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 72-41-21-840-001 HPC Stage 7 And 8 Rotor Paths - Rework With Reduced Sprayed Thickness Abradable Linings, Rework-001 - SBE 72-0030
NOTE
Preliminary Requirements
Pre-Conditions
NONESupport Equipment
| Name | Manufacturer | Part Number / Identification | Quantity | Remark |
|---|---|---|---|---|
| Lathe | LOCAL | Lathe | ||
| Air grinder | LOCAL | Air grinder | ||
| Rotary burr | LOCAL | Rotary burr | ||
| IAE 3R18570 Turning fixture | 0AM53 | IAE 3R18570 | ||
| IAE 3R18232 Lifting beam | 0AM53 | IAE 3R18232 |
Consumables, Materials and Expendables
| Name | Manufacturer | Part Number / Identification | Quantity | Remark |
|---|---|---|---|---|
| CoMat 02-001 ADHESIVE TAPE (MASKING) | LOCAL | CoMat 02-001 | ||
| CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL | K0993 | CoMat 02-006 | ||
| CoMat 03-036 METAL SPRAYING WIRE, Ni,Al | LOCAL | CoMat 03-036 | ||
| CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5) | IE200 | CoMat 03-038 | ||
| CoMat 03-089 METAL SPRAYING POWDER Ni/Al (95/5) | 00741 | CoMat 03-089 | ||
| CoMat 03-090 METAL SPRAYING POWDER Ni/Al (95/5) | 0AM53 | CoMat 03-090 | ||
| CoMat 03-235 DELETED | 0AM53 | CoMat 03-235 | ||
| CoMat 03-236 METAL SPRAYING POWDER-ALUMINUM | LOCAL | CoMat 03-236 | ||
| CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADE | LOCAL | CoMat 05-001 | ||
| CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE | LOCAL | CoMat 05-003 | ||
| CoMat 07-035 CORROSION RESISTANT COATING | LOCAL | CoMat 07-035 | ||
| CoMat 07-036 ALUMINIUM HIGH HEAT RESISTANT PAINT | 0AM53 | CoMat 07-036 | ||
| CoMat 07-037 CORROSION RESISTANT TOUCH-UP COATING | LOCAL | CoMat 07-037 | ||
| CoMat 07-038 AIR DRYING ENAMEL | K3504 | CoMat 07-038 |
Spares
NONESafety Requirements
NONEProcedure
Use lathe, IAE 3R18570 Turning fixture 1 off and IAE 3R18232 Lifting beam 1 off.
Set the machine correctly.
Assemble the fixture on to the machine.
SUBTASK 72-41-21-325-065 Machine the Abradable Lining
Refer to the SPM TASK 70-33-63-300-503.
Remove the remaining lining material.
SUBTASK 72-41-21-330-057 Chemically Remove the Lining Material
NOTE
This SUBTASK is an alternative to SUBTASK 72-41-21-350-090 and Step.Refer to the SPM TASK 70-12-02-120-501.
Remove the remaining lining material.
SUBTASK 72-41-21-120-057 Abrasive Blast the Lining Material
NOTE
This SUBTASK is an alternative to SUBTASK 72-41-21-350-090 and Step.Refer to the SPM TASK 70-34-01-340-501 and Figure and Figure.
Visually and dimensionally inspect.
SUBTASK 72-41-21-220-237 Inspect the Lining
Refer to the SPM TASK 70-23-01-230-501.
Do a penetrant crack test.
SUBTASK 72-41-21-230-100-001 Do a Crack Test
Refer to the SPM TASK 70-23-03-230-501.
Do a penetrant crack test.
SUBTASK 72-41-21-230-100-002 Do a Crack Test
Refer to the SPM TASK 70-11-01-300-503.
Remove the grease.
SUBTASK 72-41-21-110-111 Clean the Part
Use CoMat 02-001 ADHESIVE TAPE (MASKING) or locally manufactured fixture.
Put covers on the areas not to be sprayed.
Refer to the SPM TASK 70-12-02-120-501.
Remove the covers when the blasting is completed.
Do not touch the area which had been blasted.
Abrasive blast.
SUBTASK 72-41-21-120-058 Abrasive Blast
Use CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL or locally manufactured fixture.
Put the covers on the areas not to be sprayed.
Refer to the SPM TASK 70-34-01-340-501.
For powder feed plasma spray gun use CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5) or CoMat 03-089 METAL SPRAYING POWDER Ni/Al (95/5) or CoMat 03-090 METAL SPRAYING POWDER Ni/Al (95/5).
Preheat the seal ring to 221 to 257 deg F (105 to 125 deg C).
Use spray gun with feed off.
Apply the bond coat.
Spray data for metco 3MB powder feed plasma spray gun.
Gun
Metco 3MB
Cathode
3M11A
Nozzle
3M7AGH
Distibution ring
3A275A
Powdr port
No. 2
Primary gas flow tube
2M164
Secondary gas flow tube
2M166
Gases:
Arc primary
Argon
Pressure
100 psi
Arc secondary
Hydrogen
Pressure
50 psi
Gas flow Metco flow meter setting:
Primary
80
Secondary
15
Power settings:
Current
500 amps
Voltage
61-75 volts
Powder control:
Carrier gas flow meter
37
Setting
Powder feed rate
67-69 gms/min
Spray distance
4-7 ins.
Spray thickness
0.004 -0.007 ins.
SUBTASK 72-41-21-340-057-001 Apply the Bond Coat
Use CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL or locally manufactured fixture.
Put the covers on the areas not to be sprayed.
Refer to the SPM TASK 70-34-01-340-501.
For powder feed plasma burner use CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5) or CoMat 03-089 METAL SPRAYING POWDER Ni/Al (95/5) or CoMat 03-090 METAL SPRAYING POWDER Ni/Al (95/5).
Preheat the seal ring to 221 to 257 deg F (105 to 125 deg C).
Use gun with feed off.
Apply the bond coat.
Spray data for plasma technik plasma burner.
Gun
Plasma Technik F4
Nozzle dia
6.0 mm
Powder injector dia
1.8 mm
Injector angle
90 degrees
Powder gage
6.0 mm
Arc primary gas
Argon
Flow rate litres/min
55
Arc secondary gas
Hydrogen
Flow rate litres/min
9.5
Power supply
600 amps
Carrier gas litres/min
3.5
Powder spreader type
L
Powder feed rate grams/min
50
Spray distance
5.5 ins.
Spray thickness
0.004-0.007 ins.
SUBTASK 72-41-21-240-057-002 Apply the Bond Coat
Use CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL or locally manufacatured fixture.
Put the covers on the area not to be sprayed.
Refer to the SPM TASK 70-34-01-340-501.
For wire feed combustion spray use CoMat 03-036 METAL SPRAYING WIRE, Ni,Al.
Preheat the seal ring to 221 to 257 deg F (105 to 125 deg C).
Use spray gun with feed off.
Apply the bond coat.
Spray data for metco 10E or 12E wire feed combustion spray gun.
Gun
Metco 10E or 12E
Nozzle diameter
3.0 mm
Air cap
C
Gas pressures
Acetylene
10 psi
Oxygen
30 psi
Air
65 psi or 75 psi
Gas flows Metco flow meter setting
Acetylene
33
Oxygen
46
Air
49 or 65
Spray distance
5-7 ins.
Wire diameter
0.125 ins.
Deposition per pass
0.001 ins.
Spray thickness
0.004-0.007 ins.
SUBTASK 72-41-21-340-057-003 Apply the Bond Coat
Refer to the SPM TASK 70-34-01-340-501.
Remove covers after spraying is completed.
Apply the abradable lining.
Spray data for metco 3MB powder feed plasma spray gun.
Gun
Metco 3MB
Cathode
3M11A
Nozzle
3M7AGH
Distribution ring
3A275A
Powder port
No.1
Primary gas flow tube
2M164
Secondary gas flow tube
2M166
Gases:
Arc primary
Argon
Pressure
100 psi
Arc Secondary
Hydrogen
Pressure
50 psi
Gas flow Metco flow meter setting:
Primary
150
Secondary
5
Power settings:
Current
500 amps
Voltage
55-70 volts
Powder control:
Carrier gas flow meter
setting
37
Powder feed rate
49-50 gms/min
Spray distance
4-6 ins.
Spray thickness
See illustrations
SUBTASK 72-41-21-340-058-001 Apply the Abradable Lining
Refer to the SPM TASK 70-34-01-340-501.
Remove covers after spraying is completed.
Apply the abradable lining.
Spray data for plasma technick plasma burner.
Gun
Plasma Technik F4
Nozzle dia
6.0 mm
Powder injector dia
1.8 mm
Injector angle
+15 degrees
Powder gage
6.0 mm
Arc primary gas
Argon
Flow rate litres/min
38
Arc secondary gas
Hydrogen
FLow rate litres/min
12
Power supply
500 amps
Carrire gas litres/min
5.0
Powder spreader type
L
Powder feed rate grams/min
35
Spray distance
6-7 ins
Spray thickness
See illustrations
SUBTASK 72-41-21-340-058-002 Apply the Abradable Lining
Refer to the SPM TASK 70-34-01-340-501.
Visually inspect the sprayed coating on the ring.
Refer to the SPM TASK 70-34-01-340-501.
Average hardness must be 70-80 R15Y outer limits 65 min 85 max.
Hardness test the sprayed coating.
SUBTASK 72-41-21-220-238 Inspect the Lining
Refer to the SPM TASK 70-09-00-400-501.
NUMBER BEFORE: 6A3652 .
NEW NUMBER: 6A4101.
NUMBER BEFORE: 6A3652.
NEW NUMBER: 6A4102.
Vibration peen the new part number adjacent to the assembly part number.
SUBTASK 72-41-21-350-085 Identify the Reworked Rotor Path with the New Part Number
Figure: Rework of HP compressor stage 7 rotor path
Rework of HP compressor stage 7 rotor path
Figure: Rework of HP compressor stage 7 rotor path abradable lining
Rework of HP compressor stage 7 rotor path abradable lining
Figure: Rework of HP compressor stage 8 rotor path abradable lining
Rework of HP compressor stage 8 rotor path abradable lining
Figure: Rework of HP compressor stage 8 rotor path abradable lining
Rework of HP compressor stage 8 rotor path abradable lining
