TASK 72-41-14-300-007 HPC Rear Rotating Airseal - Repair Damaged Seal Fins By Welding, Repair-007 (VRS6492)

DMC:V2500-A0-72-41-1400-00A-970A-C|Issue No:004.00|Issue Date:2018-02-01

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 72-41-14-300-007 HPC Rear Rotating Airseal - Repair Damaged Seal Fins By Welding, Repair-007 (VRS6492)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

01-800

6A3305

A

01-800

6A4113

A

01-800

6A4392

B

01-800

6A5869

C

Material of component

PART IDENT

SYMBOL

MATERIAL

HP Compressor Rear Rotating

Airseal

QDY

Waspaloy - heat resistant

alloy vacuum melted

General

This Repair must only be done when the instruction to do so is given in inspection procedures (identified by the applicable part number) located in section 72-41-14.

This repair gives the instruction to repair damage on the HP Compressor Rear Rotating Airseal Seal Fins by pulsed plasma welding.

This is a source demonstration repair which can only be done by Approved Vendors.

This repair can only be applied 3 times, subject to the seal not having more than 3 post-weld heat treatment cycles during its service life.

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

Price and availability

Refer to International Aero Engines

Related repairs - none

NOTE

More equipment and materials necessary to do this Repair are in SPM TASK 70-09-00-400-501, SPM TASK 70-11-03-300-503, SPM TASK 70-11-34-300-503, SPM TASK 70-11-39-300-503, SPM TASK 70-23-05-230-501, SPM TASK 70-31-02-310-501-001, SPM TASK 70-31-04-310-501 and SPM TASK 70-37-00-370-501.

NOTE

To identify the consumable materials, refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
LatheLOCALLathe
Standard workshop equipmentLOCALStandard workshop equipment
Dial test indicatorsLOCALDial test indicators
Workshop inspection equipmentLOCALWorkshop inspection equipment
Fluorescent penetrant inspection equipment0AM53Fluorescent penetrant inspection equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Chemical cleaning equipmentLOCALChemical cleaning equipment
Pulsed plasma welding equipmentLOCALPulsed plasma welding equipment
Vibrating marking pencilLOCALVibrating marking pencil

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-192 WELDING WIRELOCALCoMat 03-192
CoMat 05-140 ABRASIVE STONE SILICON CARBIDELOCALCoMat 05-140
CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)LOCALCoMat 06-022
CoMat 03-248 METAL SPRAY POWDERLOCALCoMat 03-248

Spares

NONE

Safety Requirements

NONE

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 VRS6492 are listed below:

      Rolls-Royce Aero-Engine Services Limited

      Mavor Avenue

      Nerston

      East Kilbride

      Glasgow

      G74 4PY

      Scotland

      Rolls-Royce Inchinnan

      Inchinnan Drive

      Inchinnan Business Park

      Inchinnan, PA4 9AF

      Scotland

    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 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. Authorized Repair Vendors do not act as agents or representatives of IAE.

    2. SUBTASK 72-41-14-220-085 Make Sure the HP Compressor Rear Rotating Airseal can be Repaired

    1. For Assembly A refer to Figure.

    2. For Assembly B refer to Figure.

    3. For Assembly C refer to Figure.

      4. Visually examine the HP Compressor Rear Rotating Airseal to tell you if a heat treatment has been done before.

      1. If the symbol HT/3 is engraved adjacent to the part number, then the seal cannot be repaired.

    3. SUBTASK 72-41-14-220-098 Inspect for Previous Applications of VRS6144

    1. For Assembly B refer to Figure.

    2. For Assembly C refer to Figure.

      NOTE

      This SUBTASK only applies to Assemblies B and C. For Assembly A proceed to Step.

