TASK 72-41-13-300-019 HPC Rear Shaft - Blend Repair, Repair-019 (VRS6088)

DMC:V2500-A0-72-41-1301-04A-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 72-41-13-300-019 HPC Rear Shaft - Blend Repair, Repair-019 (VRS6088)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

01-900

6A4151

A

01-900

6A4158

B

01-900

6A5868

B

01-900

6A7708

C

01-900

6A7712

D

01-900

6A7714

D

Material of component

PART IDENT

MATERIAL

HP compressor rear shaft assembly

Nickel alloy

General

This repair must only be done when the instruction to do so is given in TASK 72-41-13-200-000 (INSPECTION/CHECK-000).

This repair permits the removal of damaged material from the HP compressor rear shaft assembly. No material removal is permitted on holes, screw threads and splines during this repair.

To put back the surface condition, it is necessary to shot peen surfaces, where the damaged material is removed.

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

This repair can only be done for a maximum of six times in each of the permitted shot peened area(s) identified on the HP compressor rear shaft assembly.

You must not use power tools or hand held power tools to repair the component.

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

Repair Facilities

Only the shot peen part of this repair is necessary for source demonstration. This means that the facilities which are 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.
ESCHENWEG 11
DAHLEWITZ
15827 BLANKENFELDE-MAHLOW
GERMANY
ATTN: MANAGER TECHNICAL SERVICES

Approved Repair Vendors for the shot peen portion of VRS6088 are listed below:

METAL IMPROVEMENT COMPANY INC.
DERBY DIVISION (UK)
ASCOT DRIVE
DERBY DE2 8ST
ENGLAND

MTU MAINTENANCE HANNOVER GMBH
REPAIR ENGINEERING TR30
MUNCHNER STRASSE 31
30855 LANGENHAGEN
GERMANY
ATTN: MANAGER, QUALITY ASSURANCE

The designation by IAE of an Approved Repair Vendor shows that the Repair Vendor has demonstrated the necessary functions to make it possible to do the listed repair work. But, IAE makes no warranties or representations related to the qualifications or quality standards of the Repair Vendors to do the repair work, and accepts no responsibility whatsoever for works that can be done 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.

NOTE

TASKs identified by SPM TASK are in the Standard Practices and Processes Manual (SPM).

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Chemical cleaning equipmentLOCALChemical cleaning equipment
Controlled shot peening equipmentLOCALControlled shot peening equipment
Glass bead peening equipmentLOCALGlass bead peening equipment
Hand toolsLOCALHand tools
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Polythene bottleLOCALPolythene bottle
Vibro-engraving equipmentLOCALVibro-engraving equipment
Binoculars 10XLOCALBinoculars 10X
IAE 3R19134 Almen test strip0AM53IAE 3R19134
IAE 3R19165 Dummy Shaft0AM53IAE 3R19165
IAE 3R19169 Fixture0AM53IAE 3R19169
IAE 3R19183 Dummy Shaft0AM53IAE 3R19183

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-003 ADHESIVE TAPE BLACK WATERPROOFLOCALCoMat 02-003
CoMat 05-028 METALLIC SHOT (CAST STEEL), S230IE249CoMat 05-028
CoMat 05-074 ALUMINIUM OXIDE ABRASIVE PAPER06565CoMat 05-074
CoMat 05-106 ABRASIVE STONEK6835CoMat 05-106
CoMat 05-111 EMERY POLISHING PAPER06565CoMat 05-111
CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)LOCALCoMat 06-022

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-13-220-114 Make Sure the Part can be Repaired

      2. Visually examine the HP compressor rear shaft assembly, to tell you if shot peen is done before in the repair area(s).

      1. If the assembly is repaired and shot peened during repair, the assembly must be identified in accordance with the table in Figure.

        You cannot repair the HP compressor rear shaft assembly again if the damaged area(s) is shot peened six times.

