TASK 72-41-11-840-002-002 HPC Stage 3 - 8 Drum Disk - Machine The Grooves For The Wire Seals, Rework-002 (Method 1) - SBE 72-0160

DMC:V2500-A0-72-41-1101-01A-933A-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 72-41-11-840-002-002 HPC Stage 3 - 8 Drum Disk - Machine The Grooves For The Wire Seals, Rework-002 (Method 1) - SBE 72-0160

Effectivity

FIG/ITEM

PART NO.

01-200

6A3934

01-200

6A3936

01-200

6A4189

General

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

Refer to the indicated Service Bulletin for specific application requirements.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
LatheLOCALLathe
Milling machineLOCALMilling machine
Dial test indicatorsLOCALDial test indicators
Standard turning toolLOCALStandard turning tool
Ball-nosed milling cutterLOCALBall-nosed milling cutter
Standard workshop toolsLOCALStandard workshop tools
Vibrating marking pencilLOCALVibrating marking pencil
IAE 3R19100 Front groove tool0AM53IAE 3R19100
IAE 3R19079 Front groove tool0AM53IAE 3R19079
IAE 3R19080 Rear groove tool0AM53IAE 3R19080

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-031 ACETONE (CH3)2COLOCALCoMat 01-031
CoMat 02-005 ADHESIVE TAPE (MASKING)LOCALCoMat 02-005
CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)LOCALCoMat 06-022
CoMat 06-032 DRY DEVELOPER37676CoMat 06-032
CoMat 06-045 EMULSIFIER - FLUORESCENT PENETRANT, HYDROPHILICLOCALCoMat 06-045

Spares

NONE

Safety Requirements

CAUTION

TITANIUM COMPONENT - USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS, BLEND AND POLISH THIS COMPONENT.
TITANIUM COMPONENT - DO NOT USE FORCE WITH MECHANICAL CUTTERS OR THE MATERIAL WILL BECOME TOO HOT.
TITANIUM COMPONENT - IF THE MATERIAL SHOWS A CHANGE IN COLOR TO DARKER THAN A LIGHT STRAW COLOR, THE COMPONENT IS TO BE REJECTED.
YOU MUST TAKE CARE AT ALL TIMES DURING THE REWORK CYCLE AND MAKE SURE THAT NO HANDLING DAMAGE OCCURS TO THE INSTALLED ROTOR BLADES.
DURING THE REWORK CYCLE OF THE HP COMPRESSOR ARRANGEMENT, MASKING IS NECESSARY. REFER TO Figure. MAKE SURE MASKING IS KEPT SOUND DURING REWORK CYCLE, REPLACE AS NECESSARY.
DURING THE REWORK CYCLE OF THE HP COMPRESSOR ARRANGEMENT ALL CUTTING AND CLEANING FLUIDS USED MUST BE CHLORINE FREE.
CHLORINE WILL CAUSE DAMAGE TO TITANIUM COMPONENTS AND IF USED WILL NECESSITATE A COMPLETE STRIP AND CLEAN OF THE HP COMPRESSOR ARRANGEMENT.

Procedure

    1. SUBTASK 72-41-11-110-069 Clean the Surfaces

      1. Clean the disk assembly locating faces.

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

    2. SUBTASK 72-41-11-350-073 Apply the Masking Tape

      1. Apply the masking tape to the interface between stage 8 and 9 disks and all other areas, surfaces that do not have to be machined.

      2. Make sure that cutting and cleaning fluids cannot penetrate the masking.

      3. Refer to Figure.

    3. SUBTASK 72-41-11-320-053 Machine the Damping Wire Location Slots

      1. Set up the HP compressor arrangement for machining.

      1. Use standard workshop tools with centre lathe.

      2. Use dial test indicator to make sure HP compressor runs true.

      3. Refer to Figure.

      2. Face-off angled surface at the rear of the stage 8 dovetail slot leaving the 0.028 in. (0.72mm) to 0.032 in. (0.82mm) dimension intact.

      1. Use standard turning tool.

      2. Flat surface required to avoid deflection/breakage of fine groove tool during machining.

      3. Refer to Figure.

      3. Machine the damping wire location slots at the front and rear of stages 7 and 8 blade root location slots.

      2. Refer to Figure and Figure.

      4. NOTE

        Do not machine to full depth of above, allowance for final machining is required.

        Machine the damping wire location slots at the front and rear of stages 7 and 8 blade root location slots.

