TASK 72-41-14-300-008 HPC Rear Rotating Air Seal - Repair The Damaged Rub Track By Metal Spray, Repair-008 (VRS 6505)

DMC:V2500-A0-72-41-1400-01A-970A-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 72-41-14-300-008 HPC Rear Rotating Air Seal - Repair The Damaged Rub Track By Metal Spray, Repair-008 (VRS 6505)

Effectivity

FIG/ITEM

PART NO.

01-800

6A4113

Material of component

RR

DESCRIPTION

SYMBOL

MATERIAL

HP compressor rear

QDY

Waspaloy heat

rotating air seal

resisting alloy,

vacuum melted

General

This Repair must only be done when the instruction to do so is given in 72-41-14 Inspection/Check.

This Repair replaces a damaged rub track on the HP compressor rear rotating air seal, by metal spray.

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.

Repair facilities

The Source Demonstration requirements of the Repair means that any facility not authorized to accomplish this Repair, either utilize the Authorized Repair Vendors listed below or contact the IAE Repair Development Group to determine if a qualification program can be initiated at their facility.

IAE - International Aero Engines AG
400 Main Street
East Hartford CT 06108
U.S.A.
ATTN:  Manager, Repair Services
Authorized Repair Vendors for the Repair VRS6505 are listed below:
General Plasma Inc.
12 Windsor Road
EAST WINDSOR CT 06088
USA
ATTN:  Director, Quality Assurance
MTU Maintenance GmbH
Flughafen Hannover
Munchner Strasse 31
Postfach 1720
D3012 LANGENHAGEN
Germany
ATTN:  Manager, Quality Assurance
Rolls-Royce Aero-Engine Services Ltd
Component Refurbishment
Mavor Avenue
Nerston
EAST KILBRIDE
Glasgow G74 4PY
Scotland
ATTN:  Manager, Engine Component Repair Development
Ishikawajima - Harima Heavy Industries Co Ltd
Aero-Engine and Space Operations
Mizuho Aero-Engine Works
229, Tonogaya
Mizuho - Machi
Mishitama - Gun
TOKYO, 190-12
Japan
ATTN:  Manager, Engine Component Repair Development
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.
NOTE
Equivalent materials or equipment can be used.
More equipment and materials necessary to do this repair are in TASK 70-09-00-400-501, TASK 70-12-02-120-501, TASK 70-23-04-230-501, TASK 70-33-59-300-503 and 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
Abrasive blast equipmentLOCALAbrasive blast equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Metal spray equipmentLOCALMetal spray equipment
Plasma Tecnik F4 MB GunLOCALPlasma Tecnik F4 MB Gun
Grinding machineLOCALGrinding machine
Dial test indicatorsLOCALDial test indicators
LatheLOCALLathe
Tufnol blockLOCALTufnol block
BrushLOCALBrush
Surface measuring equipmentLOCALSurface measuring equipment
Vibrating marking pencilLOCALVibrating marking pencil
IAE 3R19128 grind fixture0AM53IAE 3R191281
Consumables, Materials and Expendables
NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADELOCALCoMat 01-025
CoMat 02-019 TAPE, ADHESIVE PAPER HEAT RESISTING MASKING94960CoMat 02-019
CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5)IE200CoMat 03-038
CoMat 03-043 METAL SPRAYING POWDER,Al OXIDELOCALCoMat 03-043
CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADELOCALCoMat 05-001
CoMat 05-118 DIAMOND LAPPING COMPOUND,SLURRY, SPRAY, OR SUSPENSION4S8W0CoMat 05-118
CoMat 10-105 LAPPING FLUIDLOCALCoMat 10-105
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001
Spares
NONE
Safety Requirements
NONE
Procedure
    1. SUBTASK 72-41-14-110-057 Clean the HP Compressor Rear Rotating Air Seal
      1. Chemically clean.
      1. Refer to TASK 72-41-14-100-000 (CLEANING-000).
      2. Use chemical cleaning equipment.
    2. SUBTASK 72-41-14-120-052 Loosen the Rub Track Top Coat
    1. CAUTION
