TASK 72-32-93-300-003 Intermediate Structure Front Fairing - Repair The Unbond, Repair-003 (VRS1447)

DMC:V2500-A0-72-32-9302-00A-621A-C|Issue No:001.00|Issue Date:2013-11-01

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 72-32-93-300-003 Intermediate Structure Front Fairing - Repair The Unbond, Repair-003 (VRS1447)

Effectivity

FIG/ITEM

PART NO.

01-200

5A3447

01-200

5A0836

01-200

5A1444

01-200

5A1830

Material of component

DESCRIPTION

SYMBOL

MATERIAL

Fairing

CFRP

Stiffener and edge plate

Aluminum alloy

General

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

All adhesive application and bonding operations shall be done in controlled environment rooms that are designated for non-silicon materials

This repair gives two alternative procedures for adhesive process.

Price and availability - none

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Abrasive blast equipmentLOCALAbrasive blast equipment
OvenLOCALOven
Tensile testerLOCALTensile tester
Vibrating marking pencilLOCALVibrating marking pencil
IAE 3J12765 Bonding fixture0AM53IAE 3J12765

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-031 ACETONE (CH3)2COLOCALCoMat 01-031
CoMat 01-060 ACETONE (CH3)2COLOCALCoMat 01-060
CoMat 01-124 ISOPROPYL ALCOHOLLOCALCoMat 01-124
CoMat 01-201 DISTILLED, DEIONIZED, DEMINERALIZED, OR REVERSE OSMOSIS (RO) WATERLOCALCoMat 01-201
CoMat 01-275 CHROMATE CONVERSION COATING FOR ALUMINIUMLOCALCoMat 01-275
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001
CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADELOCALCoMat 05-003
CoMat 05-016 GARNET PAPER, 80-GRITLOCALCoMat 05-016
CoMat 05-017 GARNET PAPER, 60 GRITLOCALCoMat 05-017
CoMat 06-021 SURFACE INSPECTION FLUIDLOCALCoMat 06-021
CoMat 08-013 COLD CURING SILICONE COMPOUNDLOCALCoMat 08-013
CoMat 08-014 PRIMER, SILICONE ADHESIVE/SEALANT0AM53CoMat 08-014
CoMat 08-015 RESINLOCALCoMat 08-015
CoMat 08-016 HARDENERLOCALCoMat 08-016

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-32-93-360-054 Remove the Damaged Stiffeners or Edge Plate for Bond Repair

    1. Refer to Figure.

      2. CAUTION

        TAKE EXTREME CARE NOT TO DAMAGE THE CFRP FAIRING, THE STIFFENER OR EDGE PLATE.

        Remove the damaged front or rear stiffener or edge plate from the CFRP fairing.

      1. Use hand methods.

    2. SUBTASK 72-32-93-360-055 Remove Adhesive Residue

    1. Refer to Figure.

      2. Remove the adhesive residue from the mating surface of the CFRP fairing and stiffeners or edge plate.

    3. SUBTASK 72-32-93-360-056 Make the Test Pieces for the Tensile Test

    1. Refer to Figure

    2. NOTE

      This SUBTASK is not required if Step is used in bonding process.

      Make the three test pieces.

      3. Prepare the mating surfaces of the test pieces.

      1. Refer to Step.

      4. Apply and cure the adhesive.

        1. Refer to Step, B, C and F for the use of the same mixed batch as applied to the front fairing in the bond.

        1. Use an electric oven.

    4. SUBTASK 72-32-93-360-057 Prepare the Surfaces of the Front or Rear Stiffeners and the Edge Plate for Bonding

      CAUTION

      AFTER PREPARATION, THE MATING SURFACES MUST BE FULLY CLEANED AND MUST NOT BE TOUCHED BY HAND, TO PREVENT CONTAMINATION.

