes referred to in the procedure by the TASK numbers are in the SPM.

This TASK gives the procedure for plasma spraying the bearing journal of the rotor center shaft.

The use of clean gloves is necessary to carefully prevent contamination by perspiration of by salts.

NOTE

Equivalent equipment may be used.

NOTE

To identify the consumable materials refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
LatheLOCALLathe
Grinding machineLOCALGrinding machine
Fluorescent Penetrant Inspection EquipmentLOCALFluorescent Penetrant Inspection Equipment
Magnifying glassLOCALMagnifying glass

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-003 ADHESIVE TAPE BLACK WATERPROOFLOCALCoMat 02-003
CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOILK0993CoMat 02-006
CoMat 02-051 HIGH TEMPERATURE GLASS CLOTH TAPE0AM53CoMat 02-051
CoMat 03-300 METAL SPRAYING POWDER,WC/Co0AM53CoMat 03-300
CoMat 03-320 METAL SPRAYING POWDER,WC/CoLOCALCoMat 03-320
CoMat 05-031 CAST STEEL SHOT DELETED0AM53CoMat 05-031
CoMat 05-130 ABRASIVE DELETED0AM53CoMat 05-130
CoMat 07-102 STOPPING-OFF LACQUER0AM53CoMat 07-102

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-32-51-330-059 Strip the Plasma Coating

    1. Refer to Figure.

      2. Mask off areas other than plasma coating bearing journal.

      3. Strip the plasma coating.

      1. Apply the electrolytic rochelle carbonate solution to remove the coating.

      2. Refer to the SPM TASK 70-33-59-300-503.

    2. SUBTASK 72-32-51-325-052 Machine the Bearing Journal that is Plasma Sprayed

    1. Refer to Figure

      2. Locate the rotor center shaft on a lathe, set the rotor center shaft to run true. Secure the rotor center.

      1. Use a lathe.

    3. Machine off the scale surface of plasma removed area of the bearing journal.

      4. Machine off the surface of the scale surface removed at Step B area further 0.001 in. (0.03 mm) in depth. Diameter after machining must be between 8.6588in. (219.936 mm) and 8.6483in. (219.666 mm). Break any sharp edges.

      1. See Machining Data.

    3. Machining Data

    Machine speed .. .. .. 65.62 ft (20 m) per minute

    Rate of feed .. .. .. 2.54in. (0.1 mm) per revolution

    Machining Data is for guidance only.

    NOTE

    Hold the diameter to a maximum to allow for subsequent repairs. However any previous coating and damage must be removed. If less than 8.6483 in. (219.666 mm), reject the rotor center.

    3. SUBTASK 72-32-51-220-111 Inspect the Rotor center Shaft

      1. Do a visual inspection for the machined area.

      1. Refer to the SPM TASK 70-21-01-220-501.

    2. Dimensionally inspect the machined area.

    4. SUBTASK 72-32-51-230-061 Examine the Rotor center Shaft for Cracks

      1. Do a crack test.

      1. Refer to the SPM TASK 70-23-03-230-501.

      2. No cracks permitted.

    5. SUBTASK 72-32-51-380-058 Shot Peen the Rotor Center Shaft

    1. Refer to Figure.

      2. Apply the masking tape.

      1. Apply the masking tape to the areas which are not to be shot peened.

      3. Shot peen the bearing journal to an intensity of 6.A.

      1. Do the procedure given in the SPM TASK 70-38-04-300-503.

      3. Complete coverage is required.

    6. SUBTASK 72-32-41-120-054 Abrasive Blast the Rotor Center Shaft

    1. Refer to Figure.

      2. Mask off areas that are not to be plasma sprayed.

      3. Abrasive blast the rotor center shaft surface to be plasma sprayed.

      1. Refer to the SPM TASK 70-34-01-340-501.

      3. Amount of dimensional change by blasting is negligible and does not affect subsequent procedure.

    7. SUBTASK 72-32-51-340-054 Apply Plasma Spray on the Bearing Journal

    1. Refer to Figure

      2. Touch up masking if necessary.

      3. Apply plasma spray, a diameter of 8.679 in. (220.45 mm) to 8.676 in. (220.35 mm) is required after plasma spraying.

      1. Refer to the SPM TASK 70-34-01-340-501.

    8. SUBTASK 72-32-51-324-059 Grind the Bearing Journal

    1. Refer to Figure.

    2. Remove the masking tape.

      3. Locate the rotor center shaft on a grinding machine, set the rotor center shaft to run true. Secure the rotor center.

      1. Use a grinding machine.

      4. Grind the plasma sprayed bearing journal between 8.6675 in. (220.156 mm) and 8.6664 in. (220.126 mm).

      1. See Machining Data.

        Machining Data

        Grinder .. .. .. .. 487.68 ft (1600 m) per minute

        Shaft .. .. .. .. 7.92 ft (26 m) per minute

        Machining Data is given for guidance only.

    9. SUBTASK 72-32-51-324-060 Grind the Oil Hole Portion of the Bearing Journal

    1. Refer to Figure and Figure.

      2. Grind the oil hole portion of the bearing journal between 8.6633 in. (220.05 mm) and 8.6619 in. (220.01 mm).

      1. Use a grinding machine.

        See Machining Data.