      3. If damage is shown on the surface(s) identified AE and AJ.

      1. Reject the assembly, refer to General.

      4. If damage is shown in zone AX on assemblies C or D.

      1. Reject the assembly, refer to General.

    2. SUBTASK 72-41-13-100-001 Clean the Damaged Area(s)

      1. Chemically clean the damaged area(s).

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

        Use chemical cleaning equipment.

    3. SUBTASK 72-41-13-230-066 Do a Crack Test

      1. Do a local penetrant crack test of the damaged area(s).

      1. Refer to the SPM TASK 70-23-05-230-501, SUBTASK 70-23-05-230-002.

        If no cracks are found, continue with the repair.

        If cracks are found, reject the part.

    4. SUBTASK 72-41-13-350-063 Remove the Damaged Area(s)

      CAUTION

      YOU MUST NOT USE POWER TOOLS OR HAND HELD POWER TOOLS TO REPAIR THE COMPONENT.

      CAUTION

      YOU MUST MAKE SURE THAT ALL BURRS CAUSED BY THE MATERIAL REMOVAL ARE REMOVED.

      2. Remove the damaged material from the repair area(s) on the HP compressor rear shaft assembly, as necessary. Do not remove more than is necessary.

      1. Refer to the SPM TASK 70-35-03-300-501, SUBTASK 70-35-03-350-001.

        Remove material to two times the depth (or height) of the damage.

        Maximum permitted depth of dressed material is 0.0100 in. (0.254 mm) in all zones other than zone AV.

        When you remove material on a radius or chamfer, you must make sure that the radius or chamfer does not decrease in size after repair.

        NOTE

        Keep material removal to the larger limit of 0.750 in. (19.05 mm), or 100 x D in all zones other than zone AV. In zone AV, keep material removal to 50 x D.

      3. Make smooth the repaired area(s).

      1. Make sure all damage marks are fully removed and the area(s) made smooth into the adjacent material.

        Remove sharp corners.

      4. Polish the repaired area(s).

      1. Polish the repaired area(s) to remove the scratches and to give a smooth surface finish.

    5. SUBTASK 72-41-13-220-115 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 minimum radius and dimensions are maintained after material removal.

        Make sure the surface finish compares with the adjacent surfaces.

        If repaired area(s) are in the limits, continue with the repair.

        If repaired area(s) are more than the limits, reject the part.

        Use workshop inspection equipment.

    6. SUBTASK 72-41-13-110-059 Cold Ferric Chloride Etch

      1. Swab etch the repaired area(s).

      1. Refer to the SPM TASK 70-11-39-300-503, SUBTASK 70-11-39-300-001.

        Use a polythene bottle.

    7. SUBTASK 72-41-13-220-116 Examine the Repaired Area(s)

      1. Make a visual inspection of the repaired area(s).

      1. Use X10 binoculars.

        Indications of defects on the repaired surfaces are not permitted.

        If indications of defect are found, do the repair from Step again.

        If no defects are found, continue with the repair.

    8. SUBTASK 72-41-13-230-067 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, SUBTASK 70-23-05-230-002.

        If cracks are found, reject the part.

        If no cracks are found, continue with the repair.

    9. SUBTASK 72-41-13-350-064 Identify the Repair

    2. Make a mark adjacent to the assembly number.

      3. If the assembly is repaired in area(s) not necessary for shot peen, identify the assembly VRS6088.

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

        Use vibro-engraving equipment.

      4. NOTE

        Ignore Step if material removal is from area(s) identified in notes AC and/or AD only.

        If the assembly is repaired and shot peened during repair, the assembly must be identified in accordance with the table in Figure.

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

        Use vibro-engraving equipment.

        NOTE

        You cannot repair the HP compressor rear shaft again if the damaged zone(s) is shot peened six times.

    10. SUBTASK 72-41-13-380-052 Shot Peen the Repaired Area(s), Assemblies A and C

      CAUTION

      DO NOT SHOT PEEN ON AREA(S) IDENTIFIED IN NOTES AC, AD AND AE.

      CAUTION

      DO NOT SEAL THE AREA IDENTIFIED AJ.

