TASK 72-41-15-300-013 HPC Stage 5 Rotor Blade - Weld Repair The Airfoil, Repair-013 (VRS6051)

DMC:V2500-A0-72-41-1505-00A-627A-C|Issue No:003.00|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 72-41-15-300-013 HPC Stage 5 Rotor Blade - Weld Repair The Airfoil, Repair-013 (VRS6051)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

01-800

6A3335

A

01-800

6A3637

A

01-800

6A3941

A

01-800

6A4198

B

01-800

6A7506

B

01-800

6A8449

A

01-800

6A8451

B

Material of component

PART IDENT

SYMBOL

MATERIAL

HP compressor rotor blade - stage 5

TAF

Titanium alloy

General

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

This repair restores the HP compressor rotor blade, stage 5 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 demonstration 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 - Stages 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 stages 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 VRS6215, TASK 72-41-15-300-032 (REPAIR-032).

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

NameManufacturerPart Number / IdentificationQuantityRemark
Chemical cleaning equipmentLOCALChemical cleaning equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Abrasive blast equipmentLOCALAbrasive blast equipment
Welding equipmentLOCALWelding equipment

Argonarc

Heat treatment equipmentLOCALHeat treatment equipment
Hardness testerLOCALHardness tester
Grinding machineLOCALGrinding machine
Standard workshop equipmentLOCALStandard workshop equipment
Radiographic equipmentLOCALRadiographic equipment
Vibrating marking pencilLOCALVibrating marking pencil

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001
CoMat 03-195 WELDING WIRE TITANIUMLOCALCoMat 03-195
CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADELOCALCoMat 05-003

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 VRS6051 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

      Ishikawajima-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

    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 72-41-15-110-094 Clean the Stage 5 Rotor Blades

      1. Chemically clean the blades.

      1. Refer to TASK 72-41-15-100-000 (CLEANING-000).

      2. Use chemical cleaning equipment.

    3. SUBTASK 72-41-15-110-095 Remove the Rubber Sealing Strip

      1. Remove the rubber sealing strip.

      1. Refer to TASK 72-41-15-100-000 (CLEANING-000).

      2. Use standard workshop equipment and chemical cleaning equipment.

    4. SUBTASK 72-41-15-110-096 Remove the Dry Film Lubricant

      1. Remove the dry film lubricant from the blade root.

      1. Refer to TASK 72-41-15-100-000 (CLEANING-000).

      2. Use chemical cleaning equipment.

    5. SUBTASK 72-41-15-220-213-A00 Examine the Stage 5 Rotor Blades, Assembly A

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

      2. Examine the blades to make sure that the blades can be repaired.

      1. Refer to 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.

    6. SUBTASK 72-41-15-220-213-B00 Examine the Stage 5 Rotor Blades, Assembly B

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

      2. Examine the blades to make sure that the blades can be repaired.

      1. Refer to 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.

    7. SUBTASK 72-41-15-230-078 Do a Crack Test

      1. Do a penetrant crack test.

      1. Refer to TASK 72-41-15-200-000 (INSPECTION-000).

      2. Use penetrant crack test equipment.

      3. Discard any cracked blades.

    8. SUBTASK 72-41-15-120-058-A00 Vapor Blast the Stage 5 Rotor Blades, Assembly A

    1. Refer to Figure.

      2. Mask areas of the blade not to be welded.

      3. Vapour blast areas of the blade to be welded.

      1. Refer to SPM TASK 70-12-01-120-501.

    4. Remove the masking tape.

    9. SUBTASK 72-41-15-120-058-B00 Vapour Blast the Stage 5 Rotor Blades, Assembly B

    1. Refer to Figure.

      2. Mask areas of the blade not to be welded.

      3. Vapour blast areas of the blade to be welded.

      1. Refer to the SPM TASK 70-12-01-120-501.

    4. Remove the masking tape.

    10. SUBTASK 72-41-15-110-097 Clean the Stage 5 Rotor Blades

      1. NOTE

        The blades must be fully cleaned before you do Step or Step

        Chemically clean the blade.

      1. Refer to the SPM TASK 70-11-01-300-503.

      2. Use chemical cleaning equipment.

    11. SUBTASK 72-41-15-310-053-A00 Weld the Stage 5 Rotor Blade Tips, Assembly A

    1. CAUTION

      YOU MUST PREVENT ARCING ON THE BLADE DURING THE WELD PROCEDURE.

      Refer to Figure.

    2. Build up the blade tip with weld to restore the length.

    3. Refer to the SPM TASK 70-31-02-310-501-001.

    4. 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.

      5. NOTE

        An increase in blade length of up to a maximum of 0.060in. (1.52 mm) is permitted by this repair.

        Apply sufficient weld to get the necessary blade length.

      1. Identify a sample stage 5 rotor blade and repair along with each batch.

    12. SUBTASK 72-41-15-310-053-B00 Weld the Stage 5 Rotor Blade Tips, Assembly B

    1. CAUTION

      YOU MUST PREVENT ARCING ON THE BLADE DURING THE WELD PROCEDURE.

      Refer to Figure.

    2. Build up the blade tip with weld to restore the length.

    3. Refer to the SPM TASK 70-31-02-310-501-001.

    4. 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

      5. NOTE

        An increase in blade length of up to a maximum of 0.060in. (1.52 mm) is permitted by this repair.

        Apply sufficient weld to get the neccesary blade length.

      1. Identify a sample stage 5 rotor blade and repair along with each batch.

    13. SUBTASK 72-41-15-370-053 Heat-Treat the Stage 5 Rotor Blades

    1. Heat-treat the blade in a vacuum or a controlled atmosphere.

    2. Refer to the SPM TASK 70-31-02-310-501-001.

    3. Use heat treatment equipment.

      Heat-treat Data

      Heat to a temperature of 1283 to 1301 deg.F. (695 to 705 deg.C.) for 2 hours.

      Cool down to room temperature in Argon.

    14. SUBTASK 72-41-15-220-214 Do a Hardness Check

      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.

        Do a hardness check on a longitudinal cross section of a sample blade.

      1. Use a sample blade.

      2. The hardness variation should be within 30 HV across the weld material, heat affected zone and parent material.

      3. This is a guide for quality control and is not an absolute limit.

      4. Use a hardness tester.

    15. SUBTASK 72-41-15-350-101-A00 Put the Shape Back on the Stage 5 Rotor Blade Contour and Height, Assembly A

      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.

        Put the shape back on the blade contour.

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

      2. Refer to approved vendor in 4. Repair Facilities, Para B., for special machines to make the blade contour or use standard workshop equipment.

      2. Grind the blade tip to the correct height.

      1. Refer to Figure.

      2. Use a grinding machine.

      3. Dress the blade tip to remove burrs.

      1. Use standard workshop equipment.

    16. SUBTASK 72-41-15-350-101-B00 Put the Shape Back on the Stage 5 Rotor Blade Contour and Height, Assembly B

      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.

        Put the shape back on the blade contour.

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

      2. Refer to approved vendor in 4.

      3. Repair Facilities, Para B., for special machines to make the blade contour or use standard workshop equipment.

      2. Grind the blade tip to the correct height.

      1. Refer to Figure.

      2. Use a grinding machine.

      3. Dress the blade tip to remove burrs.

      1. Use standard workshop equipment.

    17. SUBTASK 72-41-15-220-215-A00 Examine the Stage 5 Rotor Blades, Assembly A

      1. Visually examine the blade for signs of electric arcing.

      1. Discard.

      2. Visually examine the airfoil surface.

      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. Visually examine the blade contour.

      1. Refer to Figure and Figure.

      5. Dimensionally examine the blade tip.

      1. Refer to Figure and Figure. Make sure the tip contour and thickness are contained within given limits.

      6. Dimensionally examine the blade height.

      1. Refer to Figure.

      2. Compare before and after repair dimensions, refer to Step

      3. Welded material must be contained within given limits.

    18. SUBTASK 72-41-15-220-215-B00 Examine the Stage 5 Rotor Blades, Assembly B

      1. Visually examine the blade for signs of electric arcing.

      1. Discard.

      2. Visually examine the airfoil surface.

      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. Visually examine the blade contour.

      1. Refer to Figure and Figure.

      5. Dimensionally examine the blade tip.

      1. Refer to Figure and Figure.

      2. Make sure the tip contour and thickness are contained within given limits.

      6. Dimensionally examine the blade height.

        1. Refer to Figure.

        1. Compare before and after repair dimensions, refer to Step

        2. Welded material must be contained within given limits.

    19. SUBTASK 72-41-15-350-102 Polish the Stage 5 Rotor Blade Airfoil Surface and Contour

    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. Polish the blade airfoil surface and contour.

