TASK 72-41-22-300-023 HPC Stage 6 Stator Vane - Weld Repair The Airfoil, Repair-023 (VRS6490)

DMC:V2500-A0-72-41-2206-00A-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 72-41-22-300-023 HPC Stage 6 Stator Vane - Weld Repair The Airfoil, Repair-023 (VRS6490)

Effectivity

FIG/ITEM

PART NO.

01-350

6A4231

01-350

6A7424

01-400

6A4230C01

01-400

6A7423C01

01-448

6A4230C01

01-448

6A7423C01

01-450

6A4230C02

01-450

6A7423C02

Material of component

PART IDENT

SYMBOL

MATERIAL

HP compressor stator vane

stage 6

QMP

52 percent Nickel

19 percent Chromium

18 percent Iron and

5 percent Niobium

General

This repair must only be done when the instruction to do so is given in 72-41-22, Inspection.

This repair restores the HP compressor stator vanes, stage 6 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, stator vanes are repaired as near to the new vane condition as possible.

Stator vanes must be repaired as soon as damage or wear is monitored, to get back HP compressor efficiency and extend the stator vane life.

This repair can be done again to the welded stator vanes if:

- The minimum airfoil dimensions are as given in 72-41-22, Inspection.

- The airfoil surface has been polished up to two times, refer to Repair VRS6210, TASK 72-41-22-300-022 (REPAIR-022)

Price and Availability

Refer to International Aero Engines

Related Repairs

HP Compressor - Stage 6 to 11 - Stator vanes - Restore airfoil surface finish, refer to TASK 72-41-22-300-022 (VRS6210).

NOTE

  1. Equivalent materials or equipment can be used.

  2. More equipment and materials necessary to do this repair are in the SPM TASKS given as follows:

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
Hand toolsLOCALTools, hand
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 03-284 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

        1. Authorized Repair Vendors for Repair VRS6490 are listed below:

          CHROMALLOY DALLAS

          14042 DISTRIBUTION WAY

          DALLAS

          TEXAS 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

        1. 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 72-41-22-110-076 Clean the Stage 6 Stator Vanes

      1. Chemically clean the vanes.

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

        Use chemical cleaning equipment.

    3. SUBTASK 72-41-22-220-169 Examine the Stage 6 Stator Vanes

      2. Examine the vanes, to make sure the vanes can be repaired.

      1. Refer to TASK 72-41-22-200-000 (INSPECTION) for Inspection Standards.

      2. The vanes must be easily identified to allow dimensions before and after repair to be checked.

      3. Record the vane length.

    4. SUBTASK 72-41-22-230-077 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 vanes.

    5. SUBTASK 72-41-22-120-059 Vapor Blast the Stage 6 Stator Vanes

    1. Refer to Figure, Figure and Figure.

      2. Mask areas of the vane, not to be welded.

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

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

    4. Remove the masking tape.

    6. SUBTASK 72-41-22-110-077 Clean the Stage 6 Stator Vanes

      1. Chemically clean the vanes.

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

      2. Use chemical cleaning equipment.

        NOTE

        The vanes must be fully cleaned before you do Step.

    7. SUBTASK 72-41-22-310-058 Weld the Stage 6 Stator Vane Tip

    1. Refer to Figure, Figure and Figure.

      2. Build up the vane 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. Apply sufficient weld to get the necessary vane length.

      1. Identify a sample stage 6 stator vane and repair along with each repair batch.

        NOTE

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

    8. SUBTASK 72-41-22-370-057 Heat-Treat the Stage 6 Stator Vanes

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

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

      2. Use heat treatment equipment.

        Heat-treat Data

        Heat to 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 to room temperature.

    9. SUBTASK 72-41-22-220-170 Do a Hardness Check

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

      1. Refer to Approved Vendor in 4.

      2. Repair Facilities, Para B.

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

      4. The minimum hardness value should be 361 HV.

      5. Use a hardness tester.

        NOTE

        If the hardness value is below 361 HV minimum, then additional sample vanes should be selected for metallurgical examination.

    10. SUBTASK 72-41-22-350-090 Put the Shape Back on the Stage 6 Stator Vane Contour and Height

      2. Put the shape back on the vane contour.

      2. Refer to Approved Vendor in 4.

      3. Repair Facilities, Para B, for special machines to make the vane contour.

      4. Hand methods are permitted to put the shape back on the vane contour.

      3. Grind the vane tip to the correct height.

      1. Refer to Figure, Figure and Figure.

      2. Use a grinding machine.

      4. Dress the vane tip to remove burrs.

      1. Use hand tools.

    11. SUBTASK 72-41-22-220-171 Examine the Stage 6 Stator Vanes

      2. Visually examine the airfoil surface.

      1. Scratches or scores on the airfoil surface are not permitted.

    3. If scratches or scores are shown on the airfoil surface, do Step.

      4. Visually and dimensionally examine the vane contour.

      5. Dimensionally examine the vane height.

      1. Refer to Figure, Figure and Figure.

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

      3. Welded material must be contained within given limits.

    12. SUBTASK 72-41-22-350-091 Polish the Stage 6 Stator Vane Airfoil Surface and Contour

      2. Polish the vane airfoil surface and contour.

      1. Refer to Approved Vendor in 4.

      2. Repair facilities, Para B, for special machines to make the vane contour.

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

    13. SUBTASK 72-41-22-230-078 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 vanes.

    14. SUBTASK 72-41-22-260-062 Radiographically Examine the Stage 6 Stator Vanes

      1. Radiographically examine the welded vane tip.

      1. Cracks or unwanted material are not permitted.

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

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

      4. Surfaces broken by pores are not permitted.

      5. Pores are not permitted less than 0.040in. (1.00 mm) from the leading and trailing edges.

      6. Use radiographic equipment.

        Radiographic Data

        Refer to Approved Vendor in 4. Repair Facitities, Para B, for the appropriate data card, and Raidiographic Examination parameters.

    15. SUBTASK 72-41-22-380-075 Restore the Airfoil Surface Finish

      1. Restore the airfoil surface finish.

      1. Refer to Repair, VRS6210 TASK 72-41-22-300-022 (REPAIR).

    16. SUBTASK 72-41-22-350-092 Identify the Repair

      CAUTION

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

    1. Refer to Figure.

      2. Mark a code symbol adjacent to the assembly number.

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

      2. Use vibro-engraving equipment.

    17. Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

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
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