Preliminary Requirements

Procedure

1. Repair Facilities

   1. The source demonstration requirements of this repair means that any facility not authorized to accomplish this repair, either utilize the Authorized Repair Vendors listed below or contact the IAE Repair Services Group to determine if a qualification program can be initiated at their facility.

      IAE International Aero Engines AG

      400 Main Street

      M/S 121-10

      East Hartford CT 06118

      U.S.A.

      Attn: Manager Technical Services

   2. Authorized Repair Vendors for Repair VRS6007 are listed below:

      ENGELHARD CORPORATION

      12 THOMPSON ROAD

      SURFACE TECHNOLOGIES

      EAST WINDSOR CT 06088

      USA

      ATTN. BUSINESS MANAGER, AVIATION SERVICES

      MTU MAINTENANCE GMBH

      FLUGHAFEN HANNOVER

      MUNCHNER STRASSE 31

      POSTFACH 1720

      3012 LANGENHAGEN

      GERMANY

      ATTN. MANAGER, QUALITY ASSURANCE

      ROLLS-ROYCE

      AERO-ENGINE SERVICES LTD

      COMPONENT REFURBISHMENT

      MAVOR AVENUE

      NERSTON

      EAST KILBRIDE

      GLASGOW

      G74 4PY

      SCOTLAND

      ATTN. BUSINESS MANAGER, COMPONENT REFURBISHMENT

      MTU MAINTANANCE ZHUHAI CO., LTD.,

      NO. 1 TIANKE ROAD

      FREE TRADE ZONE

      ZHUHAI, GUANGDONG

      PC: 519030 P.R. CHINA

      ATTN. MANAGER, PARTS REPAIR

      Christchurch Engine Centre - CHCEC

      634 Memorial Avenue

      Christchurch International Airport

      Christchurch, New Zealand

      Lufthansa Technik AG

      HAM WR 420

      PO Box 63 03 00

      D-22313 Hamburg-Airport

      Germany

      Rolls-Royce Inchinnan

      Inchinnan Drive

      Inchinnan Business Park

      Inchinnan, PA4 9AF

      Scotland

      MTU Aero Engines GmbH

      Dachauer Strasse 665

      80995 Muenchen

      Germany

   3. The designation by IAE of an Authorized Repair Vendor indicates that the Repair Vendor has demonstrated the necessary capability to enable it to carry out the listed repair work.

      However IAE makes no warranties or representations concerning the qualification or quality standards of the Repair Vendors to carry out the repair work and accept no responsibility whatsoever for any work that may be carried out by a Repair Vendor other than when IAE is listed as the Repair Vendor. Authorized Repair Vendors do not act as agents or representatives of IAE.

2. SUBTASK 72-41-11-350-059 Remove the Shank Nuts

   1. Remove the shank nuts.

      1. Refer to repair, VRS6220 TASK 72-41-11-300-011 (REPAIR-011).

3. SUBTASK 72-41-11-110-060 Clean the Assembly

   1. Refer to Figure.

   2. Chemically clean at areas marked AD.

4. SUBTASK 72-41-11-120-053 Loosen the Top Coat Lining at Each Stage

   1. Refer to Figure and Figure.

   2. 
      CAUTION
      REMOVE THE TOP COAT ONLY. THE BLAST OPERATION MUST STOP WHEN THE WHITE TOP COAT IS REMOVED. FAILURE TO STOP THE BLAST OPERATION AS SPECIFIED MAY RESULT IN THE PART BEING MADE UNSERVICABLE.

      NOTE

      It is permitted to loosen the top coat lining in part by blasting, to allow the Nitric Acid capillary action, to release both top coats at Stages 6 and 7 for chemical strip step. This step is optional when using water jet to remove linings.

      Seal all surfaces not to be blasted, except areas marked AD.

      1. Use CoMat 02-001 ADHESIVE TAPE (MASKING) or equivalent masking listed in SPM TASK 70-34-18-380-501 or refer to Step. Repair Facilities for approved vendor tools.

   3. Lightly dry blast to loosen top coat lining at each stage.

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

      2. Use CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADE.

   4. Remove the masks.

5. SUBTASK 72-41-11-350-111-001 Remove the Linings at Each Stage by Water Jet (6B1404 and 6A8316 only)

   1. Refer to Figure and Figure.

   2. Remove the lining at each stage by high pressure water blasting.

      NOTE

      This is a source demonstration processes which can only be done by approved vendors.

      NOTE

      This step is applicable to PNs 6B1404 and 6A8316 only.

      NOTE

      This step is an alternative to Step.

      1. Waterjet blasting permitted in areas labeled AH only.

      2. Blasting outside of repair area is not allowed.

      3. Hard mask required in areas labeled AG.

      4. Refer to Figure and Figure.

      5. Remove the abradable lining.

         1. Refer to SPM TASK 70-15-01-160-501.

         2. Make sure the liner is completely removed.

         3. 0.0005 in. (0.0127 mm) maximum erosion from waterjet allowed.