      2. Refer to Figure and Figure.

      5. Remove sharp edges.

      1. Use standard turning tool.

    6. Remove disk assembly from machine.

      7. Set up the disk assembly machine cusp at stage 7 location slot.

      1. Use 0.160in. (4mm) dia. ball-nosed milling cutter with standard milling machine.

      8. Machine to remove the cusp.

      1. See Figure and Figure.

      9. Remove sharp edges.

      1. Use standard workshop tools.

    4. SUBTASK 72-41-11-110-070 Clean the Surfaces

      1. Chemically clean the machined surfaces in preparation for crack test.

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

      2. Swab etch machined surfaces.

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

    6. SUBTASK 72-41-11-110-071 Clean the Disk Assembly

      1. Clean the machined surfaces.

      1. Refer to the SPM TASK 70-11-03-300-503 SUBTASK 70-11-03-300-002.

      2. Remove the masking tape.

      1. Make sure all remnants of tape are removed.

      3. Chemically clean to remove masking tape remnants as necessary.

      1. Refer to the SPM TASK 70-11-03-300-503, SUBTASK 70-11-03-300-002.

    7. SUBTASK 72-41-11-220-116 Examine the Rotor Blades and HP Compressor

      1. Visually examine the rotor blades and HP compressor arrangement for any form of handling damage.

      1. Refer to the SPM TASK 72-21-00-220-501.

    8. SUBTASK 72-41-11-350-074 Identify the Reworked Part with the New Part Number

      1. NOTE

        Stage 3 rotor blades require to be moved forwards to allow re-identification of stage 3 to 8 HP disk assembly. Disassembly/Assembly of stage 3 to 8 HP disk assembly. Refer to Engine Manual, 72-41-10.

        Replace the part number with the new part number.

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

        NUMBER BEFORE 6A4189.

        NEW NUMBER 6A5594.

        NUMBER BEFORE 6A3934.

        NEW NUMBER 6A5592.

        NUMBER BEFORE 6A3936.

        NEW NUMBER 6A5659.

      2. Use vibro-engraving equipment.

    9. Figure: Rework of stage 3 to 8 disk assembly

    Rework of stage 3 to 8 disk assembly

    Figure: Rework of HP compressor rotor assembly

    Rework of HP compressor rotor assembly

    Figure: Rework of existing compressor shaft assembly (stage 8)

    Rework of existing compressor shaft assembly (stage 8)

    Figure: Rework of existing compressor shaft assembly (stage 7)

    Rework of existing compressor shaft assembly (stage 7)

    Figure: Rework of existing compressor shaft assembly (stage 7)

    Rework of existing compressor shaft assembly (stage 7)

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: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: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 02-005
Type:sp01
Supply Short Name:CoMat 02-005 ADHESIVE TAPE (MASKING)
Supply Name:CoMat 02-005 ADHESIVE TAPE (MASKING)
Specification Groups:
Doc NumberType
OMAT: 2/94 (RR REF)AT 7 BLACK, WATERPROOF
Suppliers:
ManufacturerRemarks
LOCAL
U0415
K6835
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:37676
Supply Number:CoMat 06-032
Type:sp01
Supply Short Name:CoMat 06-032 DRY DEVELOPER
Supply Name:CoMat 06-032 DRY DEVELOPER
Specification Groups:
Doc NumberType
ZYGLO ZP-4B
Suppliers:
ManufacturerRemarks
37676
Manufacturer Code:X222X
Supply Number:CoMat 06-045
Type:sp01
Supply Short Name:CoMat 06-045 EMULSIFIER - FLUORESCENT PENETRANT, HYDROPHILIC
Supply Name:CoMat 06-045 EMULSIFIER - FLUORESCENT PENETRANT, HYDROPHILIC
Specification Groups:
Doc NumberType
USE THE COMAT 06‐045 LETTER SUFFIX MATERIAL THAT IS APPLICABLE TO THE APPLIED PENETRANT. REFER TO THE APPLICABLE SPM FPI TASK.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Tool Number:Ball-nosed milling cutter
Tool Name:Ball-nosed milling cutter
Link not Found
Manufacturer Code:0AM53
Tool Number:IAE 3R19079
Tool Name:IAE 3R19079 Front groove tool
Manufacturer Code:0AM53
Tool Number:IAE 3R19080
Tool Name:IAE 3R19080 Rear groove tool
Manufacturer Code:0AM53
Tool Number:IAE 3R19100
Tool Name:IAE 3R19100 Front groove tool
Manufacturer Code:LOCAL
Tool Number:Lathe
Tool Name:Lathe
Manufacturer Code:LOCAL
Tool Number:Milling machine
Tool Name:Milling machine
Manufacturer Code:LOCAL
Tool Number:Standard turning tool
Tool Name:Standard turning tool
Manufacturer Code:LOCAL
Tool Number:Standard workshop tools
Tool Name:Standard workshop tools
Link not Found