    1. Refer to Figure, Figure, Figure, Figure and Figure.

      2. Find the repaired area(s) to be shot peened.

      1. Refer to Step.

      3. Seal the full assembly other than the repaired area(s) which have to be shot peened.

      1. Patch mask all identification marks and symbols.

      4. Shot peen the repaired area(s) AF and/or AG, as necessary.

      1. Refer to the SPM TASK 70-38-04-300-503, SUBTASK 70-38-04-300-002.

        Use IAE 3R19134 Almen test strip almen test strip 5 off,

        IAE 3R19165 Dummy Shaft dummy shaft 1 off,

        IAE 3R19169 Fixture fixture 1 off and/or Approved Vendors in Repair Facilities, para B.

        Use CoMat 05-028 METALLIC SHOT (CAST STEEL), S230 to get an almen intensity of 0.006 in. to 0.009 in. (0.15 mm to 0.23 mm) on 'A' type test strip.

        A coverage of 100 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. (0.60 mm to 1.00 mm)

        Shot hardness

        450 to 600 Hv

        Coverage

        100 percent

        Almen intensity

        0.006 in. to 0.009 in. (0.15 mm to 0.23 mm) using an 'A' type test strip

        NOTE

        For information, the cable 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.

        NOTE

        1. Repaired surfaces AF must be locally shot peened to a maximum almen intensity of 0.009 in. (0.23 mm), where the minimum intensity is 100 percent.

        2. Unwanted shot peen spray is permitted in area AJ and AH, to get a continuous fade-out surface condition away from the repaired zones AN, AM and area AG.

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

      6. Remove iron contamination after you have shot peened, as necessary.

      1. Refer to Approved Vendors in Repair Facilities, para. B and/or refer to the SPM TASK 70-38-04-300-503, SUBTASK 70-38-04-300-002.

        Use wet or dry glass beads, with glass bead peening equipment.

    7. Remove mechanical seals and seal tape.

    11. SUBTASK 72-41-13-380-063 Shot Peen the Repaired Area(s), Assemblies B and D

      CAUTION

      DO NOT SHOT PEEN ON AREA(S) IDENTIFIED IN NOTE AC, AD AND AE.

      2. Find the repaired area(s) to be shot peened.

      1. Refer to Step.

      3. Seal the full assembly other than the repaired area(s), as necessary, which have to be shot peened.

      1. Patch mask all identification marks and symbols.

      4. Shot peen the repaired area(s) AF, as necessary.

      1. Refer to the SPM TASK 70-38-04-300-503, SUBTASK 70-38-04-300-002.

        Use IAE 3R19134 Almen test strip almen test strip 4 off,

        IAE 3R19169 Fixture fixture 1 off,

        IAE 3R19183 Dummy Shaft dummy Shaft 1 off and/or Approved Vendors in Repair Facilities, para B.

        Use CoMat 05-028 METALLIC SHOT (CAST STEEL), S230 to get an almen intensity of 0.006 in. to 0.009 in. (0.15 mm to 0.23 mm) on 'A' type test strip.

        A coverage of 100 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. (0.60 mm to 1.00 mm)

        Shot hardness

        450 to 600 Hv

        Coverage

        100 percent

        Almen intensity

        0.006 in. to 0.009 in. (0.15 mm to 0.23 mm) using an 'A' type test strip

        NOTE

        For information, the cable 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.

        NOTE

        1. Repaired surfaces AF must be locally shot peened to a maximum almen intensity of 0.009 in. (0.23 mm), where the minimum intensity is 100 percent coverage.

        2. Unwanted shot peen spray is permitted in areas AH, to get a continuous fade-out surface condition away from the repaired zone AR.

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

      6. Remove iron contamination after you have shot peened, as necessary.

      1. Refer to Approved Vendors in Repair Facilities, para. B and/or refer to the SPM TASK 70-38-04-300-503, SUBTASK 70-38-04-300-002.

        Use wet or dry glass beads, with glass bead peening equipment.

    7. Remove mechanical seals and seal tape.

    12. SUBTASK 72-41-13-220-117 Examine Shot Peened Area(s)

      1. Make a visual inspection of the shot peened area(s).

      1. Refer to Approved Vendors in Repair Facilities, para. B.

    13. Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions - Assemblies A and C

    Repair Details and Dimensions - Assemblies A and C

    Figure: Repair Details and Dimensions - Assemblies A and C

    Repair Details and Dimensions - Assemblies A and C

    Figure: Repair Details and Dimensions - Assemblies B and D

    Repair Details and Dimensions - Assemblies B and D

    Figure: Repair Details and Dimensions - Assemblies B and D

    Repair Details and Dimensions - Assemblies B and D

    Figure: Repair Details and Dimensions - Assemblies A, B, C and D

    Repair Details and Dimensions - Assemblies A, B, C and D

    Figure: Repair Details and Dimensions - Assemblies A and C

    Repair Details and Dimensions - Assemblies A and C

    Figure: Repair Details and Dimensions - Assemblies B and D

    Repair Details and Dimensions - Assemblies B and D

    Figure: Repair Details and Dimensions - Assemblies A and C

    Repair Details and Dimensions - Assemblies A and C

    Figure: Repair Details and Dimensions - Assemblies B and D

    Repair Details and Dimensions - Assemblies B and D

    Figure: Repair Details and Dimensions - Assemblies A, B, C and D

    Repair Details and Dimensions - Assemblies A, B, C and D

    Figure: Repair Details and Dimensions - Assemblies B and D

    Repair Details and Dimensions - Assemblies B and D

    Figure: Repair Details and Dimensions - Assemblies A, B, C and D

    Repair Details and Dimensions - Assemblies A, B, C and D

Requirements After Job Completion

Follow-On Conditions

NONE
Manufacturer Code:06565
Enterprise Name:SAINT-GOBAIN ABRASIVES
BU Name:SAINT-GOBAIN ABRASIVES
P.O. Box:808
City:TROY
State:NY
Zip Code:12181
Country:USA
Phone Number:1-518-266-2200
Fax Number:1-518-266-2342
Internet:www.saintgobain.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: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: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:44197
Supply Number:CoMat 05-074
Type:sp01
Supply Short Name:CoMat 05-074 ALUMINIUM OXIDE ABRASIVE PAPER
Supply Name:CoMat 05-074 ALUMINIUM OXIDE ABRASIVE PAPER
Specification Groups:
Doc NumberType
ANSI/CAMI GRIT SIZE 180 ALUMINIUM OXIDE ABRASIVE PAPER
Suppliers:
ManufacturerRemarks
44197
K6835
LOCAL
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:44197
Supply Number:CoMat 05-111
Type:sp01
Supply Short Name:CoMat 05-111 EMERY POLISHING PAPER
Supply Name:CoMat 05-111 EMERY POLISHING PAPER
Specification Groups:
Doc NumberType
FEPA GRIT SIZE P280 OR P240 EMERY POLISHING PAPER OR ALUMINUM OXIDE ABRASIVE PAPER
Suppliers:
ManufacturerRemarks
44197
K6835
KC1D9
LOCAL
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:LOCAL
Tool Number:Hand tools
Tool Name:Hand tools
Manufacturer Code:0AM53
Tool Number:IAE 3R19134
Tool Name:IAE 3R19134 Almen test strip
Manufacturer Code:0AM53
Tool Number:IAE 3R19165
Tool Name:IAE 3R19165 Dummy Shaft
Manufacturer Code:0AM53
Tool Number:IAE 3R19169
Tool Name:IAE 3R19169 Fixture
Manufacturer Code:0AM53
Tool Number:IAE 3R19183
Tool Name:IAE 3R19183 Dummy Shaft
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Manufacturer Code:LOCAL
Tool Number:Polythene bottle
Tool Name:Polythene bottle
Manufacturer Code:LOCAL
Tool Number:Vibro-engraving equipment
Tool Name:Vibro-engraving equipment