TASK 72-41-22-300-004 HPC Stage 7 Stator Vane - Weld Repair The Airfoil, Repair-004 (VRS6060)

DMC:V2500-A0-72-41-2207-00A-627A-C|Issue No:004.00|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 72-41-22-300-004 HPC Stage 7 Stator Vane - Weld Repair The Airfoil, Repair-004 (VRS6060)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

02-150

6A4215

B

02-150

6A7426

B

02-350

6A3266

A

02-350

6A4216

B

02-350

6A7427

B

02-400

6A3265C01

A

02-400

6A4213C01

B

02-400

6A7425C01

B

02-448

6A3265C01

A

02-448

6A4213C01

B

02-448

6A7425C01

B

02-450

6A3265C02

A

02-450

6A4213C02

B

02-450

6A7425C02

B

Material of component

PART IDENT

SYMBOL

MATERIAL

HP Compressor Stator Vane Stage 7

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 the relevant inspection procedures (identified by the applicable part number) located in section 72-41-22.

This repair restores the HP Compressor Stator Vanes, Stage 7 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 the relevant inspection procedures (identified by the applicable part number) located in section 72-41-22.

- 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 - Stages 7 to 11 - Stator vanes - Restore airfoil surface finish, refer to repair, VRS6210 TASK 72-41-22-300-022 (REPAIR-022).

NOTE

  1. Equivalent materials or equipment can be used.

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

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 toolsLOCALHand tools
Radiographic equipmentLOCALRadiographic equipment
Vibrating marking pencilLOCALVibrating marking pencil
Workshop inspection equipmentLOCALWorkshop inspection 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 VRS6060 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

    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 72-41-22-110-001 Clean the Stage 7 Stator Vanes

      1. Chemically clean the vanes.

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

    3. SUBTASK 72-41-22-220-001-A00 Examine the Stage 7 Stator Vanes, Assembly A

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

      1. Refer to TASK 72-41-22-200-000 (INSPECTION-000) 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 72-41-22-220-001-B00 Examine the Stage 7 Stator Vanes, Assembly B

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

      1. Refer to TASK 72-41-22-200-000 (INSPECTION/CHECK-000) 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.

    5. SUBTASK 72-41-22-230-001 Do a Crack Test

      1. Do a penetrant crack test.

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

      3. Discard any cracked vanes.

    6. SUBTASK 72-41-22-120-001-A00 Vapor Blast the Stage 7 Stator Vanes, Assembly A

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

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

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

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

    4. Remove the masking tape.

    7. SUBTASK 72-41-22-120-001-B00 Vapor Blast the Stage 7 Stator Vanes, Assembly B

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

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

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

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

    4. Remove the masking tape.

    8. SUBTASK 72-41-22-110-002 Clean the Stage 7 Stator Vanes

      1. Chemically clean the vanes.

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

        NOTE

        The vanes must be fully cleaned before you do SUBTASK 72-41-22-310-057.

    9. SUBTASK 72-41-22-310-001-A00 Weld the Stage 7 Stator Vane Tip, Asssembly A

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

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

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

        1. Weld Data

        2. Refer to Approved Vendor in Step, for weld parameters.

      3. Apply sufficient weld to get the necessary vane length.

      1. Identify a sample stage 7 stator vane and repair along with each repair batch.

    4. NOTE

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

    10. SUBTASK 72-41-22-310-001-B00 Weld the Stage 7 Stator Vane Tip, Assembly B.

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

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

        1. Use CoMat 03-284 WELDING FILLER WIRE, NiBASE, with argon arc welding equipment.

        1. Weld Data

        2. Refer to Approved Vendor in Step, for weld parameters.

      3. Apply sufficient weld to get the necessary vane length.

      1. Identify a sample stage 7 stator vane and repair along with each repair batch.

    4. NOTE

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

    11. SUBTASK 72-41-22-370-001 Heat-Treat the Stage 7 Stator Vanes

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

        1. Heat-treat Data

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

        3. 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.

        4. Cool to room temperature.

    12. SUBTASK 72-41-22-220-002 Do a Hardness Check

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

      1. Refer to Approved Vendor in Step.

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

      3. The minimum hardness value should be 361 HV.

    2. NOTE

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

    13. SUBTASK 72-41-22-350-001-A00 Put the Shape Back on the Stage 7 Stator Vane Contour and Height, Assembly A

      2. Put the shape back on the vane contour.

      2. Refer to Approved Vendor in Step, for special machines to make the vane contour.

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

      3. Grind the vane tip to the correct height.

      4. Dress the vane tip to remove burrs.

    14. SUBTASK 72-41-22-350-001-B00 Put the Shape Back on the Stage 7 Stator Vane Contour and Height, Assembly B

      2. Put the shape back on the vane contour.

      2. Refer to Approved Vendor in Step, for special machines to make the vane contour.

      3. 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, Figure and Figure.

      4. Dress the vane tip to remove burrs.

    15. SUBTASK 72-41-22-220-003-A00 Examine the Stage 7 Stator Vanes, Assembly A

      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, Figure and Figure.

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

      3. Welded material must be contained within given limits.

    16. SUBTASK 72-41-22-220-003-B00 Examine the Stage 7 Stator Vanes, Assembly B

      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, Figure and Figure.

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

      3. Welded material must be contained within given limits.

    17. SUBTASK 72-41-22-350-002-A00 Polish the Stage 7 Stator Vane Airfoil Surface and Contour, Assembly A

      2. Polish the vane airfoil surface and contour.

      1. Refer to Approved Vendor in Step for special machines to make vane contour.

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

    18. SUBTASK 72-41-22-350-002-B00 Polish the Stage 7 Stator Vane Airfoil Surface and Contour, Assembly B

      2. Polish the vane airfoil surface and contour.

      1. Refer to Approved Vendor in Step for special machines to make vane contour.

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

    19. SUBTASK 72-41-22-220-006 Do a Dimensional Inspection of the Stage 7 Stator Vanes

      1. Do a dimensional inspection of the Vanes.

      1. Make sure that vanes satisfy the minimum chord length requirements, refer to TASK 72-41-22-200-000.

      2. If the chord length is less than the minimum chord length requirements, reject the part.

    20. SUBTASK 72-41-22-110-004 Cold Ferric Chloride Etch

      1. Swab etch the repaired area.

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

    21. SUBTASK 72-41-22-230-003 Do a Crack Test

      1. Do a penetrant crack test.

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

      3. Discard any cracked vanes.

    22. SUBTASK 72-41-22-260-002 Radiographically Examine the Stage 7 Stator Vanes

      1. Radiographically examine the welded vane tip.

      1. Cracks or unwanted material are not permitted.

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

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

      4. Surfaces broken by pores are not permitted.

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

        1. Radiographic Data

        2. Refer to Approved Vendor in Step, for the appropriate data card, and raidiographic examination parameters.

    23. SUBTASK 72-41-22-380-002 Restore the Airfoil Surface Finish

      1. Restore the airfoil surface finish.

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

    24. SUBTASK 72-41-22-350-005 Identify the Repair

    1. Refer to Figure.

      2. CAUTION

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

        Mark a code symbol adjacent to the assembly number.

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

    25. 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

    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
Link not Found
Manufacturer Code:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Link not Found
Manufacturer Code:LOCAL
Tool Number:Hand tools
Tool Name:Hand tools
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:Welding equipment
Tool Name:Welding equipment
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment