TASK 72-41-11-300-014 HPC Stage 3 - 8 Drum Disk - Repair The Stage 8 Location Diameter By Metal Spray, Repair-014 (VRS6154)

DMC:V2500-A0-72-41-1101-00A-609A-C|Issue No:002.00|Issue Date:2020-02-01

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

6A3508 6A3648 6A3934 6A3936 6A4189 6A4900 6A5467 6A55926A5594 6A5659 6A6473 6A7379 6A7380 6A7382 6A7383 6A7384 6A7385 6A74016A7705 6A8236 6A8316 6A8318 6A8350

Common Information

TASK 72-41-11-300-014 HPC Stage 3 - 8 Drum Disk - Repair The Stage 8 Location Diameter By Metal Spray, Repair-014 (VRS6154)

Effectivity

FIG/ITEM

PART NO.

01-200

6A3508

01-200

6A3648

01-200

6A3934

01-200

6A3936

01-200

6A4189

01-200

6A4900

01-200

6A5467

01-200

6A5592

01-200

6A5594

01-200

6A5659

01-200

6A6473

01-200

6A7379

01-200

6A7380

01-200

6A7382

01-200

6A7383

01-200

6A7384

01-200

6A7385

01-200

6A7401

01-200

6A7705

01-200

6A8236

01-200

6A8316

01-200

6A8318

01-200

6A8350

01-200

6B1379

01-200

6B1380

01-200

6B1381

01-200

6B1382

01-200

6B1383

01-200

6B1384

01-200

6B1385

01-200

6B1386

01-200

6B1387

01-200

6B1391

01-200

6B1392

01-200

6B1393

01-200

6B1401

01-200

6B1402

01-200

6B1403

01-200

6B1404

01-200

6B1405

01-200

6B1406

General Data

This Repair must only be done when the instruction to do so is given in TASK 72-41-11-200-000 (INSPECTION-000).

The practices and processes referred to in the procedure by the TASK/SUBTASK numbers are in the Standard Practices and Processes Manual (SPM).

NOTE

  1. It is possible that some materials in the Consumable Materials chart cannot be used for some or all of the necessary applications. Before you use the materials, make sure the types, quantities and applications of the materials necessary are legally permitted in your location. All persons must obey all applicable federal, state, local and provincial laws and regulations when it is necessary to work with these materials.

  2. To identify the consumable materials, refer to the Overhaul Processes and Consumables Index (PCI).

  3. Other necessary consumable materials are referred to in the SPM TASKs.

NOTE

Special tools are identified in the procedure by the tool primary number.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Abrasive Blast EquipmentLOCALAbrasive Blast Equipment
Chemical cleaning equipmentLOCALChemical Cleaning Equipment
Dial indicatorLOCALDial indicator
Lathe/Grinding machineLOCALLathe/Grinding machine
Metal spray equipmentLOCALMetal spray equipment
OvenLOCALOven
Penetrant Crack Test EquipmentLOCALPenetrant Crack Test Equipment
Standard workshop equipmentLOCALStandard workshop equipment
Vibro-engraving equipmentLOCALVibro-engraving equipment
Workshop inspection equipmentLOCALWorkshop inspection equipment
IAE 3R19389 Grinding fixture0AM53IAE 3R193891

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-019 TAPE, ADHESIVE PAPER HEAT RESISTING MASKING76381CoMat 02-019
CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5)00BB6CoMat 03-038
CoMat 03-248 METAL SPRAY POWDERLOCALCoMat 03-248
CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADELOCALCoMat 05-001
CoMat 06-018 FLUORESCENT PENETRANT (POST-EMULSIFIED HIGH SENSITIVITY)37676CoMat 06-018
CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)LOCALCoMat 06-022

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-11-220-296 Examine the HP Compressor - Stages 3 to 8 Disk Shaft Assembly

      1. Inspect the HP compressor - stages 3 to 8 disk shaft assembly to see if production salvage PSD2873 has been carried out before.

      1. If production salvage PSD2873 has been carried out contact IAE Technical Services.

    2. SUBTASK 72-41-11-325-052 Turn the HP Compressor - Stages 3 to 8 Disk Shaft Assembly

      CAUTION

      TITANIUM COMPONENT - YOU MUST USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS, BLEND AND POLISH THIS COMPONENT.

      CAUTION

      TITANIUM COMPONENT - DO NOT USE FORCE WITH MECHANICAL CUTTERS OR THE MATERIAL WILL BECOME TOO HOT.

      CAUTION

      IF THE MATERIAL SHOWS A CHANGE IN COLOR, TO DARKER THAN A LIGHT STRAW COLOR, THE COMPONENT IS TO BE REJECTED.

      CAUTION

      DO NOT REMOVE MORE MATERIAL THAN IS NECESSARY.

    1. Refer to Figure and Figure.

      2. Install the fixture in to the lathe.

      1. Use IAE 3R19389 Grinding fixture grinding fixture 1 off a locally made fixture.

        Use a lathe and standard workshop equipment.

      3. Install the HP compressor - stages 3 to 8 disk shaft assembly on to the fixture and set to turn correctly.

      1. Use a dial test indicator and standard workshop equipment.

        Make sure that datum A and B are set to turn correctly.

