TASK 72-41-22-300-008 HPC Stage 8 Stator Vane - Weld Repair The Airfoil, Repair-008 (VRS6061)

DMC:V2500-A0-72-41-2208-00A-627A-C|Issue No:004.00|Issue Date:2021-02-01

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 72-41-22-300-008 HPC Stage 8 Stator Vane - Weld Repair The Airfoil, Repair-008 (VRS6061)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

03-150

6A3409

A

03-150

6A4250

B

03-200

6A3407

A

03-200

6A4246

B

03-250

6A3408

A

03-250

6A4248

B

03-350

6A3410

A

03-350

6A4249

B

03-400

6A3267C01

A

03-400

6A4245C01

B

03-448

6A3267C01

A

03-448

6A4245C01

B

03-450

6A3267C02

A

03-450

6A4245C02

B

Material of component

PART IDENT

SYMBOL

MATERIAL

HP Compressor stator vane

QMP

52 percent Nickel

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 72-41-22, Inspection/Check.

This repair restores the HP compressor stator vanes, stage 8 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/Check.

- 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

More equipment and materials necessary to do this repair are in the SPM TASKS that follow:
SPM TASK 70-09-00-400-501
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
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 GRADEX222XCoMat 05-003

Spares

NONE

Safety Requirements

NONE

Procedure

    1. Repair Facilities

    1. The Source Demonstration requirements of this repair means that any facility not authorised 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 VRS6061 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 72-41-22-220-081 Clean the stage 8 Stator Vanes

      1. Chemically clean the vanes.

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

        1. Use chemical cleaning equipment.

    3. SUBTASK 72-41-22-220-175-A00 Examine the Stage 8 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/CHECK-000) for Inspection Standards.

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

        2. Record the vane length.

    4. SUBTASK 72-41-22-220-175-B00 Examine the Stage 8 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.

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

        Record the vane length.

    5. SUBTASK 72-41-22-230-063 Do a Crack Test

      1. Do a penetrant crack test.

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

        Use penetrant crack test equipment.

        Discard any cracked vanes.

    6. SUBTASK 72-41-22-120-052-A00 Vapor Blast the Stage 8 Stator Vanes, Assembly A

    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.

    7. SUBTASK 72-41-22-120-052-B00 Vapor Blast the Stage 8 Stator Vanes, Assembly B

    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.

    8. SUBTASK 72-41-22-110-082 Clean the Stage 8 Stator Vanes

      1. Chemically clean the vanes.

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

        Use chemical cleaning equipment.

    2. NOTE

      The vanes must be fully cleaned before you do SUBTASK 72-41-22-310-059.

    9. SUBTASK 72-41-22-310-059-A00 Weld the Stage 8 Stator Vane Tip, Assembly A

    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.

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

      3. NOTE

        Weld Data.
        Refer to Approved Vendor in 4. Repair Facilities, Para B, for weld parameters.

        Apply sufficient weld to get the necessary vane length.

      1. Identify a sample stage 8 stator vane and repair along with each repair batch.

    4. NOTE

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

    10. SUBTASK 72-41-22-310-059-B00 Weld the Stage 8 Stator Vane Tip, Assembly B

    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.

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

      3. NOTE

        Weld Data.
        Refer to Approved Vendor in 4. Repair Facilities, Para B, for weld parameters.

        Apply sufficient weld to get the necessary vane length.

      1. Identify a sample stage 8 stator vane and repair along with each repair batch.

    4. NOTE

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

    11. SUBTASK 72-41-22-370-058 Heat-Treat the Stage 8 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.

        Use heat treatment equipment.

    2. NOTE

      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.

    12. SUBTASK 72-41-22-220-176 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.

        Repair Facilities, Para B.

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

        The minimum hardness value should be 361 HV.

        Use a hardness tester.