    1. Refer to Figure and Figure.

      2. Remove the grease from the bonding surfaces.

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

      3. Mask all the areas that are not to be blasted.

      4. Dry abrasive blast the bonding surfaces.

        1. Use an air pressure of 43 to 57 psi (297 to 393 Kpa) for the minimum time necessary to clean the parts.

        2. Refer to the SPM TASK 70-12-02-120-501.

    5. Do Step again.

      6. Do a water break test to make sure that the bonding surfaces are clean.

      7. Remove the break test fluid by swabbing.

    8. Remove the masking tape.

    5. SUBTASK 72-32-93-360-058 Prepare the Surface of the CFRP Fairing for Bonding

    1. Refer to Figure.

      2. CAUTION

        AFTER PREPARATION, THE MATING SURFACES MUST BE FULLY CLEANED AND MUST NOT BE TOUCHED BY HAND, TO PREVENT CONTAMINATION.

        Swab degrease the bonding surfaces.

      3. Mask all the areas that are not to be blasted.

      4. Dry abrasive blast the bonding surfaces.

        1. Use an air pressure of 43 to 57 psi (297 to 393 Kpa) for the minimum time necessary to clean the part.

        2. Refer to the SPM TASK 70-12-02-120-501.

    5. Do Step again.

      6. Do a water break test to make sure that the bonding surfaces are clean.

        1. Refer to the SPM TASK 70-36-02-360-501 and SUBTASK 70-36-02-360-011.

      7. Remove the break test fluid by swabbing.

    8. Remove the masking tape.

    6. SUBTASK 72-32-93-360-059 Apply and Cure the Two Part Low Temperature Curing Sealant/Adhesive

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

      2. CAUTION

        YOU MUST USE PLASTIC GLOVES, DURING THE PREPARATION AND USE OF THE ADHESIVE TO PREVENT CONTAMINATION OF THE SKIN.

        CAUTION

        YOU MUST NOT EAT ANYTHING OR SMOKE AT THE LOCATIONS WHERE THESE MATERIALS ARE USED.

        NOTE

        This SUBTASK is an alternative to Step.

        Make up the adhesive from the two parts.

      1. Refer to the SPM TASK 70-36-02-360-501 and SUBTASK 70-36-02-360-021.

      3. Apply the adhesive to each of the mating surface of the stiffener, edge plate and CFRP fairing.

      1. Use a spatula or small trowel.

    4. Align the countersunk holes of the CFRP fairing and the front or rear stiffener.

      5. Assemble the CFRP fairing front or rear stiffener and the edge plate on the bonding fixture and apply pressure.

      6. Cure the adhesive at 203 to 221 deg F (95 to 105 deg C) for one hour.

      1. Use an electric oven.

    7. SUBTASK 72-32-93-360-063 Apply and Cure the Cold Curing Silicone Rubber Compound

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

      2. CAUTION

        YOU MUST USE PLASTIC GLOVES, DURING THE PREPARATION AND USE OF THE ADHESIVE TO PREVENT CONTAMINATION OF THE SKIN.

        CAUTION

        YOU MUST NOT EAT ANYTHING OR SMOKE AT THE LOCATIONS WHERE THESE MATERIALS ARE USED.

        NOTE

        This SUBTASK is an alternative to Step.

        NOTE

        The primer must be applied immediately after the mating surfaces are prepared. It is cured at room temperature by touching to moisten in air.
        If the parts are not used immediately, after the primer is applied, they must be kept in polythene bags; but for no longer than 24 hours.

        Apply a thin layer of primer only to the mating surface of the stiffener, edge plate and CFRP fairing. Dry in air for 30 minutes.

        1. Refer to the SPM TASK 70-36-02-360-501 and SPM SUBTASK 70-36-02-360-020.

      3. Apply cold curing silicone rubber compound to each of the mating surface of the stiffener, edge plate and CFRP fairing.