        Machining Data

        Grinder .. .. .. .. 304.8 ft (1000 m) per minute

        Shaft .. .. .. .. 7.62 ft (25 m) per minute

        Feed .. .. .. .. 0.000039 in. (0.001 mm) per revolution

        Machining Data is given for guidance only

    3. If plasma sprayed layer still exists, it may be ground to the minimum diameter of 8.6591in. (219.94 mm).

    4. Remove burrs.

      NOTE

      Keep material removal to the minimum to allow subsequent repairs. However, any remaining plasma sprayed layer must be removed.

    10. SUBTASK 72-32-51-230-062 Examine the Rotor Center Shaft for Cracks

      1. Do a crack test.

      1. Refer to the SPM TASK 70-23-03-230-501.

      2. No cracks permitted.

    11. SUBTASK 72-32-51-220-112 Examine the Rotor Center Shaft

      1. Do a visual inspection.

      1. Use a magnification glass.

      2. Visually examine the plasma sprayed area for chips, cracks, lifted material and coating that is not attached to the parent material.

      3. Surfaces that show heat cracks are not permitted.

    12. SUBTASK 72-32-51-350-053 Identify the Repair

    1. Refer to Figure.

      2. Make a beehive symbol mark with the letters PS inside the beehive and mark VRS1280 adjacent to part number as shown.

      1. Make a permanent mark by the procedure given in the SPM TASK 70-09-00-400-501.

      2. Use electrolytic permanent mark.

    13. Figure: Rotor center Shaft

    Rotor center Shaft

    Figure: Machine the bearing journal

    Machine the bearing journal

    Figure: Shot peening and abrasive blast

    Shot peening and abrasive blast

    Figure: Apply plasma spraying

    Apply plasma spraying

    Figure: Grind the plasma sprayed bearing journal

    Grind the plasma sprayed bearing journal

    Figure: Grind the oil hole portion

    Grind the oil hole portion

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised note to remove "materials or". (PSAF 15VC314)

Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:K0993
Enterprise Name:3M (UK) PLC
BU Name:3M (UK) PLC
Street:3M CENTRE, CAIN ROAD
City:BRACKNELL
Zip Code:RG12 8HT
Country:UNITED KINGDOM
Phone Number:44-161-236-8500
Fax Number:44-161-237-6136
Internet:www.mmm.co.uk
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 02-003
Type:sp01
Supply Short Name:CoMat 02-003 ADHESIVE TAPE BLACK WATERPROOF
Supply Name:CoMat 02-003 ADHESIVE TAPE BLACK WATERPROOF
Specification Groups:
Doc NumberType
OMAT: 285ISATAPE 160
Suppliers:
ManufacturerRemarks
LOCAL
IE305
K6835
Manufacturer Code:K6835
Supply Number:CoMat 02-006
Type:sp01
Supply Short Name:CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL
Supply Name:CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL
Specification Groups:
Doc NumberType
OMAT: 298 (RR REF)SCOTCH 425
Suppliers:
ManufacturerRemarks
K6835
52152
76381
LOCAL
Manufacturer Code:X111X
Supply Number:CoMat 02-051
Type:sp01
Supply Short Name:CoMat 02-051 HIGH TEMPERATURE GLASS CLOTH TAPE
Supply Name:CoMat 02-051 HIGH TEMPERATURE GLASS CLOTH TAPE
Suppliers:
ManufacturerRemarks
X111X
Manufacturer Code:0AM53
Supply Number:CoMat 03-300
Type:sp01
Supply Short Name:CoMat 03-300 METAL SPRAYING POWDER, WC/Co
Supply Name:CoMat 03-300 METAL SPRAYING POWDER,WC/Co
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
0AM53
Manufacturer Code:LOCAL
Supply Number:CoMat 03-320
Type:sp01
Supply Short Name:CoMat 03-320 METAL SPRAYING POWDER, WC/Co
Supply Name:CoMat 03-320 METAL SPRAYING POWDER,WC/Co
Specification Groups:
Doc NumberType
MSRR9507/1METCO 73F-NS-2
OMAT:3/114C
Suppliers:
ManufacturerRemarks
LOCAL
39918
56923
IE103
IE195
IE200
K1030
K6835
Manufacturer Code:0AM53
Supply Number:CoMat 05-031
Type:sp01
Supply Short Name:CoMat 05-031 CAST STEEL SHOT DELETED
Supply Name:CoMat 05-031 CAST STEEL SHOT DELETED
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
0AM53
Manufacturer Code:X111X
Supply Number:CoMat 05-130
Type:sp01
Supply Short Name:CoMat 05-130 ABRASIVE DELETED
Supply Name:CoMat 05-130 ABRASIVE DELETED
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
X111X
Manufacturer Code:0AM53
Supply Number:CoMat 07-102
Type:sp01
Supply Short Name:CoMat 07-102 STOPPING-OFF LACQUER
Supply Name:CoMat 07-102 STOPPING-OFF LACQUER
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
0AM53
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Lathe
Tool Name:Lathe
Link not Found