TASK 72-41-15-300-035 HPC Stage 3 Rotor Blade - Replace The Clapper Coating, Repair-035 (VRS6236)

DMC:V2500-A0-72-41-1503-00A-970A-C|Issue No:003.00|Issue Date:2021-02-01

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 72-41-15-300-035 HPC Stage 3 Rotor Blade - Replace The Clapper Coating, Repair-035 (VRS6236)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

01-200

6A3513

A

01-200

6A3938

A

Deleted

Deleted

Deleted

Deleted

Deleted

Deleted

Deleted

Deleted

Deleted

01-200

6A8353

D

Deleted

Deleted

Deleted

01-200

6A8688

D

NOTE

Assembly B and Assembly C have been deleted.

Material of component

PART IDENT

MATERIAL

Stage 3 compressor blade

Titanium alloy

General

This repair must only be done when the instruction to do so is given in TASK 72-41-15-200-000 (INSPECTION-000).

This repair replaces the coating on the clapper abutment faces of the stage 3 compressor blades. The tungsten carbide 15 percent cobalt metal spray coating is applied by the flame detonation deposition process.

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

The Pre-flame deposition abrasive blast and flame deposition section of this repair is source controlled, which can only be done by approved vendors.

The vendor is self provisioning for the coating material.

Price and Availability

Refer to International Aero Engines.

Related Repairs

HP Compressor Rotor Blade - Stage 3 - Repair Damaged or Worn Clapper Abutment Face by Weld, refer to TASK 72-41-15-300-052 (VRS6616).

Repair Facilities

The proprietary nature of this repair requires that any facility not authorized to accomplish this repair either, utilize the Authorized Repair Vendors listed below or contact the IAE Repair Development Services to determine if a qualification program can be initiated at their facility.

IAE - INTERNATIONAL AERO ENGINES AG
C/O ROLLS-ROYCE DEUTSCHLAND Ltd and Co KG
ESCHENWEG 11
DAHLEWITZ
D-15827 BLANKENFELDE-MAHLOW
GERMANY
ATTN: Manager Technical Services

Authorized repair vendors for the pre-flame deposition abrasive blast and flame deposition section of Repair VRS6236 are listed below:

PRAXAIR SURFACE TECHNOLOGIES LTD.
Southam Industrial Estate
Westfields Road
Southam
Leamington Spa
Warwickshire
CV33 0JH

PRAXAIR SURFACE TECHNOLOGIES K.K.
Okegawa Plant
1944-3 Shimoishido-Kami
Kitamoto-Shi
Saitama
Pref 364-0022
Japan

ASIAN SURFACE TECHNOLOGIES Pte Ltd
55 Loyang Drive
Singapore
508967

The designation by IAE of an Authorized Repair Vendor indicates that the Repair Vendor has demonstrated the 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

Equipment and materials necessary to do this repair are in the SPM TASKs given below:
SPM TASK 70-09-00-400-501
SPM TASK 70-11-03-300-503
SPM TASK 70-12-02-120-501
SPM TASK 70-23-04-230-501

NOTE

To identify the consumable materials refer to the PCI.

NOTE

Special tools are identified in the procedure by tool primary number.

Preliminary Requirements

Pre-Conditions

Action/ConditionData Module/Technical Publication
Make sure that all the necessary cleaning and inspection procedures are done before this repair.

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Abrasive Blast EquipmentLOCALAbrasive Blast Equipment
Co-ordinate measurement machineLOCALCo-ordinate measurement machine
Degreasing equipmentLOCALDegreasing equipment
Detonation flame deposition equipmentLOCALDetonation flame deposition equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Rochelle carbonate tankLOCALRochelle carbonate tank
Vibrating Marking PencilLOCALVibrating Marking Pencil
IAE 3R19363 Inspection fixture0AM53IAE 3R193631
IAE 3R19366 Inspection Block0AM53IAE 3R193661
IAE 3R19367 Inspection block0AM53IAE 3R193671
IAE 3R19372 Stop block0AM53IAE 3R193721
IAE 3R19815 Clapper width checking fixture0AM53IAE 3R198151
IAE 3R19816 Inspection jaws0AM53IAE 3R198161
IAE 3R19817 Master blade0AM53IAE 3R198171