        1. Refer to the SPM TASK 70-36-02-360-501 and SPM SUBTASK 70-36-02-360-020.

    4. Align the countersunk holes of the CFRP fairing and the front or rear stiffener.

      5. Assemble the CFRP fairing front or rear stiffener and the edge plate on the bonding fixture and apply pressure.

      6. NOTE

        The part can be touched after 12 hours.

        Cure the compound at 68 deg F (20 deg C) for 48 hours.

      1. Do not apply a load during this time.

    8. SUBTASK 72-32-93-220-058 Examine the Repaired Area of the Front Fairing Assembly

    1. Refer to Figure, Figure and Figure.

    2. Visually and dimensionally examine the front fairing assembly.

      3. Do a tensile test on three test pieces.

        1. Use a tensile tester.

        1. Minimum tensile strength 3250 psi (22.4 MPa) at room temperature.

    9. SUBTASK 72-32-93-350-053 Make a Mark on the Front Fairing Assembly

    1. Vibro-engrave VRS1447 adjacent to the part number using the vibrating marking pencil.

      2. Apply the chromate conversion coating to the marked repair number.

    10. 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
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:LOCAL
Enterprise Name:LOCALLY SUPPLIED
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:LOCAL
Supply Number:CoMat 01-060
Type:sp01
Supply Short Name:CoMat 01-060 ACETONE (CH3)2CO
Supply Name:CoMat 01-060 ACETONE (CH3)2CO
Specification Groups:
Doc NumberType
OMAT:1/176 (RR REF)ANALAR GRADE
JCR-017 (JAEC REF)ANALAR GRADE
MTH 169 (96%) (MTU REF)ANALAR GRADE
392-101010 (FIAT REF)ANALAR GRADE
Suppliers:
ManufacturerRemarks
LOCAL
06637
24853
k3504
K6835
U1185
Manufacturer Code:LOCAL
Supply Number:CoMat 01-124
Type:sp01
Supply Short Name:CoMat 01-124 ISOPROPYL ALCOHOL
Supply Name:CoMat 01-124 ISOPROPYL ALCOHOL
Specification Groups:
Doc NumberType
OMAT:1/40GPR TECHNICAL GRADE
PMC 9094GPR TECHNICAL GRADE
JCR-011GPR TECHNICAL GRADE
Suppliers:
ManufacturerRemarks
LOCAL
U1185
24853
K6835
Manufacturer Code:LOCAL
Supply Number:CoMat 01-201
Type:sp01
Supply Short Name:CoMat 01-201 DISTILLED, DEIONIZED, DEMINERALIZED, OR REVERSE OSMOSIS (RO) WATER
Supply Name:CoMat 01-201 DISTILLED, DEIONIZED, DEMINERALIZED, OR REVERSE OSMOSIS (RO) WATER
Specification Groups:
Doc NumberType
DISTILLED, DEIONIZED, DEMINERALIZED, OR REVERSE OSMOSIS (RO) WATERTHAT HAS 50,000 ohm‐cm MINIMUM ELECTRICAL RESISTIVITY OR 20 microsiemens/cm MAXIMUM ELECTRICAL CONDUCTIVITY, AND pH 5.0- 8.0.
Suppliers:
ManufacturerRemarks
LOCAL
06637
Manufacturer Code:00BB6
Supply Number:CoMat 01-275
Type:sp01
Supply Short Name:CoMat 01-275 CHROMATE CONVERSION COATING FOR ALUMINIUM
Supply Name:CoMat 01-275 CHROMATE CONVERSION COATING FOR ALUMINIUM
Specification Groups:
Doc NumberType
BONDERITE M-CR-1200S AEROJCR-047 (JAEC REF)
JCR-048 (JAEC REF)SPMC 206 (PW REF)
Suppliers:
ManufacturerRemarks
00BB6
71410
Manufacturer Code:LOCAL
Supply Number:CoMat 02-001
Type:sp01
Supply Short Name:CoMat 02-001 ADHESIVE TAPE (MASKING)