      3. Visually examine the HP Compressor Rear Rotating Airseal to determine if the repair has been applied previously.

        1. Examine the identity marking location for the repair scheme number VRS6144.

          1. If repair scheme number VRS6144 is marked on the component:

          1. Strip the coating. The coating material is CoMat 03-248 METAL SPRAY POWDER.

          2. Refer to SPM TASK 70-33-59-300-503.

          3. Use chemical cleaning equipment.

          2. If the repair scheme number VRS6144 is not marked on the component:

          1. Continue with the repair.

    4. SUBTASK 72-41-14-325-052 Machine the Seal Fins

    1. For Assembly A refer to Figure and Figure.

      For Assembly B refer to Figure and Figure.

      For Assembly C refer to Figure and Figure.

      2. Install the turning fixture into the lathe.

        1. Refer to Step. repair facilities for approved vendor equipment.

        1. Use a lathe with standard workshop equipment.

      3. Install the HP Compressor Rear Rotating Airseal into the turning fixture and set to turn correctly.

        1. Refer to Step. repair facilities for approved vendor equipment.

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

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

      4. Machine the seal fins.

      1. Machine only the minimum quantity to remove scores or coating.

      5. Remove burrs.

      1. Use standard workshop equipment and/or CoMat 05-140 ABRASIVE STONE SILICON CARBIDE.

    5. SUBTASK 72-41-14-325-052-B00 Machine the HP Compressor Rear Rotating Airseal, Assembly B

    1. DELETED.

    6. SUBTASK 72-41-14-325-052-C00 Machine the HP Compressor Rear Rotating Airseal, Assembly C

    1. DELETED.

    7. SUBTASK 72-41-14-220-086 Visually and Dimensionally Inspect the HP Compressor Rear Rotating Airseal

    1. For Assembly A refer to Figure and Figure.

      For Assembly B refer to Figure and Figure.

      For Assembly C refer to Figure and Figure.

      2. Visually inspect the machined HP Compressor Rear Rotating Airseal.

        1. Make sure that all damage has been removed from the seal fins.

          1. If there is any remaining evidence of damage:

          1. Repeat the repair from Step.

          2. If all damage has been removed from the seal fins:

          1. Continue with the repair.

      3. Dimensionally inspect seal fins on the machined HP Compressor Rear Rotating Airseal.

        1. Use workshop inspection equipment.

          1. If the diameter of any of the seal fins are below the minimum dimension:

          1. Reject.

          2. If the diameter of all of the seal fins are within the acceptable limits:

          1. Record the dimensions for use with Step and continue with the repair.

    8. SUBTASK 72-41-14-220-086-B00 Examine the HP Compressor Rear Rotating Airseal, Assembly B

    1. DELETED.

    9. SUBTASK 72-41-14-220-086-C00 Examine the HP Compressor Rear Rotating Airseal, Assembly C

    1. DELETED.

    10. SUBTASK 72-41-14-110-059 Cold Ferric Chloride Etch

      1. Swab etch the repaired areas.

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

        1. Use chemical cleaning equipment.

    11. SUBTASK 72-41-14-230-061Fluorescent Penetrant Inspect

      1. Inspect for cracking at the repair area on the HP Compressor Rear Rotating Airseal using fluorescent penetrant inspection.

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

        3. Use fluorescent penetrant inspection equipment.

          1. If cracking is detected:

          1. Reject.

          2. If no cracking is detected:

          1. Continue with the repair.

    12. SUBTASK 72-41-14-110-060 Chemically Clean

      1. Chemically clean the HP Compressor Rear Rotating Airseal.

        1. Use chemical cleaning equipment.

    13. SUBTASK 72-41-14-310-051 Pulsed Plasma Weld the Repair Area(s)

    1. For Assembly A refer to Figure and Figure.

      For Assembly B refer to Figure and Figure.

      For Assembly C refer to Figure and Figure.

