TASK 72-41-11-300-009 HPC Stage 3 - 8 Drum Disk - Blend Repair To Restore The Surface Condition On The Stages 6 To 8 Dovetail Slots, Repair-009 (VRS6133)

DMC:V2500-A0-72-41-1101-04A-649A-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 72-41-11-300-009 HPC Stage 3 - 8 Drum Disk - Blend Repair To Restore The Surface Condition On The Stages 6 To 8 Dovetail Slots, Repair-009 (VRS6133)

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 72-41-11 Inspection/Check.

To restore the surface condition on the dovetail slots, it is necessary to shot-peen.

The shot peened part of this repair is necessary to be source demonstrated and can only be done by approved vendors.

Each stage of the HP compressor stage 3 to 8 disks - shaft assembly - stage 6 to 8 dovetail slots can only be shot-peened four times.

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

For Zone A if the damage is galling only, not more than to 0.002 in. (0.051 mm) maximum you must do Step.

The maximum depth permitted after damaged material (nicks, dents, scores and/or frettage) is removed, to leave a smooth surface finish in Zone B only is 0.005 in. (0.127 mm).

If the damage is galling or frettage the maximum depth of damage before material removal, in Zone B only, is 0.005 in. (0.127 mm) and you must remove the damage to depth, to a maximum depth of 0.005 in. (0.127 mm).

If the damage is nicks or scores the maximum depth of damage before material removal, in Zone B only, is 0.002 in. (0.051 mm) and you must remove the damage to 2 X depth, to a maximum depth of 0.005 in. (0.127 mm).

The maximum depth permitted after damaged material (nicks, dents, scores and/or frettage) is removed, to leave a smooth surface finish in Zone C only is 0.002 in. (0.051 mm).

If the damage is galling or frettage the maximum depth of damage before material removal, in Zone C only, is 0.002 in. (0.051 mm) and you must remove the damage to depth, to a maximum depth of 0.002 in. (0.051 mm).

If the damage is nicks or scores the maximum depth of damage before material removal, in Zone C only, is 0.001 in. (0.025 mm) and you must remove the damage to 2 X depth, to a maximum depth of 0.002 in. (0.051 mm).

Repair Facilities

Only the shot peen part of this repair is necessary for source demonstration. This means that any facility not approved to shot peen, can use the Approved Repair Vendors listed below or contact the IAE Repair Services Group to find out if a qualification program can be initiated at their facility.

IAE - INTERNATIONAL AERO ENGINES AG
C/O ROLLS-ROYCE PLC
P.O. BOX 31
DERBY DE24 8BJ
ENGLAND
ATTN: Manager Technical Services

Approved Repair Vendors for the shot peen portion of VRS6133 are listed below:

METAL IMPROVEMENT COMPANY INC
DERBY DIVISION (UK)
ASCOT DRIVE
DERBY DE2 8ST
ENGLAND
ATTN: DIVISION MANAGER
METAL IMPROVEMENT COMPANY INC
145 ADDISON ROAD
WINDSOR
CONNECTICUT
CT06095
USA
ATTN: DIVISION MANAGER
MTU MAINTENANCE GMBH
FLUGHAFEN HANNOVER
MUNCHNER STRASSE 31
POSTFACH 1720
3012 LANGENHAGEN
GERMANY
ATTN: QUALITY ASSURANCE MANAGER
ISHIKAWAJIMA-HARIMA HEAVY INDUSTRIES CO. LTD.
229 TONOGAYA, MIZUHO-MACHI
NISHITAMA-GUN
TOKYO 190-1292
JAPAN
The designation by IAE of an Approved Repair Vendor indicates that the Repair Vendor has demonstrated the necessary capability to enable it to carry out the listed repair work. But, IAE make no warranties or representations concerning the qualifications or quality standards of the Repair Vendors to carry out the repair work, and accepts 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. Approved Repair Vendors do not act as agents or representatives of IAE.
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
Binoculars 10XLOCALBinoculars 10X
Chemical cleaning equipmentLOCALChemical cleaning equipment
Controlled shot peening equipmentLOCALControlled shot peening equipment
Glass bead peening equipmentLOCALGlass bead peening equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Standard workshop equipmentLOCALStandard workshop equipment
Vibro-engraving equipmentLOCALVibro-engraving equipment
IAE 3R19465 Shot Peen Fixture0AM53IAE 3R194651
IAE 3R19466 Almen Plate Carrier0AM53IAE 3R194661
IAE 3R19467 AlmenPlate Holder0AM53IAE 3R194671
Consumables, Materials and Expendables
NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-003 ADHESIVE TAPE BLACK WATERPROOFLOCALCoMat 02-003
CoMat 05-020 WATERPROOF SILICON CARBIDELOCALCoMat 05-020
CoMat 05-021 WATERPROOF SILICON CARBIDE44197CoMat 05-021
CoMat 05-028 METALLIC SHOT (CAST STEEL), S230IE249CoMat 05-028
CoMat 05-106 ABRASIVE STONEK6835CoMat 05-106
CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)LOCALCoMat 06-022
Spares
NONE
Safety Requirements
CAUTION
YOU MUST NOT REMOVE MATERIAL FROM ZONE A OR ZONE D.
Procedure
    1. SUBTASK 72-41-11-220-101 Examine the Assembly
    1. Refer to Figure and Figure.
      2. Visually examine the HP compressor stages 3 to 8 disks shaft assembly, to tell you if shot-peen is done before in the stage 6, 7 and 8 dovetail slots.
      1. Look for the identification code symbol next to the assembly part number.
        The stage 6 dovetail slot cannot be shot-peened again if you see a code symbol with the letter H. The stage 7 dovetail slot cannot be shot-peened again if you see a code symbol with the letter M. The stage 8 dovetail slot cannot be shot-peened again if you see a code symbol with the letter S.
    2. SUBTASK 72-41-11-110-065 Clean the HP Compressor Stages 3 to 8 Disk Shaft Assembly
      1. Chemically clean the assembly.
      1. Refer to TASK 72-41-11-100-000 (CLEANING-000).
        Use chemical cleaning equipment.
    3. SUBTASK 72-41-11-230-070 Do a Crack Test
      1. Do a local penetrant crack test on the stage 6, 7 and/or 8 dovetail slot(s).
      1. Refer to the SPM TASK 70-23-05-230-501.
        Use penetrant crack test equipment.
        Cracks are not permitted.
    4. SUBTASK 72-41-11-350-085 Remove Damaged Area(s), Zone B only
      CAUTION
      TITANIUM COMPONENT - YOU MUST USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS, BLEND AND POLISH THIS COMPONENT.
      CAUTION
      TITANIUM COMPONENT - AVOID BUILD UP OF HEAT BY APPLYING ONLY GENTLE PRESSURE AND KEEPING THE TOOL SPEED AS LOW AS POSSIBLE.
      CAUTION
      TITANIUM COMPONENT - YOU MUST MAKE SURE THAT WHEN YOU DRESS MATERIAL, BLEND AND POLISH, TO MAKE SMOOTH, THAT NO SPARKS ARE PRODUCED.
      CAUTION
      TITANIUM COMPONENT - IF THE MATERIAL SHOWS A CHANGE IN COLOR, TO DARKER THAN A LIGHT STRAW COLOR, THE COMPONENT IS TO BE REJECTED.
    1. Refer to Figure, Figure and Figure.
      2. Remove damaged material, as necessary.
      1. Refer to the SPM TASK 70-35-03-300-501.
        If you use mechanical tools that must not run more than 1000 rpm.
        Use standard workshop equipment.
        You must restore corner radii.
    3. If material damage is galling or frettage you must dress to a depth to a maximum depth of 0.005 in. (0.127 mm).
    4. If material damage is nicks or scores you must dress to 2 x depth to a maximum depth of 0.005 in. (0.127 mm).
      NOTE
      Material removal can overlap into other zones. If this occurs you must use the limits with the least material removal.
      5. Make smooth the cut away area(s).
      1. Refer to the SPM TASK 70-35-03-300-501.
        Remove sharp corners.
        If you use mechanical tools that must not run more than 1000 rpm.
        Use standard workshop equipment.
        You must restore corner radii.
      6. Polish the cut away area(s).
      1. Refer to the SPM TASK 70-35-03-300-501.
        Polish to give a surface finish the same as adjacent material.
        If you use mechanical tools that must not run more than 1000 rpm.
        Use standard workshop equipment.
        You must restore corner radii.
    5. SUBTASK 72-41-11-350-086 Remove Damaged Area(s), Zone C only
      CAUTION
      TITANIUM COMPONENT - YOU MUST USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS, BLEND AND POLISH THIS COMPONENT.
      CAUTION
      TITANIUM COMPONENT - AVOID BUILD UP OF HEAT BY APPLYING ONLY GENTLE PRESSURE AND KEEPING THE TOOL SPEED AS LOW AS POSSIBLE.
      CAUTION
      TITANIUM COMPONENT - YOU MUST MAKE SURE THAT WHEN YOU DRESS MATERIAL, BLEND AND POLISH, TO MAKE SMOOTH, THAT NO SPARKS ARE PRODUCED.
      CAUTION
      TITANIUM COMPONENT - IF THE MATERIAL SHOWS A CHANGE IN COLOR, TO DARKER THAN A LIGHT STRAW COLOR, THE COMPONENT IS TO BE REJECTED.
    1. Refer to Figure, Figure and Figure.
      2. Remove damaged material, as necessary.
      1. Refer to the SPM TASK 70-35-03-300-501.
        If you use mechanical tools that must not run more than 1000 rpm.
        Use standard workshop equipment.
        You must restore corner radii.
    3. If material damage is galling or frettage you must dress to a depth to a maximum depth of 0.005 in. (0.127 mm).
    4. If material damage is nicks or scores you must dress to 2 x depth to a maximum depth of 0.005 in. (0.127 mm).
      NOTE
      Material removal can overlap into other zones. If this occurs you must use the limits with the least material removal.
      5. Make smooth the cut away area(s).
      1. Refer to the SPM TASK 70-35-03-300-501.
        Remove sharp corners.
        If you use mechanical tools that must not run more than 1000 rpm.
        Use standard workshop equipment.
        You must restore corner radii.
      6. Polish the cut away area(s).
      1. Refer to the SPM TASK 70-35-03-300-501.
        Polish to give a surface finish the same as adjacent material.
        If you use mechanical tools that must not run more than 1000 rpm.
        Use standard workshop equipment.
        You must restore corner radii.
    6. SUBTASK 72-41-11-220-241 Examine the Repaired Area(s)
      2. Make a visual inspection of the repaired area(s) and measure the depth of the repaired area(s).
      1. Make sure the surface finish compares with the adjacent surfaces.
        Refer to the different Zones for the maximum depth of material removal.
        NOTE
        Material removal can overlap into other Zones. If this occurs you must use the limit with the least material removal.
    7. SUBTASK 72-41-11-110-094 Do a Swab Etch
      1. Chemically clean.
      1. Refer to the SPM TASK 70-11-08-300-503, 70-11-08-300-001.
        Use chemical cleaning equipment.
      2. Swab etch the repaired area(s).
      1. Refer to the SPM TASK 70-11-08-300-503, 70-11-08-300-002.
        Use chemical cleaning equipment.
    8. SUBTASK 72-41-11-220-242 Binocular Examine the Repaired Area(s)
      1. Binocular examine the repaired area(s).
      1. Use X10 binoculars.
        Indications of defects on the repaired surface(s) are not permitted.
        Make sure that there is no raised material remaining.
    9. SUBTASK 72-41-11-230-100 Do a Crack Test
      1. Do a local penetrant crack test of the repaired area(s).
      1. Refer to the SPM TASK 70-23-05-230-501.
        Use CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY) florescent penetrant, post-emulsified ultra high sensitivity.
        Use penetrant crack test equipment.
        Cracks are not permitted.
    10. SUBTASK 72-41-11-110-095 Chemically Clean
      1. Chemically clean the repaired area(s) to remove the fluorescent penetrant.
      1. Refer to the SPM TASK 70-11-26-300-503.
        Use chemical cleaning equipment.
    11. SUBTASK 72-41-11-380-056 Shot Peen the Dovetail Slot(s)
    1. Refer to Figure, Figure, Figure, Figure and Figure.
      2. Seal the full assembly but for the stage or stages which have to be shot peened.
      1. Patch mask all identification marks and symbols.
      3. Shot peen the area(s) identified AD, as necessary.
      1. Refer to the SPM TASK 70-38-04-300-503,  70-38-04-300-002.
        Use IAE 3R19465 Shot Peen Fixture shot peen fixture 1 off, IAE 3R19466 Almen Plate Carrier almen plate carrier 1 off, IAE 3R19467 AlmenPlate Holder almen plate holder 1 off, and/or Approved Vendors in 4.
        Repair Facilities, Para. B.
        Use CoMat 05-028 METALLIC SHOT (CAST STEEL), S230 to get an almen intensity of 0.006 in. to 0.010 in. (0.15 mm to 0.25 mm) on 'A' type test strip.
        A coverage of 200 percent must be applied.
        Use controlled shot peening equipment.
        Shot-Peening Data
        Machine type
        Metal shot-peen
        Process type/mode
        Dry/auto
        Shot type
        Shot size
        0.024 in. to 0.040 in. (6.60 mm to 1.00 mm) diameter
        Shot hardness
        450 to 600 HV
        Coverage
        200 percent
        Almen intensity
        0.006 in. to 0.010 in. (0.15 mm to 0.25 mm) using an 'A' type test strip
        NOTE
        Unwanted shot-peen spray is permitted in area AE.
        NOTE
        For information, the table speed, oscillation speed, height, type, air pressure, nozzle type/diameter and work distance can change if different equipment is used. You must get the full coverage and Almen intensity.
    4. Make sure all loose unwanted cast steel shot is removed.
      5. Remove iron contamination after you have shot-peened, as necessary.
      1. Refer to Approved Vendors in 4. Repair Facilities, Para B. and/or the SPM TASK 70-38-04-300-503, 70-38-04-300-002.
        Use wet or dry glass beads, with glass bead peening equipment.
    6. Remove mechanical seals and/or seal tape.
    12. SUBTASK 72-41-11-220-102 Examine the Shot Peened Area(s)
    1. Refer to Figure, Figure, Figure, Figure and Figure.
      2. Make a visual inspection of the shot peened area(s).
      1. Refer to Approved Vendors in 4. Repair Facilities, Para. B.
    13. SUBTASK 72-41-11-350-071 Identify the Repair
    1. Refer to Figure and Figure.
      2. Make a code symbol adjacent to the assembly number, to show which dovetail slot(s) on the stage 6, 7 and/or 8 have been shot-peened.
      1. Refer to the SPM TASK 70-09-00-400-501, 70-09-00-400-001.
        Use vibro-engraving equipment.
        NOTE
        The letter inside the code symbol shows the number of times this area is shot-peened.
    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
    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:44197
Enterprise Name:SAINT-GOBAIN INDUSTRIAL CERAMICS INC.
BU Name:SAINT-GOBAIN ABRASIVES, INC
Street:ONE NEW BOND STREET
P.O. Box:PO BOX 15008
City:WORCESTER
State:MA
Zip Code:01615-0008
Country:USA
Phone Number:1-508-795-5000
Fax Number:1-508-795-2828
Internet:www.saint-gobain-northamerica.com
Manufacturer Code:IE249
Enterprise Name:DELETED - Was FERGUSSON AND WILD CO LTD,ABRASIVES AND AGGREGATES (no longer in business)
BU Name:DELETED - FERGUSSON AND WILD CO LTD,ABRASIVES AND AGGREGATES (no longer in business)
Manufacturer Code:K6835
Enterprise Name:MED-LAB LTD
BU Name:MED-LAB LTD
Street:COPELAND ST
City:DERBY
Zip Code:DE1 2PU
Country:GREAT BRITAIN
Phone Number:44-1332-349094
Fax Number:44-1332-371237
Email:sales@med-lab.co.uk
Internet:www.med-lab.co.uk
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 02-003
Type:sp01
Supply Short Name:CoMat 02-003 ADHESIVE TAPE BLACK WATERPROOF
Supply Name:CoMat 02-003 ADHESIVE TAPE BLACK WATERPROOF
Specification Groups:
Doc NumberType
OMAT: 285ISATAPE 160
Suppliers:
ManufacturerRemarks
LOCAL
IE305
K6835
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:IE249
Supply Number:CoMat 05-028
Type:sp01
Supply Short Name:CoMat 05-028 METALLIC SHOT (CAST STEEL), S230
Supply Name:CoMat 05-028 METALLIC SHOT (CAST STEEL), S230
Specification Groups:
Doc NumberType
AMS 2431/1 ASR 230
Suppliers:
ManufacturerRemarks
IE249
K0247
55807
Manufacturer Code:K6835
Supply Number:CoMat 05-106
Type:sp01
Supply Short Name:CoMat 05-106 ABRASIVE STONE
Supply Name:CoMat 05-106 ABRASIVE STONE
Specification Groups:
Doc NumberType
(SS-S-736/2/26) (A-A-3068/2-26)SQUARE FINE SS-S-736 TYPE II CLASS A1
Suppliers:
ManufacturerRemarks
K6835
KC1D9
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:Binoculars 10X
Tool Name:Binoculars 10X
Manufacturer Code:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Manufacturer Code:LOCAL
Tool Number:Controlled shot peening equipment
Tool Name:Controlled shot peening equipment
Manufacturer Code:LOCAL
Tool Number:Glass bead peening equipment
Tool Name:Glass bead peening equipment
Manufacturer Code:0AM53
Tool Number:IAE 3R19465
Tool Name:IAE 3R19465 Shot Peen Fixture
Manufacturer Code:0AM53
Tool Number:IAE 3R19466
Tool Name:IAE 3R19466 Almen Plate Carrier
Manufacturer Code:0AM53
Tool Number:IAE 3R19467
Tool Name:IAE 3R19467 AlmenPlate Holder
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Link not Found
Manufacturer Code:LOCAL
Tool Number:Vibro-engraving equipment
Tool Name:Vibro-engraving equipment