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOILK6835CoMat 02-006
CoMat 02-017 WAXLOCALCoMat 02-017
CoMat 02-198 ADHESIVE TAPE (MASKING METAL SPRAY)07512CoMat 02-198
CoMat 05-002 ABRASIVE MEDIUM, ALUMINUM OXIDELOCALCoMat 05-002
CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADEX222XCoMat 05-003

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-15-110-083 Clean the Blade

      1. Remove the grease.

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

      2. Use degreasing equipment.

    2. SUBTASK 72-41-15-330-051 Mask the Blade

    1. Refer to Figure, Figure, and Figure.

      2. Put the blade fully into hot wax.

    3. Cut back wax to show hard faces.

    3. SUBTASK 72-41-15-330-052 Remove Hard Facings

    1. Refer to Figure, Figure, and Figure.

      2. Remove hard facings by anodically etching the blade.

      1. Refer to approved vendor in 4. Repair Facilities, Para B.

      2. Use Vendor Techniques.

      3. Hang the blade from the tip with a clamp to make electrical contact.

      4. Use the rochelle carbonate tank.

    4. SUBTASK 72-41-15-110-084 Clean the Blade

    1. Clean the blade fully in clean cold running water.

    5. SUBTASK 72-41-15-110-085 Remove the Wax

    1. Put the blade fully into boiling water to remove the wax.

    6. SUBTASK 72-41-15-230-071 Do a Crack Test

      1. Do a penetrant crack test on clapper abutment faces.

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

        2. Use penetrant crack test equipment.

        1. Cracks are not permitted.

    7. SUBTASK 72-41-15-120-054 Abrasive Blast

      1. Lightly abrasive blast struts and airfoil to remove staining.

      1. Refer to the SPM TASK 70-12-02-120-501.

    8. SUBTASK 72-41-15-220-194-A00 Examine the Repair, Assembly A

    2. Measure the dimensions of the clapper abutment faces in relation to the blade.

    4. Identify thickness of coating required.

    5. For blades that are not within repair limits refer to TASK 72-41-15-300-052 (VRS6616).

    9. SUBTASK 72-41-15-220-194-B00 Examine the Repair, Assembly B and Assembly C (DELETED)

    1. This subtask has been deleted.

    10. SUBTASK 71-41-15-220-194-C00 Examine the Repair, Assembly D

    2. Measure the dimensions of the clapper abutment faces in relation to the blade.

      1. Alternatively, use a co-ordinate measurement machine.

    4. Identify the thickness of the coating required.

    5. For the blades that are not within repair limits refer to TASK 72-41-15-300-052 (VRS6616).

    11. SUBTASK 72-41-15-110-086 Clean the Blade

      1. Remove the grease.

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

      2. Use degreasing equipment.

    12. SUBTASK 72-41-15-350-091 Mask the Blade

    1. Refer to Figure, Figure, and Figure.

    13. SUBTASK 72-41-15-120-055 Abrasive Blast

      1. Abrasive blast the clapper abutment faces.

      1. Refer to the SPM TASK 70-12-02-120-501.

        2. Use CoMat 05-002 ABRASIVE MEDIUM, ALUMINUM OXIDE with abrasive blast equipment.

        1. Make sure that a minimum quantity of material is removed.

    14. SUBTASK 72-41-15-350-092 Remove Masking and Apply New Mask

    1. CAUTION

      DO NOT TOUCH THE AREA WHICH HAS BEEN BLASTED.

      Refer to Figure, Figure, and Figure.