Supply Name:CoMat 02-001 ADHESIVE TAPE (MASKING)
Specification Groups:
Doc NumberType
OMAT: 230 (RR REF)ZINC OXIDE AT142
JCR-197 (JAEC REF)ZINC OXIDE AT142
Suppliers:
ManufacturerRemarks
LOCAL
K6835
U0415
Manufacturer Code:X222X
Supply Number:CoMat 05-003
Type:sp01
Supply Short Name:CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE
Supply Name:CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE
Specification Groups:
Doc NumberType
Use one of the CoMat 05-003 letter suffix alternatives.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:0KHE3
Supply Number:CoMat 05-016
Type:sp01
Supply Short Name:CoMat 05-016 GARNET PAPER, 80-GRIT
Supply Name:CoMat 05-016 GARNET PAPER, 80-GRIT
Specification Groups:
Doc NumberType
GARNET PAPER, CAMI GRIT SIZE 80 GRADE 0 (ANSI B74.18)
Suppliers:
ManufacturerRemarks
0KHE3
1E1X8
LOCAL
C4347
K0993
K2F42
K6835
V571V
Manufacturer Code:0KHE3
Supply Number:CoMat 05-017
Type:sp01
Supply Short Name:CoMat 05-017 GARNET PAPER, 60 GRIT
Supply Name:CoMat 05-017 GARNET PAPER, 60 GRIT
Specification Groups:
Doc NumberType
GARNET PAPER, CAMI GRIT SIZE 60 GRADE 1/2 (ANSI B74.18)
Suppliers:
ManufacturerRemarks
0KHE3
1E1X8
C4347
LOCAL
K0993
K6835
Manufacturer Code:00BB6
Supply Number:CoMat 06-021
Type:sp01
Supply Short Name:CoMat 06-021 SURFACE INSPECTION FLUID
Supply Name:CoMat 06-021 SURFACE INSPECTION FLUID
Specification Groups:
Doc NumberType
NML 21
Suppliers:
ManufacturerRemarks
00BB6
K3504
K6835
Manufacturer Code:X222X
Supply Number:CoMat 08-013
Type:sp01
Supply Short Name:CoMat 08-013 COLD CURING SILICONE COMPOUND
Supply Name:CoMat 08-013 COLD CURING SILICONE COMPOUND
Specification Groups:
Doc NumberType
If CoMat 08-013 is specified without an asterisk or a letter suffix, use one of the letter suffix alternative materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:X222X
Supply Number:CoMat 08-014
Type:sp01
Supply Short Name:CoMat 08-014 PRIMER, SILICONE ADHESIVE/SEALANT
Supply Name:CoMat 08-014 PRIMER, SILICONE ADHESIVE/SEALANT
Specification Groups:
Doc NumberType
Use the applicable letter suffix material. Refer to SPM TASK 70-36-02-360-501.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Supply Number:CoMat 08-015
Type:sp01
Supply Short Name:CoMat 08-015 RESIN
Supply Name:CoMat 08-015 RESIN
Specification Groups:
Doc NumberType
RENGEL SV.409 OMAT: 805
RENGEL SV.409 JCR-146
Suppliers:
ManufacturerRemarks
LOCAL
IE432
IE200
IAE77
K1007
k3504
Manufacturer Code:LOCAL
Supply Number:CoMat 08-016
Type:sp01
Supply Short Name:CoMat 08-016 HARDENER
Supply Name:CoMat 08-016 HARDENER
Specification Groups:
Doc NumberType
CRAYAMID 140 OMAT: 806
CRAYAMID 140 JCR-147
Suppliers:
ManufacturerRemarks
LOCAL
18598
IE200
k3504
K3713
K6835
Link not Found
Manufacturer Code:0AM53
Tool Number:IAE 3J12765
Tool Name:IAE 3J12765 Bonding fixture
Manufacturer Code:LOCAL
Tool Number:Oven
Tool Name:Oven
Manufacturer Code:LOCAL
Tool Number:Tensile tester
Tool Name:Tensile tester
Link not Found