    2. NOTE

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

    13. SUBTASK 72-41-22-350-096-A00 Put the Shape Back on the Stage 8 Stator Vane Contour and Height, Assembly A

      2. Put the shape back on the vane contour.

      1. Refer to Approved Vendor in 4.

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

        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 FigureFigureand Fig . Figure.

        Use a grinding machine.

      4. Dress the vane tip to remove burrs.

      1. Use hand tools.

    14. SUBTASK 72-41-22-350-096-B00 Put the Shape Back on the Stage 8 Stator Vane Contour and Height, Assembly B

      2. Put the shape back on the vane contour.

      1. Refer to Approved Vendor in 4.

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

        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 FigureFigureand Fig . Figure.

        Use a grinding machine.

      4. Dress the vane tip to remove burrs.

      1. Use hand tools.

    15. SUBTASK 72-41-22-220-177-A00 Examine the Stage 8 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 FigureFigureand Figure.

        Compare before and after repair dimensions, refer to Step.

        Welded material must be contained within given limits.

    16. SUBTASK 72-41-22-220-177-B00 Examine the Stage 8 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 FigureFigureand Figure.

        Compare before and after repair dimensions, refer to Step.

        Welded material must be contained within given limits.

    17. SUBTASK 72-41-22-350-097-A00 Polish the Stage 8 Stator Vane Airfoil Surface and Contour, Assembly A

      2. Polish the vane airfoil surface and contour.

      1. Refer to Approved Vendor in 4.

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

        Hand methods are permitted to polish the vane contour.

    18. SUBTASK 72-41-22-350-097-B00 Polish the Stage 8 Stator Vane Airfoil Surface and Contour, Assembly B

      2. Polish the vane airfoil surface and contour.

      1. Refer to Approved Vendor in 4.

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

        Hand methods are permitted to polish the vane contour.

    19. SUBTASK 72-41-22-110-083 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.

        Use chemical cleaning equipment.

    20. SUBTASK 72-41-22-230-064 Do a Crack Test

      1. Do a penetrant crack test.

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

        Use penetrant crack test equipment.

        Discard any cracked vanes.

    21. SUBTASK 72-41-22-260-057 Radiographically Examine the Stage 8 Stator Vanes

      1. Radiographically examine the welded vane tip.

      1. Cracks or unwanted material are not permitted.

        Pores larger than 0.006in. (0,15mm) diameter are not permitted.

        Pores with a distance of less than 0.200in. (5,10mm) 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.

        Use radiographic equipment.

    2. NOTE

      Radiographic Data.
      Refer to Approved Vendor in 4. Repair Facilities, Para B, for the appropriate data card, and Radiographic Examination parameters.

    22. SUBTASK 72-41-22-380-066 Restore the Airfoil Surface Finish

      1. Restore the airfoil surface finish.

      1. Refer to VRS6210, TASK 72-41-22-300-022(REPAIR-022, page-901).

    23. SUBTASK 72-41-22-350-112 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 the SPM TASK 70-09-00-400-501, SUBTASK 70-09-00-400-001.

        Use vibro-engraving equipment.

    24. 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 figure. (20VG152)

Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
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:Abrasive Blast Equipment
Tool Name:Abrasive Blast Equipment
Manufacturer Code:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Link not Found
Manufacturer Code:LOCAL
Tool Number:Hardness Tester
Tool Name:Hardness Tester
Manufacturer Code:LOCAL
Tool Number:Heat Treatment Equipment
Tool Name:Heat Treatment Equipment
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Manufacturer Code:LOCAL
Tool Number:Radiographic Equipment
Tool Name:Radiographic Equipment
Manufacturer Code:LOCAL
Tool Number:Tools, Hand
Tool Name:Hand Tools
Manufacturer Code:LOCAL
Tool Number:Vibrating Marking Pencil
Tool Name:Vibrating Marking Pencil
Manufacturer Code:LOCAL
Tool Number:Welding equipment
Tool Name:Welding equipment