      2. Install the weld fixture on to the table.

        1. Refer to Step. Repair Facilities for approved vendor equipment.

        1. Use pulsed plasma welding equipment with standard workshop equipment.

      3. Install the HP Compressor Rear Rotating Airseal on to the weld fixture and set to turn correctly.

        1. Refer to Step. Repair Facilities for approved vendor equipment.

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

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

      4. Pulsed plasma weld the seal fins.

        1. Refer to SPM TASK 70-31-04-310-501.

        1. Use CoMat 03-192 WELDING WIRE with pulsed plasma welding equipment.

        2. Refer to approved vendor data cards for equipment and parameters to be used.

        3. Make sure sufficient weld material is applied to allow for the machining of the seal fins to the required size.

    14. SUBTASK 72-41-14-310-051-B00 Pulsed Plasma Weld the HP Compressor Rear Rotating Airseal, Assembly B

    1. DELETED.

    15. SUBTASK 72-41-14-310-051-C00 Pulsed Plasma Weld the HP Compressor Rear Rotating Airseal, Assembly C

    1. DELETED.

    16. SUBTASK 72-41-14-220-087 Visually Examine the HP Compressor Rear Rotating Airseal

      1. Visually examine the welded areas.

        1. Refer to SPM TASK 70-31-02-310-501-001, SUBTASK 70-31-02-220-001.

        1. Use workshop inspection equipment.

    17. SUBTASK 72-41-14-370-051 Heat Treat the HP Compressor Rear Rotating Airseal

      1. Heat the HP Compressor Rear Rotating Airseal in a vacuum or controlled atmosphere.

        1. Refer to SPM TASK 70-37-00-370-501.

        1. Use heat treatment equipment.

          Heat Treat Data

          Heat to a temperature of 1400 deg F (760 deg C) for 4 hours in a vacuum.

          Gas fan quench to 212 deg F (100 deg C)

    18. SUBTASK 72-41-14-220-099 Dimensionally Inspect the Spigot

    1. For Assembly B refer to Figure and Figure.

      For Assembly C refer to Figure and Figure.

      NOTE

      This SUBTASK only applies to Assemblies B and C.

      2. Dimensionally inspect the inner and outer diameters of the HP Compressor Rear Rotating Airseal Spigot.

        1. Measure Dim D1 and measure and record Dim D2 (Inner Diameter).

          1. If Dim D1 is within the given dimension:

          1. Continue with the repair from Step.

            NOTE

            If the HP Compressor Rear Rotating Airseal had coating removed during Step the spigot diameter will be smaller than the given limits. For these components continue with the repair from Step.

          2. If Dim D1 is larger than the given dimension:

          1. Continue the repair from Step.

    19. SUBTASK 72-41-14-320-002 Machine the Spigot Diameter

    1. For Assembly B refer to Figure, Figure and Figure.

      For Assembly C refer to Figure, Figure and Figure.

      NOTE

      This SUBTASK only applies to Assemblies B and C.

      2. Install the grinding fixture into the grinding machine.

      1. Use a grinding machine with a locally manufactured grinding fixture.

        NOTE

        If tooling exists for application of the repair scheme VRS6144 the same tooling can be used.

      3. Install the HP Compressor Rear Rotating Airseal into the turning fixture and set to turn correctly.

      1. Set Datums A and C to turn correctly.

      2. Use a dial test indicator.

      4. Machine Dim D1 on the spigot diameter of the HP Compressor Rear Rotating Airseal.

      1. Machine to restore Dim D1 and the forward chamfer to within the specified dimensions.

      2. Remove the minimum amount of material necessary to restore the spigot diameter and chamfer.

      5. Remove burrs and raised material produced by the machining process.

    20. SUBTASK 72-41-14-220-100 Dimensionally Inspect the Machined Component

    1. For Assembly B refer to Figure, Figure, Figure and Figure.

      For Assembly C refer to Figure, Figure, Figure and Figure.

      NOTE

      This SUBTASK only applies to Assemblies B and C.