      4. Turn the location diameter, to remove all damage.

      1. Use a lathe and standard workshop equipment.

        Machine only the minimum quantity of material to remove scores or coating.

        NOTE

        If a metal spray layer has been applied before, make sure all metal spray is removed.

      5. Remove burrs.

      1. Use standard workshop equipment.

    3. SUBTASK 72-41-11-110-075 Do a Swab Etch

      1. Chemically clean.

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

        Use chemical cleaning equipment.

      2. Swab etch the location diameter.

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

        Use chemical cleaning equipment.

    4. SUBTASK 72-41-11-230-077 Do a Crack Test

      1. Do a local penetrant crack test on the location diameter.

    5. SUBTASK 72-41-11-220-297 Examine the HP Compressor - Stages 3 to 8 Disk Shaft Assembly

    1. Refer to Figure and Figure.

      2. Measure the dimension of the location diameter.

      1. Use workshop inspection equipment.

        Keep this dimension for use with Step.

    6. SUBTASK 72-41-11-110-076 Clean the HP Compressor - Stages 3 to 8 Disk Shaft Assembly

      1. Chemically clean the assembly.

      1. Refer to the SPM TASK 70-11-34-300-503.

        Use chemical cleaning equipment.

      2. Oven dry the assembly.

      1. Heat to a temperature of 302 deg F (150 deg C) for 1 hour.

        Use an oven.

    7. SUBTASK 72-41-11-350-077 Seal the Surfaces Not to be Repaired

    1. Refer to Figure, Figure and Figure.

      2. Locally degrease in the area to be repaired.

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

        Use chemical cleaning equipment.

      3. Seal the areas not to be repaired.

      1. NOTE

        The heat resistant masking tape permits the blasting and sprayed coating to be done in one operation.

    8. SUBTASK 72-41-11-120-056 Abrasive Blast the Surface to be Repaired

      CAUTION

      TO PREVENT CONTAMINATION, DO NOT TOUCH THE SURFACE WHICH IS CLEANED FOR REPAIR.

      CAUTION

      TOO MUCH ABRASIVE BLAST CAN CAUSE DETERIORATION OF THE PREPARED SURFACE CONDITION AND MUST BE PREVENTED.

    1. Refer to Figure, Figure and Figure.

      2. Abrasive blast the surface to be repaired.

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

    9. SUBTASK 72-41-11-340-056 Metal Spray the Location Diameter

    1. Refer to Figure, Figure and Figure.

      2. Apply metal spray.

      1. Refer to the SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-025 or SUBTASK 70-34-01-340-021.

        Apply sufficient metal spray to get the correct dimensions when machined, refer to Step.

    3. Remove masking tape.

    10. SUBTASK 72-41-11-320-054 Turn/Grind the HP Compressor - Stages 3 to 8 Disk Shaft Assembly

      CAUTION

      TITANIUM COMPONENT - YOU MUST USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS, BLEND AND POLISH THIS COMPONENT.

      CAUTION

      TITANIUM COMPONENT - DO NOT USE FORCE WITH MECHANICAL CUTTERS OR THE MATERIAL WILL BECOME TOO HOT.

      CAUTION

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

      CAUTION

      TITANIUM COMPONENT - YOU MUST ENSURE THAT DURING TURNING/GRINDING NO SPARKS ARE PRODUCED.

    1. Refer to Figure and Figure.

      2. Install the fixture in to the lathe/grinding machine.

      1. Use IAE 3R19389 Grinding fixture grinding fixture 1 off or a locally made fixture.

        Use a lathe/grinding machine and standard workshop equipment.

      3. Install the HP compressor - stages 3 to 8 disk shaft assembly on to the fixture and set to turn/grind correctly.

      1. Use a dial test indicator and standard workshop equipment.

        Make sure that datum A and B are set to turn correctly.

      4. Turn/grind the location diameter.

      1. Use a lathe/grinding machine and standard workshop equipment.

        NOTE

        1. If you use CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5) you can turn or grind the component.

        2. If you use CoMat 03-248 METAL SPRAY POWDER you must grind the component.

      5. Remove burrs and overspray.

      1. Use standard workshop equipment.

    11. SUBTASK 72-41-11-110-077 Clean the HP Compressor - Stages 3 to 8 Disk Shaft Assembly

      1. Chemically clean the assembly.

      1. Refer to the SPM TASK 70-11-34-300-503.

        Use chemical cleaning equipment.

      2. Oven dry the assembly.

      1. Heat to a temperature of 302 deg F (150 deg C) for 1 hour.

        Use an oven.

    12. SUBTASK 72-41-11-220-298 Examine the HP Compressor - Stages 3 to 8 Disk Shaft Assembly

    1. Refer to Figure, Figure and Figure.

      2. Visually examine.

      1. If the material shows a change in color, to a darker than a light straw color, the component is to be rejected.

      2. If any abrasive blasting or metal spray has occurred in area AC you must contact IAE Technical Services.

      3. Measure the dimensions of the location diameter.

        NOTE

        If material removal is found on Location 1005 up to 0.0197 in. (0.50 mm) over a maximum of 180 degrees, the part can be accepted. No additional material removal to this location is permissible.

