TASK 72-41-23-300-022 HPC Rear Outer Case - Weld Repair The Damaged Insert Hole(s), Repair-022 (VRS6526)

DMC:V2500-A0-72-41-2301-00A-627A-C|Issue No:002.00|Issue Date:2016-08-01

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 72-41-23-300-022 HPC Rear Outer Case - Weld Repair The Damaged Insert Hole(s), Repair-022 (VRS6526)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

02-400

6A2949

A

02-400

6A3557

B

02-400

6A4154

C

02-400

6A5495

D

02-400

6A5682

D

02-400

6A8162

E

02-400

6B1427

E

Material of component

PART IDENT

MATERIAL

HP Compressor Rear Outer Case Assembly

Corrosion resistant steel

General

This repair must only be done when the instruction to do so is given in the 72-41-23, Inspection/Check.

This TASK gives the procedure to repair the damaged insert holes on the HP Compressor Rear Outer Case by welding.

TASKS identified by SPM TASK are in the Standard Practices Manual (SPM)

Price and Availability

Refer to International Aero Engines

Related Repairs

Repair the HP Compressor Rear Outer Case by Replacing the Surface Protection, refer to VRS6178, TASK 72-41-23-300-003 (REPAIR-003).

Repair Damaged Helicoil or Thinwall Insert(s) in the HP Compressor Rear Outer Case Assembly, by Replacement, refer to VRS6306, TASK 72-41-23-300-019 (REPAIR-019).

NOTE

Equipment and materials necessary to do this repair are in the SPM TASKS given below:
SPM TASK 70-09-00-400-501
SPM TASK 70-11-26-300-503
SPM TASK 70-23-02-230-501
SPM TASK 70-23-05-230-501
SPM TASK 70-31-02-310-501-001
SPM TASK 70-31-02-310-501-008

NOTE

It is possible that some materials in the consumable materials chart cannot be used for some or all of the necessary applications. Before you use the materials, make sure the types, quantities and applications of the materials necessary are legally permitted in your location. All persons must obey all applicable federal, state, local and provincial laws and regulations when it is necessary to work with these materials.

NOTE

To identify the consumable materials, refer to the Overhaul Processes and Consumables Index (PCI).

NOTE

Other necessary consumable materials are referred to in the SPM TASKS.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Welding equipmentLOCALWelding equipment
Chemical cleaning equipmentLOCALChemical cleaning equipment
Drilling equipmentLOCALDrilling equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Standard workshop toolsLOCALStandard workshop tools
Thermal blanketLOCALThermal blanket
Vibrating marking pencilLOCALVibrating marking pencil
Workshop inspection equipmentLOCALWorkshop inspection equipment

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYONIE304CoMat 02-121
CoMat 03-181 WELDING WIRE 12% Cr. STEELLOCALCoMat 03-181
CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)LOCALCoMat 06-064

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-23-110-079 Chemically Clean