      2. Dimensionally inspect the spigot on the HP Compressor Rear Rotating Airseal.

      1. Make sure that the wall thickness on the spigot and the position of the boltholes are within the acceptable limits.

        2. Measure Dim D1 after machining and use value for Dim D2 as recorded in Step.

          1. If (Dim D1 - Dim D2) divided by 2 is less than the minimum wall thickness:

          1. Reject.

          2. If the position of the boltholes are not within the limits:

          1. Reject.

          3. If (Dim D1 - Dim D2) divided by 2 is greater than or equal to the minimum wall thickness and the position of the boltholes are within the given limits:

          1. Continue with the repair.

    21. SUBTASK 72-41-14-325-053 Machine the Welded Seal Fins

    1. For Assembly A refer to Figure, Figure and Figure.

      For Assembly B refer to Figure, Figure and Figure.

      For Assembly C refer to Figure, Figure and Figure.

      2. Install the turn fixture into the lathe.

        1. Refer to Step. Repair Facilities for approved vendor equipment.

        1. Use a lathe with standard workshop equipment.

      3. Install the HP Compressor Rear Rotating Airseal into the turn fixture and set to turn correctly.

        1. Refer to Step. Repair Facilities for approved vendor equipment.

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

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

      4. Machine the seal fins.

      1. Use a lathe.

      5. Remove burrs.

      1. Use standard workshop equipment and/or CoMat 05-140 ABRASIVE STONE SILICON CARBIDE.

    22. SUBTASK 72-41-14-325-053-B00 Machine the HP Compressor Rear Rotating Airseal, Assembly B

    1. DELETED.

    23. SUBTASK 72-41-14-325-053-C00 Machine the HP Compressor Rear Rotating Airseal, Assembly C

    1. DELETED.

    24. SUBTASK 72-41-14-220-088 Dimensionally Inspect the HP Compressor Rear Rotating Airseal

    1. For Assembly A refer to Figure, Figure and Figure.

      For Assembly B refer to Figure, Figure and Figure.

      For Assembly C refer to Figure, Figure and Figure.

      2. Dimensionally inspect the seal fins on the machined HP Compressor Rear Rotating Airseal.

        1. Use workshop inspection equipment.

          1. If the dimensions of any of the seal fins are outside the given dimensions:

          1. Reject.

          2. If the dimensions of all of the seal fins are within the given dimensions:

          1. Continue with the repair.

    25. SUBTASK 72-41-14-220-088-B00 Examine the HP Compressor Rear Rotating Airseal, Assembly B

    1. DELETED.

    26. SUBTASK 72-41-14-220-088-C00 Examine the HP Compressor Rear Rotating Airseal, Assembly C

    1. DELETED.

    27. SUBTASK 72-41-14-110-061 Cold Ferric Chloride Etch

      1. Swab etch the repair area on the HP Compressor Rear Rotating Airseal.

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

        1. Use chemical cleaning equipment.

    28. SUBTASK 72-41-14-230-062 Fluorescent Penetrant Inspect

      1. Inspect for cracking at the repair area on the HP Compressor Rear Rotating Airseal using fluorescent penetrant inspection.

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

          2. Use fluorescent penetrant inspection equipment.

            1. If cracking is detected:

            1. Reject.

            2. If no cracking is detected:

            1. Continue with the repair.

    29. SUBTASK 72-41-14-350-066 Identify the Repair

    1. For Assembly A refer to Figure.

      For Assembly B refer to Figure.

      For Assembly C refer to Figure.

      2. Make a mark VRS6492 adjacent to part number at the identified location.

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

      2. Use vibro-peen equipment.

        NOTE

        If the HP Compressor Rear Rotating Airseal is already identified with the repair scheme number VRS6492 then only the post weld heat treatment reference number needs to the updated.

      3. Mark the heat treatment reference number adjacent to the part number at the identified location:

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

      2. If this is the first post weld heat treatment on the seal, then vibro-peen HT/1 adjacent to the scheme number.

      3. If this is the second post weld heat treatment on the seal, then vibro-peen HT/2 adjacent to the scheme number.

      4. If this is the third post weld heat treatment on the HP Compressor Rear Rotating Airseal, then vibro-peen HT/3 adjacent to the repair scheme number.

      5. Use vibro-peen equipment.

      4. Remove all raised material and burrs created by the vibro-peen marking process.

    30. SUBTASK 72-41-14-340-053 Re-apply the Flame Spray Coating (if required)

      1. Re-apply the coating to the location diameter of the HP Compressor Rear Rotating Airseal if required.

        NOTE

        This SUBTASK only applies to Assemblies B and C and to component that had the coating removed in Step.

      1. Reapply the coating, refer to VRS6144, TASK 72-41-14-300-002 (REPAIR-002).

      2. Make sure there is sufficient remaining wall thickness to allow for the application of VRS6144, use the results obtained in Step.

    31. Figure: Repair Details and Dimensions - Assembly A

    Repair Details and Dimensions - Assembly A

    Figure: Repair Details and Dimensions - Assembly A

    Repair Details and Dimensions - Assembly A

    Figure: Repair Details and Dimensions - Assembly A

    Repair Details and Dimensions - Assembly A

    Figure: Repair Details and Dimensions - Assembly B and Assembly C

    Repair Details and Dimensions - Assembly B and Assembly C

    Figure: Repair Details and Dimensions - Assembly B and Assembly C

    Repair Details and Dimensions - Assembly B and Assembly C

    Figure: Repair Details and Dimensions - Assembly B

    Repair Details and Dimensions - Assembly B

    Figure: Repair Details and Dimensions - Assembly C

    Repair Details and Dimensions - Assembly C

    Figure: Repair Details and Dimensions - Assembly A, Assembly B and Assembly C

    Repair Details and Dimensions - Assembly A, Assembly B and Assembly C

    Figure: Rear Spigot Machining Mismatch - Assembly B and Assembly C

    Rear Spigot Machining Mismatch - Assembly B and Assembly C

    Figure: Rear Spigot Machining Mismatch - Assembly B and Assembly C

    Rear Spigot Machining Mismatch - Assembly B and Assembly C

    Figure: HP Compressor Rear Rotating Airseal Bolthole Locations - Assembly B and Assembly C

    HP Compressor Rear Rotating Airseal Bolthole Locations - Assembly B and Assembly C

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the repair facilities to update vendor addresses. (17VC206)

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 03-192
Type:sp01
Supply Short Name:CoMat 03-192 WELDING WIRE
Supply Name:CoMat 03-192 WELDING WIRE
Specification Groups:
Doc NumberType
OMAT: 3/99W-A ALLOY (WASPALOY) AMS 5828D
OMAT: 3/99W-A ALLOY (WASPALOY) AMS 5828D
Suppliers:
ManufacturerRemarks
LOCAL
2R602
IE138
IE306
55596
58401
K6835
Manufacturer Code:LOCAL
Supply Number:CoMat 03-248
Type:sp01
Supply Short Name:CoMat 03-248 METAL SPRAY POWDER
Supply Name:CoMat 03-248 METAL SPRAY POWDER
Specification Groups:
Doc NumberType
MSRR9507/35METCO 447 NS
OMAT:3/179MIL-P-85856/27
Suppliers:
ManufacturerRemarks
LOCAL
39918
K1030
K6835
IE103
IE195
IE200
Manufacturer Code:LOCAL
Supply Number:CoMat 05-140
Type:sp01
Supply Short Name:CoMat 05-140 ABRASIVE STONE SILICON CARBIDE
Supply Name:CoMat 05-140 ABRASIVE STONE SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/114MJF 244 (ROUND OR HALF-ROUND), SS-S-736/3-20, TYPE II CLASS A2
Suppliers:
ManufacturerRemarks
LOCAL
44197
A2549
IE216
IE302
K3895
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:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Lathe
Tool Name:Lathe
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Manufacturer Code:LOCAL
Tool Number:Pulsed plasma welding equipment
Tool Name:Pulsed plasma welding equipment
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment