TASK 72-32-85-300-056 Fan Case - Repair Worn Or Damaged Countersunk Bolthole At Flange FA, Repair-056 (VRS1512)

DMC:V2500-A0-72-32-8501-07A-649A-C|Issue No:004.00|Issue Date:2021-08-01

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 72-32-85-300-056 Fan Case - Repair Worn Or Damaged Countersunk Bolthole At Flange FA, Repair-056 (VRS1512)

Effectivity

FIG/ITEM

PART No.

01-100

5W0069

01-100

5W0072

01-100

5W0081

01-100

5W0093

01-100

5W0094

01-100

5W0100

01-100

5W0124

01-100

5W0144

01-100

5W0149

01-100

5W0154

01-100

5W0168

01-100

5W0169

01-100

5W0171

01-100

5W0172

01-100

5W0184

01-100

5W0186

01-100

5W0187

01-100

5W0188

01-100

5W0189

01-100

5W0190

01-100

5W0191

01-100

5W0192

01-100

5W0193

01-100

5W0194

01-100

5W0195

01-100

5W0196

01-100

5W0197

01-100

5W0198

01-100

5W0199

01-100

5W0200

01-100

5W0201

01-100

5W0202

01-100

5W0203

01-100

5W0204

01-100

5W0205

01-100

5W0206

01-100

5W0207

01-100

5W0208

01-100

5W0209

01-100

5W0210

01-100

5W0211

01-100

5W0212

01-100

5W0213

01-100

5W0214

01-100

5W0215

01-100

5W0216

01-100

5W0217

01-100

5W0218

01-100

5W0219

01-100

5W0220

01-100

5W0221

01-100

5W0222

01-100

5W0223

01-100

5W0224

01-100

5W0225

01-100

5W0226

01-100

5W0306

01-100

5W0307

01-100

5W0313

General

This Repair scheme gives the procedure for re-shaping the bolt holes by filling repair for worn or damaged countersunk hole in the Fan Case Assembly.

Material of Components

PART IDENT

SYMBOL

MATERIAL

Fan Case Assembly

Titanium alloy

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

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Portable blending equipmentLOCALPortable blending equipment
Standard Workshop EquipmentLOCALStandard Workshop Equipment
Vibro-engraving equipmentLOCALVibro-engraving equipment
Vacuum cleanerLOCALVacuum cleaner
Workshop inspection equipmentLOCALWorkshop inspection equipment

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-031 ACETONE (CH3)2COLOCALCoMat 01-031
CoMat 02-097 LINT-FREE GLOVESX111XCoMat 02-097
CoMat 02-100 GLOVES, LINT-FREELOCALCoMat 02-100
CoMat 05-020 WATERPROOF SILICON CARBIDE1E1X8CoMat 05-020
CoMat 05-021 WATERPROOF SILICON CARBIDE1E1X8CoMat 05-021
CoMat 05-075 WATERPROOF SILICON CARBIDE1E1X8CoMat 05-075
CoMat 05-076 WATERPROOF SILICON CARBIDE1E1X8CoMat 05-076
CoMat 05-084 WATERPROOF SILICON CARBIDE1E1X8CoMat 05-084
CoMat 05-085 WATERPROOF SILICON CARBIDE1E1X8CoMat 05-085
CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)X222XCoMat 06-063
CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)X222XCoMat 06-064
CoMat 08-147 FILLER, METAL FILLEDLOCALCoMat 08-147
CoMat 08-165 SURFACE REPLICATING MATERIAL,QUICK SET THIXOTROPIC2R260CoMat 08-165

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-32-85-220-198 Examine the Fan case Assembly (01-100) for Damaged Area

      WARNING

      ALWAYS MAKE SURE THAT THERE IS SUFFICIENT VENTILATION IN THE WORK AREA. PROTECTIVE CLOTHING, FACE MASKS AND EYE PROTECTION MUST ALWAYS BE USED. DO NOT LET THE SOLVENT CLEANER OR ITS VAPOR TOUCH YOUR EYES OR SKIN. ALWAYS KEEP OPEN FLAMES AWAY FROM THE WORK AREA.

      2. Clean the fan case.

      1. Refer to SPM TASK 70-11-26-300-503.

      3. Examine the damaged area dimensionally.

      1. Measure the dimensions of the damaged areas. The damaged area must satisfy dimension given in Figure, Figure, Figure and Figure.

        If more than dimensional limits, do bush repair, refer to repair, VRS1565 TASK 72-32-85-300-057 (REPAIR-057).

      4. Crack test on the damaged area.

      1. Do the crack test.

      3. Cracked in the bore and countersunk surface.

      4. Blend cracks which begin only from bore and countersunk surface. Refer to maximum limits given in figure for the countersunk bolt hole dimensions, refer to Figure and Figure.

