TASK 72-41-13-300-025 HPC Rear Shaft - Repair Of The Heatshield Snap Diameter By Plasma Spray, Repair-025 (VRS6510)

DMC:V2500-A0-72-41-1301-03A-609A-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 72-41-13-300-025 HPC Rear Shaft - Repair Of The Heatshield Snap Diameter By Plasma Spray, Repair-025 (VRS6510)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

01-900

6A4151

A

01-900

6A7708

A

01-900

6A4158

B

01-900

6A5868

B

01-900

6A7712

B

01-900

6A7714

B

Material of component

RR

DESCRIPTION

SYMBOL

MATERIAL

HP Compressor Rear

QYX

Inconnel 718

Shaft Assembly

General

This Repair must only be done when the instruction to do so is given in 72-41-13, Inspection.

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

To put back the fatigue strength, it is necessary to shot peen surfaces, where the damaged material is removed prior to plasma spray.

This repair can only be done twice on the HP Compressor Rear Shaft Assembly.

Do not discard this component part until contact is made with the Manager Repair Services at International Aero Engines.

Price and availability - Refer to International Aero Engines

Related repairs - none

NOTE

More equipment and materials necessary to do this Repair are in the SPM TASK 70-09-00-400-501, SPM TASK 70-11-01-300-503, SPM TASK 70-23-04-230-501, SPM TASK 70-23-05-230-501, SPM TASK 70-38-04-300-503 and SPM TASK 70-34-01-340-501.

NOTE

To identify the consumable materials, refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Chemical cleaning equipmentLOCALChemical cleaning equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Grinding machineLOCALGrinding machine

Cylindrical

Standard workshop equipmentLOCALStandard workshop equipment
Dial test indicatorsLOCALDial test indicators
Workshop inspection equipmentLOCALWorkshop inspection equipment
Shot peening equipmentLOCALShot peening equipment

Automatic

Abrasive blast equipmentLOCALAbrasive blast equipment
Plasma spray equipmentLOCALPlasma spray equipment
Vibrating marking pencilLOCALVibrating marking pencil

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-003 ADHESIVE TAPE BLACK WATERPROOFLOCALCoMat 02-003
CoMat 02-198 ADHESIVE TAPE (MASKING METAL SPRAY)LOCALCoMat 02-198
CoMat 03-265 NICKEL CHROMIUM ALUMINIUMPOWDERLOCALCoMat 03-265
CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADELOCALCoMat 05-001
CoMat 05-029 CAST STEEL SHOT, S110LOCALCoMat 05-029
CoMat 05-030 CAST STEEL SHOT DELETED0AM53CoMat 05-030
CoMat 05-031 CAST STEEL SHOT DELETED0AM53CoMat 05-031
CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)LOCALCoMat 06-022

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-13-220-155 Make Sure the HP Compressor Rear Shaft Assembly Can Be Repaired

      1. Visually examine the HP Compressor rear shaft assembly, to tell you if this repair has been done before.

      1. You can not repair the HP Compressor rear shaft assembly if the assembly has been repaired two times before and the assembly is identified VRS6510/2.

    2. SUBTASK 72-41-13-110-076 Clean the HP Compressor Rear Shaft Assembly

      1. Chemically clean the assembly.

      1. Refer to SPM TASK 72-41-13-100-000.

      2. Use chemical cleaning equipment.

    3. SUBTASK 72-41-13-230-089 Do a Crack Test

      1. Do a penetrant crack test on the assembly.

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

      2. Use penetrant crack test equipment.

    4. SUBTASK 72-41-13-324-055-A00 Grind the HP Compressor Rear Shaft Assembly, Assembly A

    1. Refer to Figure and Figure.

      2. CAUTION

        DO NOT REMOVE MORE MATERIAL THAN IS NECESSARY.

        Install the fixture into the cylindrical grinding machine.

      1. Use a locally made grinding fixture.

      2. Use a cylindrical grinding machine and standard workshop equipment.

      3. Install the HP compressor rear shaft assembly on to the fixture and set to turn correctly.

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

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

      4. Grind the heatshield snap diameter and location face at location AB, to remove all damage.

      1. Use a cylindrical grinding machine.

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

      5. NOTE

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

        Remove burrs.

      1. Use standard workshop equipment.

    5. SUBTASK 72-41-13-324-055-B00 Grind the HP Compressor Rear Shaft Assembly, Assembly B

    1. Refer to Figure and Figure.

      2. CAUTION

        DO NOT REMOVE MORE MATERIAL THAN IS NECESSARY.