      1. Use workshop inspection equipment.

    13. SUBTASK 72-41-11-350-078 Identify the Repair

    1. Refer to Figure.

      2. Vibro-engrave VRS6154 adjacent to the part number.

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

        Use vibro-engraving equipment.

        NOTE

        If the parts are already identified with VRS6154 from a repair that was done before, more identification is not necessary.

    14. 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:

Added note. (19VG251)

Manufacturer Code:00BB6
Enterprise Name:INDESTRUCTIBLE PAINT INC
BU Name:INDESTRUCTIBLE PAINT INC
Street:1 INDEPENDENCE DRIVE
City:MONROE
State:CT
Zip Code:06468
Country:USA
Phone Number:1-203-880-9130
Fax Number:1-203-880-9133
Email:dave@indestructiblepaint.com
Internet:www.indestructiblepaint.com
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:37676
Enterprise Name:ITW MAGNAFLUX
BU Name:MAGNAFLUX CORPORATION
Street:155 HARLEM AVE
City:GLENVIEW
State:IL
Zip Code:60025
Country:USA
Phone Number:1-847-657-5300
Fax Number:1-847-867-5388
Internet:www.magnaflux.com
Manufacturer Code:76381
Enterprise Name:3M COMPANY
BU Name:3M COMPANY
Department:3M CENTER
City:ST PAUL
State:MN
Zip Code:55144-1000
Country:USA
Phone Number:1-651-733-1110
Fax Number:1-651-733-9973
Internet:www.mmm.com
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:76381
Supply Number:CoMat 02-019
Type:sp01
Supply Short Name:CoMat 02-019 TAPE, ADHESIVE PAPER HEAT RESISTING MASKING
Supply Name:CoMat 02-019 TAPE, ADHESIVE PAPER HEAT RESISTING MASKING
Specification Groups:
Doc NumberType
OMAT: 2/40 (RR REF)SELLOTAPE 2595 SCAPA 2595 OR 3M HT214
JCR-201 (JAEC REF)SELLOTAPE 2595 SCAPA 2595 OR 3M HT214
Suppliers:
ManufacturerRemarks
76381
K3312
K6835
Manufacturer Code:00BB6
Supply Number:CoMat 03-038
Type:sp01
Supply Short Name:CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5)
Supply Name:CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5)
Specification Groups:
Doc NumberType
OMAT: 3/188 (RR REF)METCO 450NS
JCR-020 (JAEC REF)
Suppliers:
ManufacturerRemarks
00BB6
01FK3
0Y7E4
C1840
IE103
K0455
K6835
Manufacturer Code:LOCAL
Supply Number:CoMat 03-248
Type:sp01
Supply Short Name:CoMat 03-248 METAL SPRAY POWDER
Supply Name:CoMat 03-248 METAL SPRAY POWDER
Specification Groups:
Doc NumberType
MSRR9507/35METCO 447 NS
OMAT:3/179MIL-P-85856/27
Suppliers:
ManufacturerRemarks
LOCAL
39918
K1030
K6835
IE103
IE195
IE200
Manufacturer Code:LOCAL
Supply Number:CoMat 05-001
Type:sp01
Supply Short Name:CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADE
Supply Name:CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADE
Specification Groups:
Doc NumberType
Use one of the CoMat 05-001 letter suffix alternatives.
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:X222X
Supply Number:CoMat 06-018
Type:sp01
Supply Short Name:CoMat 06-018FLUORESCENT PENETRANT (POST-EMULSIFIED HIGH SENSITIVITY)
Supply Name:CoMat 06-018 FLUORESCENT PENETRANT (POST-EMULSIFIED HIGH SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐018 letter suffix material with other CoMat 06‐018 letter suffix materials. Where CoMat 06‐018 is specified with no suffix, use one of the CoMat 06‐018 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:X222X
Supply Number:CoMat 06-022
Type:sp01
Supply Short Name:CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)
Supply Name:CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)
Specification Groups:
Doc NumberType
ARDROX 985-P14 OMAT: 652 (CHEMETALL OAKITE 985-P14)It is not permitted to mix the selected CoMat 06‐022 letter suffix material with other CoMat 06‐022 letter suffix materials. Where CoMat 06‐022 is specified with no suffix, use one of the CoMat 06‐ 022 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Tool Number:Abrasive Blast Equipment
Tool Name:Abrasive Blast Equipment
Link not Found
Manufacturer Code:LOCAL
Tool Number:Dial indicator
Tool Name:Dial indicator
Manufacturer Code:0AM53
Tool Number:IAE 3R19389
Tool Name:IAE 3R19389 Grinding fixture
Manufacturer Code:LOCAL
Tool Number:Lathe/Grinding machine
Tool Name:Lathe/Grinding machine
Manufacturer Code:LOCAL
Tool Number:Metal spray equipment
Tool Name:Metal spray equipment
Manufacturer Code:LOCAL
Tool Number:Oven
Tool Name:Oven
Link not Found
Link not Found
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