    2. SUBTASK 72-32-85-350-158 Blend the Worn or Damaged Fan Case Assembly (01-100)

      CAUTION

      TITANIUM COMPONENT - YOU MUST USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS, BLEND AND POLISH THIS COMPONENT. IF MECHANICAL CUTTERS ARE USED, ONLY LIGHT CUTS MUST BE MADE TO AVOID OVERHEATING THE MATERIAL.

      CAUTION

      TITANIUM COMPONENT - AVOID BUILD UP OF HEAT BY APPLYING ONLY GENTLE PRESSURE AND KEEPING THE TOOL SPEED AS LOW AS POSSIBLE. USE TECHNIQUES WHICH ALLOW FOR PROGRESSIVE WEAR OF THE DRESSING MEDIA TO PRESENT A CONTINUALLY FRESH CUTTING SURFACE TO THE WORK PIECE. DO NOT DWELL ON ONE AREA OF THE COMPONENT. DRESS, WHERE POSSIBLE, IN A CIRCULAR MOTION; TAKING LIGHT CUTS TO AVOID OVERHEATING.

      CAUTION

      TITANIUM COMPONENT - YOU MUST MAKE SURE THAT WHEN YOU REMOVE MATERIAL, BLEND AND POLISH, TO MAKE SMOOTH, THAT NO SPARKS ARE PRODUCED AND THE ADJACENT AREA IS MASKED OFF.

      CAUTION

      TITANIUM COMPONENT - IF THE MATERIAL SHOWS A CHANGE IN COLOUR DURING DRESSING, TO DARKER THAN A LIGHT STRAW COLOUR, THE COMPONENT IS TO BE REJECTED.

      CAUTION

      POWER BLENDING TOOLS MAY BE USED IF DAMAGED TITANIUM PART IS PERIODICALLY CHECKED FOR HEAT BUILD-UP BY TOUCHING OCCASIONALLY WITH UNGLOVED HAND. IF TITANIUM PART BECOMES TOO HOT TO TOUCH, ALLOW MATERIAL TO COOL BEFORE CONTINUING REPAIR.

      CAUTION

      THE FAN CASE IS MADE FROM TITANIUM ALLOY AND IS THIN IN SOME AREAS. IF YOU BLEND TOO MUCH, THE PART CANNOT BE SERVICEABLE AND WILL HAVE TO BE REPLACED.

      CAUTION

      DO NOT OPERATE WITHOUT SAFETY GOGGLES AND OTHER GUARDS EQUIPMENT. FLYING PARTICLES CAN CAUSE INJURY.

    1. Refer to Figure, Figure, Figure and Figure.

      NOTE

      1. Dull tools and worn or loaded abrasive equipments generate heat rapidly and should be checked frequently and replaced when necessary.

      2. Remove the minimum quantity of material necessary to remove the damage. All blends must be smooth and continuous.

      3. Keep the material removal to the minimum necessary to remove damage.

      2. Blend the fan case assembly at fretted surfaces.

      1. Remove all raised materials and sudden changes the contour of the fan case.

        Remove only the minimum amount of material.

      3. Polish the blended area.

      1. Polish the repaired area to give a surface finish the same as the adjacent material.

    3. SUBTASK 72-32-85-110-092 Do a Swab Etch

      1. Chemically clean.

      1. Refer to SPM TASK 70-11-08-300-503, SUBTASK 70-11-08-300-001.

        Use chemical cleaning equipment.

      2. Swab etch the blended area.

      1. Refer to SPM TASK 70-11-08-300-503, SUBTASK 70-11-08-300-002.

      2. Use chemical cleaning equipment.

    4. SUBTASK 72-32-85-230-070 Examine the Blended Area of the Fan Case Assembly (01-100)

    1. Refer to Figure and Figure.

      3. Examine the blended area.

        1. Measure the dimensions of the blended areas.

        1. The blended area must satisfy dimension given in Figure and Figure.

        2. If necessary, do Step to Step again.

        3. If more than dimensional limits, do bush repair, refer to repair, VRS1565 TASK 72-32-85-300-057 (REPAIR-057).

    5. SUBTASK 72-32-85-350-159 Prepare the Repair Area

      WARNING

      ALWAYS MAKE SURE THERE IS SUFFICIENT VENTILATION IN THE WORK AREA. EYE PROTECTION MUST ALWAYS BE USED. DO NOT LET THE SOLVENT CLEANER OR ITS VAPOR TOUCH THE EYES OR SKIN. PROTECTIVE CLOTHING AND FACE MASKS MUST ALWAYS BE USED. ALWAYS KEEP OPEN FLAMES AWAY FROM THE WORK AREA. IT IS THE RESPONSIBILITY OF THE OPERATOR TO OBTAIN AND OBSERVE THE MANUFACTURERS MATERIAL SAFETY DATA SHEETS FOR CONSUMABLE MATERIALS INFORMATION SUCH AS, HAZARDOUS INGREDIENTS, PHYSICAL/CHEMICAL CHARACTERISTICS, FIRE EXPLOSION, REACTIVITY, HEALTH HAZARD DATA, PRECAUTIONS FOR SAFE HANDLING, USE AND CONTROL MEASURES AND ALSO TO TAKE LOCAL REGULATIONS INTO CONSIDERATION.

      WARNING

      DO NOT OPERATE WITHOUT SAFETY GOGGLES AND OTHER GUARDS EQUIPMENT. FLYING PARTICLES CAN CAUSE INJURY.

      CAUTION

      YOU MUST USE OIL FREE DRY AIR ONLY.

    1. Refer to Figure and Figure.

      2. Make the roughed surface for better adhesion on fretted (repaired) surfaces.

      3. Clean the roughed area.

        1. Remove all remaining unwanted material with a vacuum cleaner or oil free dry air blast.

    6. SUBTASK 72-32-85-360-106 Apply the Filler

    1. Refer to Figure, Figure and Figure.

      2. Prepare the filler.

      1. Use CoMat 08-147 FILLER, METAL FILLED. Weigh out 43 parts of base compound and ten parts of curing compound.

        Mix the two parts by kneading until the color of compound is constant quality. No streaks permitted.

        NOTE

        Wear CoMat 02-097 LINT-FREE GLOVES or CoMat 02-100 GLOVES, LINT-FREE before you touch the parts.
        The life of the mixed filling material is approximately 20 minutes at 77 deg F (25 deg C).

      3. Apply the filler to the polished area.

        1. Take care not to touch the prepared (polished) surfaces.

        1. Use putty knife or spatula.

          NOTE

          Applying filling material at temperatures below 70 deg F (21 deg C) lengthens functional cure and application life times.

      4. Cure the filler.

      1. Allow the CoMat 08-147 FILLER, METAL FILLED to cure for four hours at ambient temperature 75 deg F (24 deg C). Refer to attached technical data sheet.

        NOTE

        Make sure the full cure time is used and hold the correct temperature.

      5. Remove unwanted filler.

      1. Remove all unwanted filler.

        NOTE

        Allow material to cure for at least four hours before machining, but wait no longer than 24 hours.

      6. Polish the area of the repair.

      1. Use CoMat 05-075 WATERPROOF SILICON CARBIDE or CoMat 05-076 WATERPROOF SILICON CARBIDE. Polish the repaired area to smooth surface. Make sure that the surface finish is the same as the adjacent surface.

    7. SUBTASK 72-32-85-220-199 Examine the Filled Area

    1. Refer to Figure, Figure, Figure and Figure.

      2. Examine the repaired area.

      1. Measure the dimensions of the repaired area.

        The repaired area must satisfy dimension given in Figure, Figure and Figure.

        If necessary, do step 9. again.

    8. SUBTASK 72-32-85-350-160 Identify the Repair

    1. Refer to Figure, Figure and Figure.

      2. Make a mark repair symbol adjacent the repaired hole, refer to Figure and Figure.

      1. Refer to SPM TASK 70-09-00-400-501, SUBTASK 70-09-00-400-001.

        Use vibro-engraving equipment.

      3. Make a mark repair symbol, VRS1512 and hole numbers adjacent the part number, refer to Figure and Figure.

      1. Refer to SPM TASK 70-09-00-400-501, SUBTASK 70-09-00-400-001.

        Use vibro-engraving equipment.

    9. Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Update step reference links in task. (CAS-105804-M5S4Y3)