        Install the fixture into the cylindrical grinding machine.

      1. Use a locally made grinding fixture.

      2. Use a cylindrical grinding machine and standard workshop equipment.

      3. Install the HP compressor rear shaft assembly on to the fixture and set to turn correctly.

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

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

      4. Grind the heatshield snap diameter and location face at location AB, to remove all damage.

      1. Use a cylindrical grinding machine.

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

      5. NOTE

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

        Remove burrs.

      1. Use standard workshop equipment.

    6. SUBTASK 72-41-13-110-064 Clean the HP Compressor Rear Shaft Assembly

      1. Chemically clean the assembly.

      1. Refer to SPM TASK 70-11-01-300-503.

      2. Use chemical cleaning equipment.

    7. SUBTASK 72-41-13-230-079-A00 Do a Crack Test, Assembly A

    1. Refer to Figure

      2. Do a local penetrant crack test on the heatshield snap diameter and location face, at location AB.

      1. Refer to SPM TASK 70-23-05-230-501.

      3. Cracks are not permitted.

    8. SUBTASK 72-41-13-230-079-B00 Do a Crack Test, Assembly B

    1. Refer to Figure.

      2. Do a local penetrant crack test on the heatshield snap diameter and location face, at location AB.

      1. Refer to SPM TASK 70-23-05-230-501.

      3. Cracks are not permitted.

    9. SUBTASK 72-41-13-220-156-A00 Examine the HP Compressor Rear Shaft Assembly, Assembly A

    1. Refer to Figure and Figure.

      2. Measure the dimensions of the heatshield snap diameter and location face, at location AB.

      1. Use workshop inspection equipment. Keep this dimension for use with Step.

    10. SUBTASK 72-41-13-220-156-B00 Examine the HP Compressor Rear Shaft Assembly, Assembly B

    1. Refer to Figure and Figure.

      2. Measure the dimensions of the heatshield snap diameter, and location face, at location AB.

      1. Use workshop inspection equipment.

      2. Keep this dimension for use with Step

    11. SUBTASK 72-41-13-380-060-A00 Shot Peen the Repaired Area, Assembly A

    1. Refer to Figure and Figure.

      2. Seal the full assembly but for the area to be shot peened.

      3. Shot peen the HP Compressor rear shaft assembly heatshield snap diameter and location face, at location AB.

        1. Refer to SPM TASK 70-38-04-300-503 SUBTASK 70-38-04-300-002. Use CoMat 05-029 CAST STEEL SHOT, S110, CoMat 05-030 CAST STEEL SHOT DELETED or CoMat 05-031 CAST STEEL SHOT DELETED to get an Almen intensity of 0.006 to 0.009 in. (0.15 to 0.23 mm) on 'A' type test strip A coverage of 100 percent minimum, 150 percent maximum must be applied.

        1. Use automatic shot peening equipment.

          Shot-Peening Data

          Machine Type

          Metal shot peen

          Process type/mode

          Dry/auto

          Shot type

          Shot size

          S110R

          Coverage

          100 percent minimum, 150 percent maximum

          Nozzle/work distance

          120 mm

          Number of nozzles

          1

          Nozzle angle

          40 degrees

          Almen intensity

          0.006 to 0.009 in. (0.15 to 0.23 mm) using

          test strip 'A'

    4. Make sure all loose unwanted cast steel shot is removed.

    5. Remove mechanical seals and seal tape.

    12. SUBTASK 72-41-13-380-060-B00 Shot Peen the Repaired Area, Assembly B

    1. Refer to Figure and Figure.

      2. Seal the full assembly but for the area to be shot peened.

      3. Shot peen the HP Compressor rear shaft assembly heatshield snap diameter and location face, at location AB.

      1. Refer to SPM TASK 70-38-04-300-503 SUBTASK 70-38-04-300-002. Use CoMat 05-029 CAST STEEL SHOT, S110, CoMat 05-030 CAST STEEL SHOT DELETED or CoMat 05-031 CAST STEEL SHOT DELETED to get an Almen intensity of 0.006 to 0.009 in. (0.15 to 0.23 mm) on 'A' type test strip A coverage of 100 percent minimum, 150 percent maximum must be applied. Use automatic shot peening equipment.

        Shot-Peening Data

        Machine Type

        Metal shot peen

        Process type/mode

        Dry/auto

        Shot type

        Shot size

        S110R

        Coverage

        100 percent minimum, 150 percent maximum

        Nozzle/work distance

        120 mm

        Number of nozzles

        1

        Nozzle angle

        40 degrees

        Almen intensity

        0.006 to 0.009 in. (0.15 to 0.23 mm) using

        test strip 'A'

    4. Make sure all loose unwanted cast steel shot is removed.

    5. Remove mechanical seals and seal tape.

    13. SUBTASK 72-41-13-340-053-A00 Apply the Plasma Spray to the Surface(s) to be Repaired, Assembly A

    1. Refer to Figure, Figure and Figure.

      2. CAUTION

        DO NOT TOUCH SURFACE(S) TO BE REPAIRED AFTER THEY ARE CLEANED.
        TOO MUCH ABRASIVE BLAST CAN CAUSE DETERIORATION OF THE REPAIRED SURFACE CONDITION AND MUST BE PREVENTED.

        Seal areas not to be repaired.

      3. NOTE

        The adhesive tape (masking metal spray), permits the blasting and plasma spray to be done in one operation.

        Lightly dry blast to prepare the surface for the plasma spray.

      1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-001.

      3. The maximum abrasive blast air pressure must not be more than 60 psi (414 kPa).

      4. NOTE

        When plasma spray equipment is used, the CoMat 03-265 NICKEL CHROMIUM ALUMINIUMPOWDER is self-bonding.

        Apply the plasma spray to the heatshield snap diameter and location face, at location AB.

      1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-018.

      2. Use CoMat 03-265 NICKEL CHROMIUM ALUMINIUMPOWDER with plasma spray equipment.

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

    5. Remove the masking tape.

    14. SUBTASK 72-41-13-340-053-B00 Apply the Plasma Spray to the Surface(s) to be Repaired, Assembly B,and 907)

    1. Refer to Figure, Figure and Figure.

      2. CAUTION

        DO NOT TOUCH SURFACE(S) TO BE REPAIRED AFTER THEY ARE CLEANED.
        TOO MUCH ABRASIVE BLAST CAN CAUSE DETERIORATION OF THE REPAIRED SURFACE CONDITION AND MUST BE PREVENTED.

        Seal areas not to be repaired.

      3. NOTE

        The adhesive tape (masking metal spray), permits the blasting and plasma spray to be done in one operation.

        Lightly dry blast to prepare the surface for the plasma spray.

      1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-001.

        1. The maximum abrasive blast air pressure must not be more than 60 psi (414 kPa).

      4. NOTE

        When plasma spray equipment is used, the CoMat 03-265 NICKEL CHROMIUM ALUMINIUMPOWDER is self-bonding.

        Apply the plasma spray to the heatshield snap diameter and location face, at location AB.

      1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-018.

      2. Use CoMat 03-265 NICKEL CHROMIUM ALUMINIUMPOWDER with plasma spray equipment.

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

    5. Remove the masking tape.

    15. SUBTASK 72-41-13-220-157 Visually Examine

      1. Visually examine the plasma sprayed coat.

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

    16. SUBTASK 72-41-13-324-056-A00 Grind the HP Compressor Rear Shaft Assembly, Assembly A

    1. Refer to Figure, Figure and Figure.

      2. Install the fixture into the cylindrical grinding machine.

      1. Use a locally made grinding fixture. Use a cylindrical grinding machine and standard workshop equipment.

      3. Install the HP compressor rear shaft assembly on to the fixture and set to turn correctly.

      1. Use a dial test indicator and standard workshop equipment. Make sure that datums A and B are set to turn correctly.

      4. Machine the heatshield snap diameter and location face, at Location AB.

      1. Use a cylindrical grinding machine.

      5. NOTE

        You must remove all unwanted plasma spray from the adjacent area(s).

        Remove burrs.

      1. Use standard workshop equipment.

    17. SUBTASK 72-41-13-324-056-B00 Grind the HP Compressor Rear Shaft Assembly, Assembly B

    1. Refer to Figure, Figure and Figure.

      2. Install the fixture into the cylindrical grinding machine.

      1. Use a locally made grinding fixture. Use a cylindrical grinding machine and standard workshop equipment.

      3. Install the HP compressor rear shaft assembly on to the fixture and set to turn correctly.

      1. Use a dial test indicator and standard workshop equipment. Make sure that datums A and B are set to turn correctly.

      4. Machine the heatshield snap diameter and location face, at Location AB.

      1. Use a cylindrical grinding machine.

      5. NOTE

        You must remove all unwanted plasma spray from the adjacent area(s).

        Remove burrs.

      1. Use standard workshop equipment.

    18. SUBTASK 72-41-13-110-065 Clean the HP Compressor Rear Shaft Assembly

      1. Chemically clean the assembly.

      1. Refer to SPM TASK 70-11-01-300-503. Use chemical cleaning equipment.

    19. SUBTASK 72-41-13-220-158-A00 Examine the HP Compressor Rear Shaft Assembly, Assembly A

    1. Refer to Figure, Figure and Figure.

      2. Make a visual inspection and measure the dimensions of the heatshield snap diameter and location face, at location AB and the adjacent areas.

      1. Use workshop inspection equipment.

    20. SUBTASK 72-41-13-220-158-B00 Examine the HP Compressor Rear Shaft Assembly, Assembly B

    1. Refer to Figure, Figure and Figure.

      2. Make a visual inspection and measure the dimensions of the heatshield snap diameter and location face, at location AB and the adjacent areas.

      1. Use workshop inspection equipment.

    21. SUBTASK 72-41-13-350-076 Identify the Repair

      1. Make a mark adjacent to the assembly number.

      1. Refer to SPM TASK 70-09-00-400-501, SUBTASK 70-09-00-400-001. Use vibro-engraving equipment If this is the first time that the shaft assembly has been repaired to this scheme then vibro-engrave VRS6510/1. If this is the second time that the shaft assembly has been repaired to this scheme then vibro-engrave VRS6510/2.

    22. Figure: Repair details and dimension - Assembly A

    Repair details and dimension - Assembly A

    Figure: Repair details and dimensions - Assembly B

    Repair details and dimensions - Assembly B

    Figure: Repair details and dimensions - Assembly A

    Repair details and dimensions - Assembly A

    Figure: Repair details and dimensions - Assembly B

    Repair details and dimensions - Assembly B

    Figure: Repair details and dimensions - Assembly A and Assembly B

    Repair details and dimensions - Assembly A and Assembly B

    Figure: Repair details and dimensions - Assembly A

    Repair details and dimensions - Assembly A

    Figure: Repair details and dimensions - Assembly B

    Repair details and dimensions - Assembly B

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 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:07512
Supply Number:CoMat 02-198
Type:sp01
Supply Short Name:CoMat 02-198 ADHESIVE TAPE (MASKING METAL SPRAY)
Supply Name:CoMat 02-198 ADHESIVE TAPE (MASKING METAL SPRAY)
Specification Groups:
Doc NumberType
OMAT: 2/96 (RR REF)CHR 23816 TAPE
Suppliers:
ManufacturerRemarks
07512
K6835
K1369
KC622
Manufacturer Code:LOCAL
Supply Number:CoMat 03-265
Type:sp01
Supply Short Name:CoMat 03-265 NICKEL CHROMIUM ALUMINIUM POWDER
Supply Name:CoMat 03-265 NICKEL CHROMIUM ALUMINIUMPOWDER
Specification Groups:
Doc NumberType
METCO 443-NS MIL-P-85856/21 MSRR9507/14
METCO 443-NS MIL-P-85856/21OMAT:3/135
Suppliers:
ManufacturerRemarks
LOCAL
39918
IE103
IE195
IE200
K1030
K6835
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:55807
Supply Number:CoMat 05-029
Type:sp01
Supply Short Name:CoMat 05-029 CAST STEEL SHOT, S110
Supply Name:CoMat 05-029 CAST STEEL SHOT, S110
Specification Groups:
Doc NumberType
AMS 2431/1 ASR 110
Suppliers:
ManufacturerRemarks
55807
Manufacturer Code:0AM53
Supply Number:CoMat 05-030
Type:sp01
Supply Short Name:CoMat 05-030 CAST STEEL SHOT DELETED
Supply Name:CoMat 05-030 CAST STEEL SHOT DELETED
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
0AM53
Manufacturer Code:0AM53
Supply Number:CoMat 05-031
Type:sp01
Supply Short Name:CoMat 05-031 CAST STEEL SHOT DELETED
Supply Name:CoMat 05-031 CAST STEEL SHOT DELETED
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
0AM53
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
Link not Found
Manufacturer Code:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Manufacturer Code:LOCAL
Tool Number:Plasma spray equipment
Tool Name:Plasma spray equipment
Manufacturer Code:LOCAL
Tool Number:Shot peening equipment
Tool Name:Shot peening equipment
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment