DMC:V2500-A0-72-41-1504-00A-627A-C|Issue No:003|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 72-41-15-300-012 HPC Stage 4 Rotor Blade - Weld Repair The Airfoil, Repair-012 (VRS6050)

Effectivity

FIG/ITEM	PART NO.	ASSEMBLY
01-500	6A3333	A
01-500	6A3635	A
01-500	6A3939	A
01-500	6A4254	B
01-500	6A7635	C

Material of component

PART IDENT	SYMBOL	MATERIAL
HP compressor rotor blade - stage 4	TAF	Titanium alloy

General

This repair must only be done when the instruction to do so is given in 72-41-15 Inspection/Check.

This repair restores the HP compressor rotor blade, stage 4 tip length by welding.

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

This is a source demonstrated repair which can only be done by approved vendors.

To keep the HP compressor efficiency, rotor blades are repaired as near to the new blade condition as possible.

Rotor blades must be repaired as soon as damage or wear is monitored, to get back HP compressor efficiency and extend the rotor blade life.

This repair can be done again to the welded rotor blades if:

The minimum airfoil dimensions are as given in 72-41-15 Inspection/Check.

The airfoil surface has been polished up to two times, refer to VRS6150, TASK 72-41-15-300-040 (REPAIR-040).

Discard the blades if, during the weld procedure, arcing has occurred on any part of the blades.

Price and Availability

Refer to International Aero Engines

Related Repairs

HP Compressor - Stages 3 to 12 - Rotor Blades - Restore Airfoil Surface Finish, refer to VRS6150, TASK 72-41-15-300-040 (REPAIR-040).

HP Compressor Rotor Blades - Stage 3 to 6 - Shot Peen Root of Blade to Restore Fatigue Strength, refer to VRS6151, TASK 72-41-15-300-041 (REPAIR-041).

HP Compressor Blades - Restore Stage 3 to 5 Anti-Fret Treatment, refer to VRS6486, TASK 72-41-15-300-046 (REPAIR-046).

HP Compressor - Stage 4 Rotor Blade - Repair by Replacement of Seal Strip, refer to VRS6214, TASK 72-41-15-300-031 (REPAIR-031).

NOTE

More equipment and materials necessary to do this repair are in the SPM TASKS given below:

SPM TASK 70-09-00-400-501

SPM TASK 70-11-01-300-503

SPM TASK 70-11-08-300-503

SPM TASK 70-12-01-120-501

SPM TASK 70-23-04-230-501

SPM TASK 70-31-02-310-501-001

NOTE

To identify the consumable materials, refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

Name	Manufacturer	Part Number / Identification	Remark
Chemical cleaning equipment	LOCAL	Chemical cleaning equipment
Penetrant Crack Test Equipment	LOCAL	Penetrant crack test equipment
Abrasive blast equipment	LOCAL	Abrasive blast equipment
Welding equipment	LOCAL	Welding equipment	Argonarc
Heat treatment equipment	LOCAL	Heat treatment equipment
Hardness tester	LOCAL	Hardness tester
Grinding machine	LOCAL	Grinding machine
Standard workshop equipment	LOCAL	Standard workshop equipment
Radiographic equipment	LOCAL	Radiographic equipment
Vibrating marking pencil	LOCAL	Vibrating marking pencil

Consumables, Materials and Expendables

Name	Manufacturer	Part Number / Identification
CoMat 02-001 ADHESIVE TAPE (MASKING)	LOCAL	CoMat 02-001
CoMat 03-195 WELDING WIRE TITANIUM	LOCAL	CoMat 03-195
CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE	LOCAL	CoMat 05-003

Spares

NONE

Safety Requirements

NONE

Procedure

1. 1. Authorized Repair Vendors for Repair VRS6050 are listed below:
    Chromalloy Dallas
    14042 Distribution Way
    Dallas, TX 75234
    U.S.A
    MTU Maintenance GmbH
    Flughafen Hannover
    Muncher Strasse 31
    30855 LANGENHAGEN
    GERMANY
    Rolls-Royce Aero-Engine Services Ltd.
    Component Refurbishment
    Mavor Avenue
    Nerston
    East Kilbride
    Glasgow G74 4PY
    SCOTLAND
    Airfoil Technologies International (ATI)
    High Holborn Road
    Codnor
    Ripley
    Derbyshire
    DE5 3NW
    ENGLAND
    Ishikawajimia-Harima Heavy Industries Co. Ltd.
    229 Tonogaya, Mizuho-Machi
    Nishitama-gun
    Tokyo 190-1297
    JAPAN
    Airfoil Services Sdn Bhd (ASSB)
    No. 12 Jalan Teknologi
    Taman Sains Selangor 1
    Kota Damansara PJU5
    47810 Petailing Jaya
    Selangor Darul Ehsan
    MALAYSIA
    Turbine Overhaul Services Pte, Ltd. (TOS)
    5 Tuas Drive Two - Mail Stop 107-58
    Singapore 638639
    Tel: 65-6860-2260
    Fax: 65-6862-1068
    Rolls-Royce Inchinnan
    Inchinnan Drive
    Inchinnan Business Park
    Inchinnan, PA4 9AF
    Scotland
    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.
1. 1. Refer to TASK 72-41-15-100-000.
  2. Use chemical cleaning equipment.
1. 1. Refer to TASK 72-41-15-100-002.
  2. Use standard workshop equipment and chemical cleaning equipment.
1. 1. Refer to TASK 72-41-15-100-000.
  2. Use chemical cleaning equipment.
1. Refer to Figure, Figure, Figure, Figure and Figure.
2. 1. Refer to Figure, Figure, Figure, Figure, and Figure for inspection standards.
  2. The blades must be easily identified to allow dimensions before and after repair to be checked.
  3. Record the blade length.
1. Refer to Figure, Figure, Figure, Figure and Figure.
2. 1. Refer to Figure, Figure, Figure, Figure and Figure for inspection standards.
  2. The blades must be easily identified to allow dimensions before and after repair to be checked.
  3. Record the blade length.
1. Refer to Figure, Figure, Figure, Figure and Figure.
2. 1. Refer to Figure, Figure, Figure, Figure and Figure for inspection standards. The blades must be easily identified to allow dimensions before and after repair to be checked.
  2. Record the blade length.
1. 1. Refer to TASK 72-41-15-200-000.
  2. Use penetrant crack test equipment.
1. Refer to Figure.
2. 1. Use CoMat 02-001 ADHESIVE TAPE (MASKING).
3. 1. Refer to the SPM TASK 70-12-01-120-501.
  2. Use CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE with abrasive blast equipment.
4. Remove the masking tape.
1. Refer to Figure.
2. 1. Use CoMat 02-001 ADHESIVE TAPE (MASKING).
3. 1. Refer to the SPM TASK 70-12-01-120-501.
  2. Use CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE with abrasive blast equipment.
4. Remove the masking tape.
1. Refer to Figure.
2. 1. Use CoMat 02-001 ADHESIVE TAPE (MASKING).
3. 1. Refer to the SPM TASK 70-12-01-120-501.
  2. Use CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE with abrasive blast equipment.
4. Remove the masking tape.
1. 1. Refer to the SPM TASK 70-11-01-300-503.
  2. Use chemical cleaning equipment.
1. CAUTION
  YOU MUST PREVENT ARCING ON THE BLADE DURING THE WELD PROCEDURE.
  Refer to Figure.
2. 1. Refer to the SPM TASK 70-31-02-310-501-001.
  2. Use CoMat 03-195 WELDING WIRE TITANIUM with argonarc welding equipment.
  3. Weld Data: Refer to approved vendor in 4. Repair Facilities, Para.B., for weld parameters.
3. 1. Identify a sample stage 4 rotor blade and repair along with each batch.
1. CAUTION
  YOU MUST PREVENT ARCING ON THE BLADE DURING THE WELD PROCEDURE.
  Refer to: Figure
2. 1. Refer to the SPM TASK 70-31-02-310-501-001.
  2. Use CoMat 03-195 WELDING WIRE TITANIUM with argonarc welding equipment.
    Weld Data
    Refer to approved vendor in 4. Repair Facilities, Para.B., for weld parameters.
3. 1. Identify a sample stage 4 rotor blade and repair along with each batch.
1. CAUTION
  YOU MUST PREVENT ARCING ON THE BLADE DURING THE WELD PROCEDURE.
  Refer to Figure.
2. 1. Refer to the SPM TASK 70-31-02-310-501-001. Use CoMat 03-195 WELDING WIRE TITANIUM with argonarc welding equipment.
    Weld Data
    Refer to approved vendor in 4. Repair Facilities, Para.B., for weld parameters.
3. 1. Identify a sample stage 4 rotor blade and repair along with each batch.
1. 1. Refer to the SPM TASK 70-31-02-310-501-001.
  2. Use heat treatment equipment.
    Heat-Treat Data
    Heat to a temperature of 1283 to 1301 deg.F. (695 to 705 deg.C.) and hold for 2 hours.
    Cool down to room temperature in Argon.