Manufacturer Code:1E1X8
Enterprise Name:SAINT-GOBAIN CERAMICS AND PLASTICS, INC
BU Name:SAINT-GOBAIN CERAMICS AND PLASTICS, INC
Street:1 NEW BOND ST
City:WORCESTER
State:MA
Zip Code:01606
Country:UNITED STATES OF AMERICA
Phone Number:1-508-795-5000, 1-800-243-0028
Fax Number:1-508-795-2380
Internet:www.saint-gobain-northamerica.com
Manufacturer Code:2R260
Enterprise Name:FLEXBAR MACHINE CORP.
BU Name:FLEXBAR MACHINE CORP.
Street:250 GIBBS ROAD
City:ISLANDIA
State:NY
Zip Code:11749
Country:USA
Phone Number:1-631-582-8440, 1-800-879-7575
Fax Number:1-631-582-8487
Email:sales@flexbar.com
Internet:www.flexbar.com
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X111X
Enterprise Name:N/A – DELETED CONSUMABLE MATERIAL
Manufacturer Code:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
Manufacturer Code:LOCAL
Supply Number:CoMat 01-031
Type:sp01
Supply Short Name:CoMat 01-031 ACETONE (CH3)2CO
Supply Name:CoMat 01-031 ACETONE (CH3)2CO
Specification Groups:
Doc NumberType
OMAT: 150 (RR REF)COMMERCIAL GRADE O-A-51
PMC 9008 (PW REF)COMMERCIAL GRADE O-A-51
JCR-041 (JAEC REF)COMMERCIAL GRADE O-A-51
MTH 169 (98%) (MTU REF)COMMERCIAL GRADE O-A-51
Suppliers:
ManufacturerRemarks
LOCAL
K6835
81348
K3504
U1185
24853
70657
Manufacturer Code:X111X
Supply Number:CoMat 02-097
Type:sp01
Supply Short Name:CoMat 02-097 LINT-FREE GLOVES
Supply Name:CoMat 02-097 LINT-FREE GLOVES
Specification Groups:
Doc NumberType
DELETED. USE COMAT 02-100.
Suppliers:
ManufacturerRemarks
X111X
Manufacturer Code:LOCAL
Supply Number:CoMat 02-100
Type:sp01
Supply Short Name:CoMat 02-100 GLOVES, LINT-FREE
Supply Name:CoMat 02-100 GLOVES, LINT-FREE
Specification Groups:
Doc NumberType
MISC 127 (PW REF)WHITE LINT-FREE NYLON INSPECTION/INSPECTOR GLOVES
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:1E1X8
Supply Number:CoMat 05-020
Type:sp01
Supply Short Name:CoMat 05-020 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-020 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/33 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 320 (ANSI B74.18)
JCR-027 (JAEC REF)
JCR-186 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
LOCAL
K6835
Manufacturer Code:1E1X8
Supply Number:CoMat 05-021
Type:sp01
Supply Short Name:CoMat 05-021 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-021 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/35 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 240 (ANSI B74.18 )
JCR-188 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
K6835
LOCAL
Manufacturer Code:1E1X8
Supply Number:CoMat 05-075
Type:sp01
Supply Short Name:CoMat 05-075 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-075 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/28 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 800
JCR-181 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
K1905
K6835
LOCAL
Manufacturer Code:1E1X8
Supply Number:CoMat 05-076
Type:sp01
Supply Short Name:CoMat 05-076 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-076 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/30 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 500
JCR-183 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
K6835
LOCAL
Manufacturer Code:1E1X8
Supply Number:CoMat 05-084
Type:sp01
Supply Short Name:CoMat 05-084 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-084 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/41 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 80 (ANSI B74.18)
JCR-194 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
K6835
LOCAL
Manufacturer Code:1E1X8
Supply Number:CoMat 05-085
Type:sp01
Supply Short Name:CoMat 05-085 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-085 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/42 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 60 (ANSI B74.18)
JCR-195 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
K6835
LOCAL
Manufacturer Code:X222X
Supply Number:CoMat 06-063
Type:sp01
Supply Short Name:CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)
Supply Name:CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐063 letter suffix material with other CoMat 06‐063 letter suffix materials. Where CoMat 06‐063 is specified with no suffix, use one of the CoMat 06‐063 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:X222X
Supply Number:CoMat 06-064
Type:sp01
Supply Short Name:CoMat 06-064FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Supply Name:CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐064 letter suffix material with other CoMat 06‐064 letter suffix materials.Where CoMat 06‐064 is specified with no suffix, use one of the CoMat 06‐064 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Supply Number:CoMat 08-147
Type:sp01
Supply Short Name:CoMat 08-147 FILLER, METAL FILLED
Supply Name:CoMat 08-147 FILLER, METAL FILLED
Specification Groups:
Doc NumberType
TITANIUM PUTTY DOD-C-24176B
Suppliers:
ManufacturerRemarks
LOCAL
16059
IE399
IE400
Manufacturer Code:2R260
Supply Number:CoMat 08-165
Type:sp01
Supply Short Name:CoMat 08-165 SURFACE REPLICATINGMATERIAL, QUICK SET THIXOTROPIC
Supply Name:CoMat 08-165 SURFACE REPLICATING MATERIAL,QUICK SET THIXOTROPIC
Specification Groups:
Doc NumberType
REPRORUBBER 16130 OR 16131
Suppliers:
ManufacturerRemarks
2R260
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Manufacturer Code:LOCAL
Tool Number:Portable blending equipment
Tool Name:Portable blending equipment
Manufacturer Code:LOCAL
Tool Number:Standard Workshop Equipment
Tool Name:Standard Workshop Equipment
Manufacturer Code:LOCAL
Tool Number:Vacuum cleaner
Tool Name:Vacuum cleaner
Manufacturer Code:LOCAL
Tool Number:Vibro-engraving equipment
Tool Name:Vibro-engraving equipment
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment