TASK 72-41-15-300-019 HPC Stage 11 Rotor Blade - Weld Repair The Airfoil, Repair-019 (VRS6057)

DMC:V2500-A0-72-41-1511-00A-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 72-41-15-300-019 HPC Stage 11 Rotor Blade - Weld Repair The Airfoil, Repair-019 (VRS6057)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

02-670

6A3258

A

02-670

6A4728

B

02-670

6A5641

A

02-670

6A6564

A

02-670

6A6568

B

02-685

6A3259

A

02-685

6A4253

B

02-685

6A5642

A

02-685

6A5647

B

02-700

6A3257C01

A

02-700

6A4251C01

B

02-715

6A3257C01

A

02-715

6A4251C01

B

02-717

6A3257C02

A

02-717

6A4251C02

B

Material of component

PART IDENT

SYMBOL

MATERIAL

HP Compressor rotor blade -

QMP

52 percent Nickel

stage 11

19 percent Chromium

18 percent Iron

5 percent Niobium

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 11 tip length by welding.

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

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

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

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 Repair VRS6150, TASK 72-41-15-300-040 (REPAIR-040).

NOTE

More equipment and materials necessary to do this repair are in the SPM TASKS given below:
SPM TASK 70-11-01-300-503
SPM TASK 70-11-39-300-503
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
Vapor blast equipmentLOCALVapor 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

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001
CoMat 03-284 WELDING FILLER WIRE, NiBASELOCALCoMat 03-284
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 VRS6057 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 72-41-15-110-108 Clean the Stage 11 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 72-41-15-220-231-A00 Examine the Stage 11 Rotor Blades, Assembly A

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

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

      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.

    4. SUBTASK 72-41-15-220-231-B00 Examine the Stage 11 Rotor Blades, Assembly B

    1. Refer to Figure and Figure.

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

      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.

    5. SUBTASK 72-41-15-230-090 Do a Crack Test

      1. Do a penetrant crack test.

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

      2. Use penetrant crack test equipment.

      3. Discard any cracked blades.

    6. SUBTASK 72-41-15-120-066-A00 Vapour Blast the Stage 11 Rotor Blades, Assembly A

    1. Refer to Figure, Figure and Figure.

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

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

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

    4. Remove the masking tape.

    7. SUBTASK 72-41-15-120-066-B00 Vapour Blast the Stage 11 Rotor Blades, Assembly B

    1. Refer to Figure, Figure and Figure.

      2. Seal the 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.

    8. SUBTASK 72-41-15-110-109 Clean the Stage 11 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.

        Use chemical cleaning equipment.

    9. SUBTASK 72-41-15-310-059-A00 Weld the Stage 11 Rotor Blade Tips, Assembly A

    1. CAUTION

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

      Refer to: Figure, Figure and Figure.

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

      1. Refer to the SPM TASK 70-31-02-310-501-001. Use CoMat 03-284 WELDING FILLER WIRE, NiBASE with argonarc welding equipment.

        Weld Data

        Refer to approved vendor in 4. Repair Facilities, Para B., for weld parameters.

      3. 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 11 rotor blade and repair along with each batch.

    10. SUBTASK 72-41-15-310-059-B00 Weld the Stage 11 Rotor Blade Tips, Assembly B

    1. CAUTION

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

      Refer to: Figure, Figure and Figure.

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

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

      2. Use CoMat 03-284 WELDING FILLER WIRE, NiBASE with argonarc welding equipment.

        Weld Data

        Refer to approved vendor in 4. Repair Facilities, Para B., for weld parameters

      3. 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 11 rotor blade and repair along with each batch.

    11. SUBTASK 72-41-15-370-059 Heat-Treat the Stage 11 Rotor Blades

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

      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 1400 deg F (760 deg C) and hold for 2 hours in a vacuum or argon.

        Furnace cool at a rate of 100 deg.F. (56 deg.C.) per hour to 1150 deg F (621 deg C) and hold for 4 hours.

        Cool down to room temperature in air.

    12. SUBTASK 72-41-15-220-232 Do a Hardness Check

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

      1. NOTE

        If the sample blade is below 361 HV minimum, then additional sample blades should be selected for metallurgical examination.

        Do a hardness check across the weld material, heat affected zone and base material.

        The minimum hardness value should be 361 HV.

      2. Use a hardness tester.

    13. SUBTASK 72-41-15-350-119-A00 Put the Shape Back on the Stage 11 Rotor Blade Contour and Height, Assembly A

      1. Put the shape back on the blade contour.

        1. 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, Figure and Figure.

      2. Use a grinding machine.

      3. Remove burrs from the blade tip.

      1. Use standard workshop equipment.

    14. SUBTASK 72-41-15-350-119-B00 Put the Shape Back on the Stage 11 Rotor Blade Contour and Height, Assembly B

      1. Put the shape back on the blade contour.

        1. 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, Figure and Figure.

      2. Use a grinding machine.

      3. Remove burrs from the blade tip.

      1. Use standard workshop equipment.

    15. SUBTASK 72-41-15-220-233-A00 Examine the Stage 11 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, Figure, Figure, Figure and Figure.

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

      6. Measure the dimension of the blade height.

        1. Refer to Figure, Figure and Figure.

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

          Weld material must be contained within given limits.

    16. SUBTASK 72-41-15-220-233-B00 Examine the Stage 11 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. Measure the dimension of the blade height.

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

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

      6. Measure the dimension of the blade height.

        1. Refer to Figure, Figure and Figure.

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

          Weld material must be contained within given limits.

    17. SUBTASK 72-41-15-350-120-A00 Polish the Stage 11 Rotor Blade Airfoil Surface and Contour, Assembly A

    1. Refer to Figure, Figure and Figure.

      2. Polish the blade airfoil surface and contour.

      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.

    18. SUBTASK 72-41-15-350-120-B00 Polish the Stage 11 Rotor Blade Airfoil Surface and Contour, Assembly B

    1. Refer to Figure, Figure and Figure.

      2. Polish the blade airfoil surface and contour.

      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.

    19. SUBTASK 72-41-15-110-133 Cold Ferric Chloride Etch

      1. Swab etch the repaired area.

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

      2. Use chemical cleaning equipment.

    20. SUBTASK 72-41-15-230-091 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.

        Cracks are not permitted.

    21. SUBTASK 72-41-15-260-080 Radiographically Examine the Stage 11 Rotor Blades

      1. Radiographically examine the welded blade tip.

      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

    22. SUBTASK 72-41-15-380-090 Restore the Airfoil Surface Finish

      1. Restore the airfoil surface finish.

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

    23. 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

    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 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 03-284
Type:sp01
Supply Short Name:CoMat 03-284 WELDING FILLER WIRE, Ni BASE
Supply Name:CoMat 03-284 WELDING FILLER WIRE, NiBASE
Specification Groups:
Doc NumberType
INCONEL 718 AMS 5832 AWS 5.14 MSRR9500/220
INCONEL 718 AMS 5832 AWS 5.14CLASS ER NI FE Cr-2 OMAT:3/206
INCONEL 718 AMS 5832 AWS 5.14CLASS ER NI FE Cr-2
Suppliers:
ManufacturerRemarks
LOCAL
28553
IE137
08489
IE508
0ZDB5
2R602
55596
58401
80357
K6835
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: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
Manufacturer Code:LOCAL
Tool Number:Vapor blast equipment
Tool Name:Vapor blast equipment
Manufacturer Code:LOCAL
Tool Number:Welding equipment
Tool Name:Welding equipment