1. 1. NOTE
    If the sample blade is outside the hardness variation limits, additional blades must be sampled, if more than 10 percent have a variation in hardness greater than 30 HV, then the cause must be investigated.
    Use a sample blade. The hardness variation should be within 30 HV across the weld material, heat affected zone and parent material. This is a guide for quality control and is not an absolute limit. Use a hardness tester.
1. 1. Refer to Figure, Figure, Figure, Figure, Figure and Figure. Refer to approved vendor in 4. Repair Facilities, Para.B., for special machines to make the blade contour or use standard workshop equipment.
2. 1. Refer to Figure. Use a grinding machine.
3. 1. Use standard workshop equipment.
1. 1. Refer to Figure, Figure, Figure, Figure, Figure and Figure. Refer to approved vendor in 4. Repair Facilities, Para.B., for special machines to make the blade contour or use standard workshop equipment.
2. 1. Refer to Figure. Use a grinding machine.
3. 1. Use standard workshop equipment.
1. 1. Refer to Figure, Figure, Figure, Figure, Figure and Figure. Refer to approved vendor in 4. Repair Facilities, Para B., for special machines to make the blade contour or use standard workshop equipment.
2. 1. Refer to Figure. Use a grinding machine.
3. 1. Use standard workshop equipment.
1. 1. Discard.
2. 1. Scratches or scores on the airfoil surfaces are not permitted.
3. If scratches or scores are shown on the airfoil surface, do Step.
4. 1. Refer to Figure and Figure.
5. 1. Refer to Figure and Figure. Make sure the tip contour and thickness are contained within given limits.
6. 1. Refer to Figure.
    Compare before and after repair dimensions, refer to Step Welded material must be contained within given limits.
1. 1. Discard.
2. 1. Scratches or scores on the airfoil surfaces are not permitted.
3. If scratches or scores are shown on the airfoil surface, do Step.
4. 1. Refer to Figure and Figure.
5. 1. Refer to Figure and Figure. Make sure the tip contour and thickness are contained within given limits.
6. 1. Refer to Figure.
  2. Compare before and after repair dimensions, refer to Step Welded material must be contained within given limits.
1. 1. Discard.
2. 1. Scratches or scores on the airfoil surfaces are not permitted.
3. If scratches or scores are shown on the airfoil surface, do Step.
4. 1. Refer to Figure and Figure.
5. 1. Refer to Figure and Figure. Make sure the tip contour and thickness are contained within given limits.
6. 1. Refer to Figure. Compare before and after repair dimensions, refer to Step Welded material must be contained within given limits.
1. CAUTION
  TITANIUM COMPONENT - YOU MUST USE SILICON CARBIDE TYPE ABRASIVE WHEELS, STONES AND PAPERS TO DRESS, BLEND AND POLISH THIS COMPONENT.
  CAUTION
  TITANIUM COMPONENT - AVOID BUILD UP OF HEAT BY APPLYING ONLY GENTLE PRESSURE AND KEEPING THE TOOL SPEED AS LOW AS POSSIBLE.
  CAUTION
  TITANIUM COMPONENT - YOU MUST MAKE SURE THAT WHEN YOU DRESS MATERIAL, BLEND AND POLISH, TO MAKE SMOOTH, THAT NO SPARKS ARE PRODUCED.
  CAUTION
  TITANIUM COMPONENT - IF THE MATERIAL SHOWS A CHANGE IN COLOR, TO DARKER THAN A LIGHT STRAW COLOR, THE COMPONENT IS TO BE REJECTED.
  Refer to Figure.
2. 1. Refer to approved vendor in 4. Repair Facilities, Para.B., for special machines to make the blade contour. Hand methods are permitted to polish the blade contour.
1. 1. Refer to the SPM TASK 70-11-08-300-503 SUBTASK 70-11-08-300-001. Use chemical cleaning equipment.
2. 1. Refer to the SPM TASK 70-11-08-300-503 SUBTASK 70-11-08-300-002. Use chemical cleaning equipment.
1. 1. Refer to the SPM TASK 70-23-04-230-501.
  2. Use penetrant crack test equipment.
  3. Discard any cracked blades.
1. 1. Cracks or unwanted material are not permitted.
    Pores larger than 0.006in. (0.15 mm) diameter are not permitted.
    Pores with a distance of less than 0.200in. (5.10 mm) between them, are not permitted.
    Surfaces broken by pores are not permitted.
    Pores are not permitted less than 0.040in. (1.00 mm) from the leading and trailing edges.
  2. Use radiographic equipment.
    Radiographic Data: Refer to approved vendor in 4. Repair Facilities, Para.B., for the appropriate data card and Radiographic Examination parameters.
1. 1. Refer to VRS6150, TASK 72-41-15-300-040.
1. 1. Refer to VRS6151, TASK 72-41-15-300-041.
1. 1. Refer to VRS6214, TASK 72-41-15-300-031.
1. 1. Refer to VRS6486, TASK 72-41-15-300-046.
1. 1. Refer to the SPM TASK 70-09-00-400-501 SUBTASK 70-09-00-400-001. Use Vibrating marking pencil.