      1. Chemically clean the HP Compressor Rear Outer Case.

      1. Refer to TASK 72-41-23-100-003 (CLEANING-003).

    2. SUBTASK 72-41-23-220-171 Do a Crack Test

      1. Do a penetrant crack test on the part.

      1. Refer to SPM TASK 70-23-02-230-501.

      4. Cracks are not permitted.

    3. SUBTASK 72-41-23-230-087 Examine the Part

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

      2. Examine the HP Compressor Rear Outer Case.

      1. Visually examine the part.

      2. Make sure that the damage is within the limits.

      3. Identify the repaired area.

      1. Mark all damaged insert hole(s).

    4. SUBTASK 72-41-23-350-082 Machine the Damaged Holes

      2. Machine the damaged insert holes.

      1. Drill on the centre-line of effected hole to remove remaining thread form.

      2. Use recommended standard drill size to remove the thread.

    5. SUBTASK 72-41-23-110-080 Chemically Clean

      1. Locally clean the repair area.

      1. Refer to SPM TASK 70-11-26-300-503.

    6. SUBTASK 72-41-23-220-172 Examine the Repair Area

      2. Visually examine the repair area.

      1. Make sure that all thread form are removed. If not, do from Step again.

    7. SUBTASK 72-41-23-230-088 Do a Crack Test

      1. Do a local penetrant crack test on the repair area.

      1. Refer to SPM TASK 70-23-05-230-501.

      4. Cracks are not permitted.

    8. SUBTASK 72-41-23-110-081 Chemically Clean

      1. Locally clean the repair area.

      1. Refer to SPM TASK 70-11-26-300-503.

    9. SUBTASK 72-41-23-350-083 Weld Build up Damaged Holes

      2. Weld build up damaged holes.

      2. Apply the weld filler to the repaired area(s).

      3. Apply sufficient weld to let it for final machining.

      6. Use locally manufactured fixtures and chills to minimize distortion.

    3. NOTE

      If welding is necessary for more than three adjacent holes, then make sure that the outermost hole from the last welded hole is repaired next, to minimize distortion.

    10. SUBTASK 72-41-23-350-084 Heat Treat the Part

      2. Locally heat treat the repaired areas only.

      2. Increase the temperature to 610 deg C (1130 deg F) for 60 minutes.

    11. SUBTASK 72-41-23-350-085 Repair the Casing Contour

      2. Repair the casing contour.

      1. Dress to remove unwanted weld.

      2. Make boss faces flat and flush with adjacent surface where applicable.

      3. Polish the dressed areas to make sure a surface finish similar to the adjacent surface that surrounds the holes.

      4. Use hand methods.

    3. NOTE

      Areas adjacent to repair location can be seal lands for pneumatic connections, thus more precaution is necessary to get a flat and flush surface condition.

    12. SUBTASK 72-41-23-350-086 Machine the Insert Holes

      2. Machine to make holes again.

      1. Drill, counter bore, chamfer and wobble broach to make serrations.

      2. Break burrs and remove sharp edges.

    13. SUBTASK 72-41-23-110-082 Chemically Clean

      1. Locally clean the repaired areas.

      1. Refer to SPM TASK 70-11-26-300-503.

    14. SUBTASK 72-41-23-220-173 Examine the HP Compressor Rear Outer Case

      2. Visually and dimensionally examine the repaired area.

      1. If there is indication of distortion, reject the part.

      2. Make sure machined dimensions are in less than the specified limits.

      3. If the machined dimensions are outside the limit, reject.

      4. Thread marks on counter bore are permitted.

    15. SUBTASK 72-41-23-230-089 Do a Crack Test

      1. Do a local penetrant crack test on the repaired area.

      1. Refer to SPM TASK 70-23-05-230-501.

      4. Cracks are not permitted.

    16. SUBTASK 72-41-23-350-087 Identify the Repair

      1. Mark VRS6526 adjacent to the part number.

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

    17. SUBTASK 72-41-23-350-088 Apply Surface Protection again

      1. Apply surface protection again with identity marking.

      1. Refer to VRS6178, TASK 72-41-23-300-003 (REPAIR-003).

    18. SUBTASK 72-41-23-350-089 Replace the Inserts

      1. Replace the inserts as required.

      1. Refer to VRS6306, TASK 72-41-23-300-019 (REPAIR-019).

      2. Use new replacement insert.

    19. Figure: Repair Details and Dimensions Assembly A, Assembly B, Assembly C, Assembly D and Assembly E

    Repair Details and Dimensions Assembly A, Assembly B, Assembly C, Assembly D and Assembly E

    Figure: Repair Details and Dimensions - Assembly A

    Repair Details and Dimensions - Assembly A

    Figure: Repair Details and Dimensions Assembly B, Assembly C, Assembly D and Assembly E

    Repair Details and Dimensions Assembly B, Assembly C, Assembly D and Assembly E

    Figure: Repair Details and Dimensions Assembly A, Assembly B, Assembly C, Assembly D and Assembly E

    Repair Details and Dimensions Assembly A, Assembly B, Assembly C, Assembly D and Assembly E

    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 C, Assembly D and Assembly E

    Repair Details and Dimensions Assembly C, Assembly D and Assembly E

    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 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 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 A and Assembly B

    Repair Details and Dimensions Assembly A and Assembly B

    Figure: Repair Details and Dimensions Assembly C, Assembly D and Assembly E

    Repair Details and Dimensions Assembly C, Assembly D and Assembly E

    Figure: Repair Details and Dimensions Assembly C and Assembly D

    Repair Details and Dimensions Assembly C and Assembly D

    Figure: Repair Details and Dimensions - Assembly E

    Repair Details and Dimensions - Assembly E

    Figure: Repair Details and Dimensions Assembly C, Assembly D and Assembly E

    Repair Details and Dimensions Assembly C, Assembly D and Assembly E

    Figure: Repair Details and Dimensions Assembly C, Assembly D and Assembly E

    Repair Details and Dimensions Assembly C, Assembly D and Assembly E

    Figure: Repair Details and Dimensions Assembly C, Assembly D and Assembly E

    Repair Details and Dimensions Assembly C, Assembly D and Assembly E

    Figure: Repair Details and Dimensions Assembly C, Assembly D and Assembly E

    Repair Details and Dimensions Assembly C, Assembly D and Assembly E

    Figure: Repair Details and Dimensions Assembly C, Assembly D and Assembly E

    Repair Details and Dimensions Assembly C, Assembly D and Assembly E

    Figure: Repair Details and Dimensions - Assembly C

    Repair Details and Dimensions - Assembly C

    Figure: Repair Details and Dimensions Assembly D and Assembly E

    Repair Details and Dimensions Assembly D and Assembly E

    Figure: Repair Details and Dimensions - Assembly C

    Repair Details and Dimensions - Assembly C

    Figure: Repair Details and Dimensions Assembly D and Assembly E

    Repair Details and Dimensions Assembly D and Assembly E

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added part number 6B1427 to the effectivity table and revised all the subtask numbers in the procedure. (09VR061B)

Manufacturer Code:IE304
Enterprise Name:DELETED
BU Name:DELETED,SEE CAGE CODE 0V6W9
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:IE304
Supply Number:CoMat 02-121
Type:sp01
Supply Short Name:CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYON
Supply Name:CoMat 02-121 TEMPORARY MARKER PENCIL/CRAYON
Specification Groups:
Doc NumberType
OMAT: 261BEROL VERITHIN (HARD TYPE)
Suppliers:
ManufacturerRemarks
IE304
K5720
K6835
LOCAL
Manufacturer Code:LOCAL
Supply Number:CoMat 03-181
Type:sp01
Supply Short Name:CoMat 03-181 WELDING WIRE 12% Cr. STEEL
Supply Name:CoMat 03-181 WELDING WIRE 12% Cr. STEEL
Specification Groups:
Doc NumberType
MSRR9500/10JETHETE M190 AMS 5823 AMS 5822
OMAT:3/54JETHETE M190 AMS 5823 AMS 5822
Suppliers:
ManufacturerRemarks
LOCAL
IE306
2R602
IE441
Manufacturer Code:X222X
Supply Number:CoMat 06-064
Type:sp01
Supply Short Name:CoMat 06-064FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Supply Name:CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐064 letter suffix material with other CoMat 06‐064 letter suffix materials.Where CoMat 06‐064 is specified with no suffix, use one of the CoMat 06‐064 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Manufacturer Code:LOCAL
Tool Number:Drilling equipment
Tool Name:Drilling equipment
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Manufacturer Code:LOCAL
Tool Number:Standard workshop tools
Tool Name:Standard workshop tools
Manufacturer Code:LOCAL
Tool Number:Thermal blanket
Tool Name:Thermal blanket
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