      REMOVE THE TOP COAT ONLY, THE BLAST OPERATION MUST STOP WHEN THE WHITE TOP COAT IS REMOVED.  FAILURE TO STOP THE BLAST OPERATION AS SPECIFIED CAN RESULT IN SUBSEQUENT ENGINE FAILURE.
      NOTE
      It is permitted to loosen the rub track top coat in part, to let the Nitric Acid by capillary action, release both top and bond coats.
      Refer to Figure and Figure.
      2. Apply masking to all surfaces not to be blasted.
      3. Lightly dry blast to loosen the rub track top coat.
      1. Refer to the SPM TASK 70-12-02-120-501.
    4. Remove the masking tape.
    3. SUBTASK 72-41-14-330-051 Chemically Remove the Rub Track Coating
    1. Refer to Figure and Figure
      2. Remove the rub track coating.
      1. Refer to the SPM TASK 70-33-59-300-503.
      2. Use CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE with chemical cleaning equipment.
      3. Put the HP compressor rear rotating air seal into the nitric acid solution and keep below the surface until the bubbles stop.
    4. SUBTASK 72-41-14-220-079 Visually Examine the Surface for Repair
    1. Refer to Figure and Figure.
      2. Visually examine.
        1. Make sure all the lining materials has been removed.
        1. If not, do SUBTASK 72-41-14-120-051 and SUBTASK 72-41-14-330-052 again, as necessary.
    5. SUBTASK 72-41-14-230-059 Do a Crack Test
      1. Do a penetrant crack test.
        1. Refer to the SPM TASK 70-23-04-230-501.
        1. Use penetrant crack test equipment.
        2. Discard the HP compressor rear rotating air seal, if cracked.
    6. SUBTASK 72-41-14-220-080 Measure the Dimension of the Surface for Repair
    1. CAUTION
      HP COMPRESSOR REAR ROTATING AIR SEALS, WHICH ARE NOT ACCEPTED AND CANNOT BE REPAIRED, ARE TO BE DISCARDED.
      Refer to Figure and Figure.
      2. Measure the radial depth of the rub track groove minimum diameter.
      1. Use standard workshop equipment.
        The minimum diameter must not be less than 12.366 in. (314.10 mm).
    7. SUBTASK 72-41-14-350-061 Apply masking to all Surfaces not to be Repaired
    1. Refer to Figure and Figure.
      2. NOTE
        The heat resistant paper masking tape, permits the blasting and spray coating to be done in one operation.
        Apply masking to applicable surfaces.
    8. SUBTASK 72-41-14-120-053 Prepare the Surface for Repair
    1. CAUTION
      DO NOT TOUCH AREAS TO BE REPAIRED AFTER THEY ARE CLEANED.
      TOO MUCH ABRASIVE BLAST CAN CAUSE DETERIORATION OF THE PREPARED SURFACE CONDITION AND MUST BE PREVENTED.
      Refer to Figure and Figure.
      2. Lightly dry blast to prepare the surface for the rub track coating.
      1. Refer to the SPM TASK 70-12-02-120-501.
    9. SUBTASK 72-41-14-340-052 Apply the Rub Track Coating
    1. Refer to Figure and Figure.
      2. Apply the bond coat to the rub track groove.
      1. Refer to the SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-025.
      2. Use CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5) with metal spray equipment and a Plasma Tecnik F4 MB spray gun or equivalent.
      3. Apply a thickness of 0.003 to 0.005in. (0.076 to 0.127 mm).
      3. Apply the top coat to the rub track groove.
      1. Refer to TASK 70-34-01-340-501, SUBTASK 70-34-01-340-013.
      2. Use CoMat 03-043 METAL SPRAYING POWDER,Al OXIDE with metal spray equipment and a Plasma Tecnik F4 MB spray gun or equivalent.
      3. Apply a layer of sufficient thickness to get the correct dimensions after the HP compressor rear rotating air seal rub track is machined.
    4. Remove the masking tape.
    10. SUBTASK 72-41-14-220-081 Visually Examine
      1. Visually examine the rub track coating.
      1. Refer to the SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-002.
    11. SUBTASK 72-41-14-324-053 Machine the Rub Track Coating
    1. CAUTION
      DO NOT USE THE AUTOMATIC FEED WHEN YOU GRIND THE COATING.
      Refer to Figure and Figure.
      2. Set up the HP compressor rear rotating air seal to be machined, to turn correctly.
        1. Use IAE 3R19128 grind fixture 1 off, or a locally made grind fixture, with a grinding machine.
        1. Use a dial test indicator.
        2. Make sure the HP compressor rear rotating air seal datum points A and B, turn correctly.
      3. Grind the rub track coating on the HP compressor rear rotating air seal, to the given dimensions.
      1. Refer to Figure.
        GRINDING DATA
        Wheel
        Standard 120 Grit
        Wheel speed
        3000rpm
        Feed
        Manual
        NOTE
        The information given above is for guidance only.  Local conditions and equipment can change.
    12. SUBTASK 72-41-14-325-051 Lap the Rub Track Coating
    1. CAUTION
      YOU MUST KEEP THE RUB TRACK COATING WELL LUBRICATED WITH THE LAPPING FLUID, DURING THE LAPPING OPERATION.  IF NOT, THE COATING WILL BECOME SCORED WITH THE DIAMOND COMPOUND.
      DO NOT USE THE AUTOMATIC FEED, WHEN YOU LAPP THE COATING.
      Refer to Figure and Figure.
      2. Set up the HP compressor rear rotating air seal, to turn correctly.
        1. Use IAE 3R19128 grind fixture 1 off, and a locally made grind fixture, with a lathe.
        1. Use a dial test indicator.
        2. Make sure the HP compressor rear rotating air seal datum points A and B, turn correctly.
      3. NOTE
        1. Keep the rub track coating well lubriacted during the lapping operation.
        2. Most times you can get the necessary surface finish in one cycle.
        3. The information given above is for guidance only.  Local conditions and equipment can change.
        Lap the machined rub track coating, to get a good surface finish.
        1. Apply lapping paste, CoMat 05-118 DIAMOND LAPPING COMPOUND,SLURRY, SPRAY, OR SUSPENSION or a 20 micro inch (0.5 micron) equivalent, to a Tufnol block.
        1. Lubricate the rub track coating with CoMat 10-105 LAPPING FLUID or equivalent.
        2. Apply a large quantity of the fluid with a brush.
        3. Load the Tufnol block into contact with the rub track coating surface and apply a 0.020 in. (0.508 mm) feed depth on the cross-slide indicator of the lathe.
        4. Turn the work for 20 minutes, to get the necessary surface finish.
        5. Use a Tufnol block.
    13. SUBTASK 72-41-14-220-082 Examine the Repaired Rub Track
    1. Refer to Figure and Figure.
      2. Visually examine the rub track coating.
      1. Refer to the SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-002.
      3. If scored.
      1. Remove and apply the rub track coating again.
      4. Measure the dimension of the rub track coating.
      1. Use standard workshop equipment.
      5. Examine the surface finish of the rub track coating.
        1. A surface finish of 20 micro in. (0.5 microns) has to be achieved.
        1. Use surface measuring equipment.
        2. If necessary, do Step again.
    14. SUBTASK 72-41-14-350-062 Identify the Repair
      1. Vibro-engrave VRS6505 adjacent to the part number.
        1. Refer to the SPM TASK 70-09-00-400-501, SUBTASK 70-09-00-400-001.
    15. 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:4S8W0
Enterprise Name:DIAMOND INNOVATIONS (WORLD HEADQUARTERS)
BU Name:DIAMOND INNOVATIONS (WORLD HEADQUARTERS)
Street:6325 HUNTLEY ROAD WORTHINGTON OH 43085 USA
City:WORTHINGTON
State:OH
Zip Code:43085
Country:USA
Phone Number:1-614-438-2000, 1-800-443-1955
Fax Number:1-614-438-2931, 1-800-472-7379
Internet:www.abrasivesnet.com
Manufacturer Code:94960
Enterprise Name:3M TRAFFIC CONTROL
BU Name:3M TRAFFIC CONTROL
Department:MATERIALS DIVISION
Building:225 55
Street:3M CENTER
City:ST PAUL
State:MN
Zip Code:55144-1000
Country:USA
Phone Number:1-612-733-0477
Internet:www.3m.com/tcm
Manufacturer Code:IE200
Enterprise Name:DELETED, REFER TO CAGE CODE 00BB6
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:5FCA4
Supply Number:CoMat 01-025
Type:sp01
Supply Short Name:CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE
Supply Name:CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE
Specification Groups:
Doc NumberType
orTECHNICAL GRADE SP.GR. 1.42 NITRIC ACID
orTECHNICAL GRADE 42 BAUME NITRIC ACID
TECHNICAL GRADE 67.5 WT% NITRIC ACID
Suppliers:
ManufacturerRemarks
5FCA4
K6835
LOCAL
U0PR4
U0SV8
U6726
V272V
Manufacturer Code:LOCAL
Supply Number:CoMat 02-001
Type:sp01
Supply Short Name:CoMat 02-001 ADHESIVE TAPE (MASKING)
Supply Name:CoMat 02-001 ADHESIVE TAPE (MASKING)
Specification Groups:
Doc NumberType
OMAT: 230 (RR REF)ZINC OXIDE AT142
JCR-197 (JAEC REF)ZINC OXIDE AT142
Suppliers:
ManufacturerRemarks
LOCAL
K6835
U0415
Manufacturer Code:76381
Supply Number:CoMat 02-019
Type:sp01
Supply Short Name:CoMat 02-019 TAPE, ADHESIVE PAPER HEAT RESISTING MASKING
Supply Name:CoMat 02-019 TAPE, ADHESIVE PAPER HEAT RESISTING MASKING
Specification Groups:
Doc NumberType
OMAT: 2/40 (RR REF)SELLOTAPE 2595 SCAPA 2595 OR 3M HT214
JCR-201 (JAEC REF)SELLOTAPE 2595 SCAPA 2595 OR 3M HT214
Suppliers:
ManufacturerRemarks
76381
K3312
K6835
Manufacturer Code:00BB6
Supply Number:CoMat 03-038
Type:sp01
Supply Short Name:CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5)
Supply Name:CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5)
Specification Groups:
Doc NumberType
OMAT: 3/188 (RR REF)METCO 450NS
JCR-020 (JAEC REF)
Suppliers:
ManufacturerRemarks
00BB6
01FK3
0Y7E4
C1840
IE103
K0455
K6835
Manufacturer Code:LOCAL
Supply Number:CoMat 03-043
Type:sp01
Supply Short Name:CoMat 03-043 METAL SPRAYING POWDER, Al OXIDE
Supply Name:CoMat 03-043 METAL SPRAYING POWDER,Al OXIDE
Specification Groups:
Doc NumberType
MSRR9507/9METCO 105 NS MIL-P-85856/10
OMAT:3/94METCO 105 NS MIL-P-85856/10
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:4S8W0
Supply Number:CoMat 05-118
Type:sp01
Supply Short Name:CoMat 05-118 DIAMONDLAPPING COMPOUND, SLURRY, SPRAY, OR SUSPENSION
Supply Name:CoMat 05-118 DIAMOND LAPPING COMPOUND,SLURRY, SPRAY, OR SUSPENSION
Specification Groups:
Doc NumberType
PMC 3129-1K-700 MWS or No. 3 STD. 18M03OSS
Suppliers:
ManufacturerRemarks
4S8W0
1E1X8
Manufacturer Code:LOCAL
Supply Number:CoMat 10-105
Type:sp01
Supply Short Name:CoMat 10-105 LAPPING FLUID
Supply Name:CoMat 10-105 LAPPING FLUID
Specification Groups:
Doc NumberType
METADI FLUID NO.40-6064
Suppliers:
ManufacturerRemarks
LOCAL
09405
U6032
Link not Found
Manufacturer Code:LOCAL
Tool Number:Brush
Tool Name:Brush
Manufacturer Code:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Link not Found
Link not Found
Manufacturer Code:0AM53
Tool Number:IAE 3R19128
Tool Name:IAE 3R19128 grind fixture
Manufacturer Code:LOCAL
Tool Number:Lathe
Tool Name:Lathe
Manufacturer Code:LOCAL
Tool Number:Metal spray equipment
Tool Name:Metal spray equipment
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Manufacturer Code:LOCAL
Tool Number:Plasma Tecnik F4 MB Gun
Tool Name:Plasma Tecnik F4 MB Gun
Manufacturer Code:LOCAL
Tool Number:Surface measuring equipment
Tool Name:Surface measuring equipment
Manufacturer Code:LOCAL
Tool Number:Tufnol block
Tool Name:Tufnol block
Link not Found