    2. Remove the masking tape.

      3. Put the masking fixture onto the blade.

      1. Refer to approved vendor in 4. Repair Facilities, Para B, for the correct masking fixture.

    15. SUBTASK 72-41-15-340-052 Apply the Flame Deposition Material, Assembly A

    1. Refer to Figure, Figure and Figure.

    2. Apply the flame deposition material to clapper abutment faces.

    3. Refer to approved vendor on 4. Repair Facilities, Para B.

    4. Apply required thickness of coating identified in Step

    5. Use LWIN40 coating and detonation flame deposition equipment to vendor technique.

    16. SUBTASK 72-41-15-340-060 Apply the Flame Depositon Material, Assembly B and Assembly C (DELETED)

    1. This subtask has been deleted.

    17. SUBTASK 72-41-15-340-061 Apply the Flame Deposition Material, Assembly D

    1. Refer to Figure, Figure and Figure.

    2. Apply the flame deposition material to clapper abutment faces.

    3. Refer to approved vendor on 4. Repair Facilities, Para B.

    4. Apply required thickness of coating identified in Step.

    5. Use LWIN40 coating and detonation flame deposition equipment to vendor technique.

    18. SUBTASK 72-41-15-220-195-A00 Examine the Repair, Assembly A

    2. Make a visual and dimensional inspection of the coated clapper abutment faces.

      1. Clapper faces with coating defects are not permitted.

    4. Remove the masking fixture.

    19. SUBTASK 72-41-15-220-195-B00 Examine the Repair, Assembly B and Assembly C (DELETED)

    1. This subtask has been deleted.

    20. SUBTASK 72-41-15-220-195-C00 Examine the Repair, Assembly D

    2. Make a visual and dimensional inspection of the coated clapper abutment faces.

      1. Alternatively use a co-ordinate measurement machine.

      2. Clapper faces with coating defects are not permitted.

    4. Remove the masking fixture.

    21. SUBTASK 72-41-15-350-093 Identify the Repair

      1. Vibro engrave VRS6236 adjacent to existing part number.

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

    22. Figure: Repair Details And Dimensions - Assembly A

    Repair Details And Dimensions - Assembly A

    Figure: Repair Details And Dimensions - Assembly D

    Repair Details And Dimensions - Assembly D

    Figure: Repair Details And Dimensions - Assembly A

    Repair Details And Dimensions - Assembly A

    Figure: Repair Details And Dimensions - Assembly D

    Repair Details And Dimensions - Assembly D

    Figure: Repair Details And Dimensions - Assembly A

    Repair Details And Dimensions - Assembly A

    Figure: Repair Details And Dimensions - Assembly D

    Repair Details And Dimensions - Assembly D

    Figure: Repair Details And Dimensions - Assembly A And Assembly D

    Repair Details And Dimensions - Assembly A And Assembly D

    Figure: Repair Details And Dimensions - Assembly A

    Repair Details And Dimensions - Assembly A

    Figure: Repair Details And Dimensions - Assembly D

    Repair Details And Dimensions - Assembly D

    Figure: Repair Details And Dimensions - Assembly A

    Repair Details And Dimensions - Assembly A

    Figure: Repair Details And Dimensions - Assembly B And Assembly C (Deleted)

    Repair Details And Dimensions - Assembly B And Assembly C (Deleted)

    Figure: Repair Details And Dimensions - Assembly D

    Repair Details And Dimensions - Assembly D

    Figure: Repair Details And Dimensions - Assembly A And Assembly D

    Repair Details And Dimensions - Assembly A And Assembly D

    Figure: Repair Details And Dimensions - Assembly A

    Repair Details And Dimensions - Assembly A

    Figure: Repair Details And Dimensions - Assembly C (Deleted)

    Repair Details And Dimensions - Assembly C (Deleted)

    Figure: Repair Details And Dimensions - Assembly D

    Repair Details And Dimensions - Assembly D

    Figure: Repair Details And Dimensions - Assembly A And Assembly D

    Repair Details And Dimensions - Assembly A And Assembly D

    Figure: Repair Details And Dimensions - Assembly A

    Repair Details And Dimensions - Assembly A

    Figure: Repair Details And Dimensions - Assembly B And Assembly C (Deleted)

    Repair Details And Dimensions - Assembly B And Assembly C (Deleted)

    Figure: Repair Details And Dimensions - Assembly D

    Repair Details And Dimensions - Assembly D

    Figure: Overspray Requirements

    Overspray Requirements

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedure and deleted figures. (19VG078)

Manufacturer Code:07512
Enterprise Name:SAINT-GOBAIN PERFORMANCE PLASTICS
BU Name:SAINT-GOBAIN PERFORMANCE PLASTICS
Street:150 DEY ROAD
City:WAYNE
State:NJ
Zip Code:07470
Country:USA
Phone Number:1-973-696-4700
Fax Number:1-973-696-4056
Internet:www.plastics.saint-gobain.com, www.saint-gobain.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: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:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
Manufacturer Code:K6835
Supply Number:CoMat 02-006
Type:sp01
Supply Short Name:CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL
Supply Name:CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL
Specification Groups:
Doc NumberType
OMAT: 298 (RR REF)SCOTCH 425
Suppliers:
ManufacturerRemarks
K6835
52152
76381
LOCAL
Manufacturer Code:LOCAL
Supply Number:CoMat 02-017
Type:sp01
Supply Short Name:CoMat02-017 WAX
Supply Name:CoMat 02-017 WAX
Specification Groups:
Doc NumberType
11429Y/Y MIL-P-23242 OMAT: 228PLATING WAX WILKINS CAMPBELL
JCR-178PLATING WAX WILKINS CAMPBELL
Suppliers:
ManufacturerRemarks
LOCAL
K6835
K4404
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:X222X
Supply Number:CoMat 05-002
Type:sp01
Supply Short Name:CoMat 05-002 ABRASIVE MEDIUM, ALUMINUM OXIDE
Supply Name:CoMat 05-002 ABRASIVE MEDIUM, ALUMINUM OXIDE
Specification Groups:
Doc NumberType
Where CoMat 05-002 is specified with no letter suffix, use one of the CoMat 05-002 letter suffix alternatives.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:X222X
Supply Number:CoMat 05-003
Type:sp01
Supply Short Name:CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE
Supply Name:CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE
Specification Groups:
Doc NumberType
Use one of the CoMat 05-003 letter suffix alternatives.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Tool Number:Abrasive Blast Equipment
Tool Name:Abrasive Blast Equipment
Manufacturer Code:LOCAL
Tool Number:Co-ordinate measurement machine
Tool Name:Co-ordinate measurement machine
Manufacturer Code:LOCAL
Tool Number:Degreasing equipment
Tool Name:Degreasing equipment
Manufacturer Code:LOCAL
Tool Number:Detonation flame deposition equipment
Tool Name:Detonation flame deposition equipment
Manufacturer Code:0AM53
Tool Number:IAE 3R19363
Tool Name:IAE 3R19363 Inspection fixture
Manufacturer Code:0AM53
Tool Number:IAE 3R19366
Tool Name:IAE 3R19366 Inspection Block
Manufacturer Code:0AM53
Tool Number:IAE 3R19367
Tool Name:IAE 3R19367 Inspection block
Manufacturer Code:0AM53
Tool Number:IAE 3R19372
Tool Name:IAE 3R19372 Stop block
Manufacturer Code:0AM53
Tool Number:IAE 3R19815
Tool Name:IAE 3R19815 Clapper width checking fixture
Manufacturer Code:0AM53
Tool Number:IAE 3R19816
Tool Name:IAE 3R19816 Inspection jaws
Manufacturer Code:0AM53
Tool Number:IAE 3R19817
Tool Name:IAE 3R19817 Master blade
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Manufacturer Code:LOCAL
Tool Number:Rochelle carbonate tank
Tool Name:Rochelle carbonate tank
Manufacturer Code:LOCAL
Tool Number:Vibrating Marking Pencil
Tool Name:Vibrating Marking Pencil