         4. Overspray permitted in areas labeled AJ.

6. SUBTASK 72-41-11-350-112-002 Remove the Linings at Each Stage by Chemical Strip (All PNs)

   1. Refer to Figure, Figure and Figure.

   2. Seal lining to prevent removal.

      1. Refer to Figure.

      2. Seal the lining of the sealing sleeve to prevent removal during the subsequent operation.

         1. Refer to SPM TASK 70-11-35-110-501.

         2. Use CoMat 02-145 STOPPING-OFF COMPOUND.

   3. Chemically remove the linings at each stage.

      1. Refer to Figure and Figure.

      2. Remove the lining at each stage.

         1. Refer to SPM TASK 70-33-59-300-503, SUBTASK 70-33-59-300-002.

         2. Use CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE.

         3. Put the assembly into nitric acid solution and keep below surface until bubbles stop.

         4. Remove assembly from acid immediately after gassing stops.

7. SUBTASK 72-41-11-220-239 Visually Examine Surfaces for Repair

   1. Refer to Figure.

   2. Visually examine.

      1. Make sure all the lining material has been removed. If not do Step and Step or Step again as necessary.

8. SUBTASK 72-41-11-230-061 Do a Focused Crack Test

   1. Do a focused crack test on the rubstrip groove.

      1. Refer to SPM TASK 70-23-04-230-501.

      2. No cracks allowed, reject part if found.

9. SUBTASK 72-41-11-220-090 Dimensionally Examine Surfaces for Repair

   1. Refer to Figure.

   2. Dimensionally examine the radial depth of the groove for the lining at each stage.

      1. If the part is outside the limits given, Reject.

10. SUBTASK 72-41-11-350-083 Seal all Surfaces not to be Repaired

    1. Refer to Figure and Figure.

    2. Seal all surfaces not identified for repair.

       1. Use IAE 3R18056 Mask 1 off, IAE 3R18057 Mask 1 off and/or CoMat 02-001 ADHESIVE TAPE (MASKING) or equivalent masking listed in the SPM TASK 70-34-18-380-501 to seal all surfaces around areas AD.

          1. Alternatively refer to Step. Repair Facilities for approved vendor tools.

11. SUBTASK 72-41-11-120-052 Prepare Surfaces for Repair

    1. 
       CAUTION
       DO NOT TOUCH AREAS TO BE REPAIRED AFTER THEY ARE CLEANED.
       
       CAUTION
       TOO MUCH ABRASIVE BLAST CAN CAUSE DETERIORATION OF THE PREPARED SURFACE CONDITION AND MUST BE PREVENTED.

       Lightly dry blast to prepare surfaces for the lining.

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

       2. Use CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADE.

       3. Be careful not to touch prepared surfaces before plasma spraying.

12. SUBTASK 72-41-11-340-051 Apply the New Linings

    1. Refer to Figure.

    2. Apply the bond coat at each stage.

       1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-007.

       2. Use CoMat 03-037 METAL SPRAYING POWDER,Ni Al.

       3. Apply a thickness of 0.0030 in. to 0.0050 in. (0.076 mm to 0.127 mm).

    3. Apply the top coat at each stage.

       1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-013.

       2. Use CoMat 03-043 METAL SPRAYING POWDER,Al OXIDE.

       3. Total resultant coating thickness (top and bond coat) must be (0.019 in. +/- 0.003 in.) 0.50 mm +/- 0.1 mm.

       4. Apply a layer of sufficient thickness to get the correct dimensions after assembly is machined.

    4. Remove the masks.

13. SUBTASK 72-41-11-220-091 Visually Examine

    1. Visually examine the new linings.

       1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-002.

14. SUBTASK 72-41-11-325-053 Machine the Linings

    1. Refer to Figure and Figure.

    2. Set up the disk assembly to be machined.

       1. Use IAE 3R18735 Turning arbor 1 off.

    3. Machine the linings.

       1. Use IAE 3R18751 Holder 1 off, with IAE 3R18748 RH Insert 1 off.

       2. For titanium linings use IAE 3R18746 Holder 1 off.

       3. For ceramic linings use IAE 3R18747 Diamond insert 1 off.

       4. Machine at 200 feet/min (60 meters per min).

       5. Alternatively refer to Step. Repair Facilities for approved vendor tools.

15. SUBTASK 72-41-11-220-240 Visually and Dimensionally Examine the Repair

    1. Refer to Figure and Figure.

    2. Visually examine the repaired area.

       1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-002.

    3. Dimensionally examine the repaired linings at each stage.

    4. Ensure surface finish on machined surfaces specified AE is 125 microinches (3.2 micrometers) or better.

    5. If the surface finish is not within limits.

       1. Re-machine provided dimensionally repairable.

    6. If the surface finish is not repairable.

       1. Re-apply lining as follows, remove the lining as per Step and Step or Step and repeat repair from Step to Step.

16. SUBTASK 72-41-11-350-062 Replace the Shank Nuts

    1. Replace the shank nuts.

       1. Refer to Repair, VRS6220 TASK 72-41-11-300-011 (REPAIR-011).

17. SUBTASK 72-41-11-110-062 Clean the Assembly

    1. Chemically clean the part.

       1. Refer to TASK 72-41-00-100-000.

18. SUBTASK 72-41-11-350-063 Identify the Repair

    1. Refer to Figure.

    2. Vibro-engrave VRS6007 adjacent to the part number.

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: The Position of the Identification Marks

The Position of the Identification Marks