      1. Refer to approved vendor in 4.

      2. Repair Facilities, Para B, for special machines to make the blade contour.

      3. Hand methods are permitted to polish the blade contour.

    20. SUBTASK 72-41-15-110-139 Do a Swab Etch

      1. Chemically clean.

      1. Refer to the SPM TASK 70-11-08-300-503 SUBTASK 70-11-08-300-001.

      2. Use chemical cleaning equipment.

      2. Swab etch the repaired area.

      1. Refer to the SPM TASK 70-11-08-300-503 SUBTASK 70-11-08-300-002.

      2. Use chemical cleaning equipment.

    21. SUBTASK 72-41-15-230-079 Do a Crack Test

      1. Do a penetrant crack test.

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

      2. Use penetrant crack test equipment.

      3. Discard any cracked blades.

    22. SUBTASK 72-41-15-260-074 Radiographically Examine the Stage 5 Rotor Blades

      1. Radiographically examine the welded blade tip.

        1. Cracks or unwanted material are not permitted.

        1. Pores larger than 0.006 in. (0.15 mm) diameter are not permitted.

        2. Pores with a distance of less than 0.200 in. (5.10 mm) between them, are not permitted.

        3. Surfaces broken by pores are not permitted.

        4. Pores are not permitted less than 0.040 in. (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.

    23. SUBTASK 72-41-15-380-083 Restore the Airfoil Surface Finish

      1. Restore the airfoil surface finish.

      1. Refer to VRS6150, TASK 72-41-15-300-040 (REPAIR-040).

    24. SUBTASK 72-41-15-380-113 Shot-Peen the Dovetail Root of the HP Compressor Stage 5 Rotor Blade

      1. Shot-peen the dovetail root of the the HP Compressor stage 5 rotor blade.

      1. Refer to VRS6151, TASK 72-41-15-300-041 (REPAIR-041).

    25. SUBTASK 72-41-15-360-055 Replace the Rubber Sealing Strip

      1. Replace the rubber sealing strip.

      1. Refer to VRS6215, TASK 72-41-15-300-032 (REPAIR-032).

    26. SUBTASK 72-41-15-380-084 Apply the Dry Film Lubricant

      1. Apply the dry film lubricant to the blade root.

      1. Refer to VRS6486, TASK 72-41-15-300-046 (REPAIR-046).

    27. SUBTASK 72-41-15-350-103 Identify the Repair

      1. CAUTION

        DO NOT VIBRO-ENGRAVE ON THE BLADE AIRFOIL OR LOCATION FACES.

        Make a mark VRS6051 adjacent to the assembly number.

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

    28. Figure: Repair details and dimensions - Assembly A

    Repair details and dimensions - Assembly A

    Figure: Repair details and dimensions - Assembly B

    Repair details and dimensions - Assembly B

    Figure: Repair details and dimensions - Assembly A and Assembly B

    Repair details and dimensions - Assembly A and Assembly B

    Figure: Repair details and dimensions - Assembly A

    Repair details and dimensions - Assembly A

    Figure: Repair details and dimensions - Assembly B

    Repair details and dimensions - Assembly B

    Figure: Repair details and dimensions - Assembly A

    Repair details and dimensions - Assembly A

    Figure: Repair details and dimensions - Assembly B

    Repair details and dimensions - Assembly B

    Figure: Repair details and dimensions - Assembly A

    Repair details and dimensions - Assembly A

    Figure: Repair details and dimensions - Assembly B

    Repair details and dimensions - Assembly B

    Figure: Repair details and dimensions - Assembly A

    Repair details and dimensions - Assembly A

    Figure: Repair details and dimensions - Assembly B

    Repair details and dimensions - Assembly B

    Figure: Repair details and dimensions - Assembly A and Assembly B

    Repair details and dimensions - Assembly A and Assembly B

    Figure: Repair details and dimensions - Assembly A and Assembly B

    Repair details and dimensions - Assembly A and Assembly B

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

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

Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
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:LOCAL
Supply Number:CoMat 03-195
Type:sp01
Supply Short Name:CoMat 03-195 WELDING WIRE TITANIUM
Supply Name:CoMat 03-195 WELDING WIRE TITANIUM
Specification Groups:
Doc NumberType
MSRR9500/73IMI 318
MSRR8632 COMPAMS 4954
OMAT:3/145AMS 4954
TI 6-4
Suppliers:
ManufacturerRemarks
LOCAL
U9025
K6835
2R602
58401
3G172
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
Link not Found
Manufacturer Code:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Link not Found
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Link not Found
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Welding equipment
Tool Name:Welding equipment