TASK 72-41-23-300-024 HPC Rear Outer Case - Weld Repair A Crack At Rear Flange Bolt Hole, Repair-024 (VRS6530)

DMC:V2500-A0-72-41-2301-01A-627A-C|Issue No:002.00|Issue Date:2017-11-01

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 72-41-23-300-024 HPC Rear Outer Case - Weld Repair A Crack At Rear Flange Bolt Hole, Repair-024 (VRS6530)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

02-400

6A2949

A

02-400

6A3557

A

02-400

6A4154

A

02-400

6A5495

A

02-400

6A5682

B

02-400

6A8162

B

02-400

6B1427

B

Material of component

PART IDENT

MATERIAL

HP Compressor Rear Outer Case

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 boltholes on the HP Compressor Rear Outer Case by welding.

This repair can only be applied three times. If the part marking showed VRS6530/3, reject the part.

TASKs identified by SPM TASK are in the Standard Practices and Processes 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).

Replace Damaged Shank Nuts in the HP Compressor Rear Outer Case Assembly, refer to VRS6279 TASK 72-41-23-300-011 (REPAIR-011).

NOTE

Equipment and materials necessary to do this repair are in the SPM TASKs given below:
TASK 70-09-00-400-501
TASK 70-11-01-300-503
TASK 70-11-03-300-503
TASK 70-11-26-300-503
TASK 70-23-02-230-501
TASK 70-23-05-230-501
TASK 70-31-02-310-501-001
TASK 70-31-02-310-501-002
TASK 70-35-03-300-501

NOTE

  1. 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.

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

  3. Other necessary consumable materials are referred to in the SPM TASKs.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Welding equipmentLOCALWelding equipment

Argon arc

Chemical cleaning equipmentLOCALChemical cleaning equipment
Drilling equipmentLOCALDrilling equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Standard workshop toolsLOCALStandard workshop tools
Thermal blanketsLOCALThermal blankets
TIG welding equipmentLOCALTIG welding equipment
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 05-106 ABRASIVE STONEK6835CoMat 05-106
CoMat 05-111 EMERY POLISHING PAPER06565CoMat 05-111
CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)LOCALCoMat 06-064

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-23-110-095 Chemically Clean

      1. Chemically clean the HP Compressor Rear Outer Case.

      1. Refer to SPM TASK 70-11-03-300-503.

      2. Use chemical cleaning equipment.

    2. SUBTASK 72-41-23-220-198 Examine the HP Compressor Rear Outer Case

    1. Refer to Figure and Figure.

      2. Visually examine the HP Compressor Rear Outer Case.

      1. Make sure that the damage is less than the limits.

      2. Use workshop inspection equipment.

      3. Identify the repair area.

      1. Mark all damaged crack on flange hole(s).

    3. SUBTASK 72-41-23-230-099 Do a Crack Test

      1. Do a penetrant crack test on the part.

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

      3. Use penetrant crack test equipment.

      4. Cracks are not permitted.

    4. SUBTASK 72-41-23-220-199 Pre-weld Dimensional Inspection

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

      2. Do Pre-weld dimensional inspection.

      1. Make sure the limits are kept as specified before welding.

    5. SUBTASK 72-41-23-350-123 Remove Shank Nuts

      2. Remove shank nuts.

      1. Refer to Repair VRS6279, TASK 72-41-23-300-011 (REPAIR-011).

      2. Remove shank nuts from the inner flange around the heat affected areas.

    6. SUBTASK 72-41-23-350-124 Remove the Paint on the Repair Area

      1. Locally remove high heat resisting enamel.

      1. Locally remove the paint in 1.968 in. (50.00 mm) of the affected area.

    7. SUBTASK 72-41-23-110-096 Prepare the Repair Area for Welding

      1. Prepare the repair area for welding.

      1. Refer to SPM TASK 70-35-03-300-501.

      2. Dress to remove cracks.

      3. Remove burrs and sharp edges.

      4. Remove minimum material.

    8. SUBTASK 72-41-23-230-097 Do a Crack Test

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

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

      3. Use penetrant crack test equipment.

      4. Cracks are not permitted.

    9. SUBTASK 72-41-23-110-097 Chemically Clean

      1. Chemically clean.

      1. Refer to SPM TASK 70-11-03-300-503.

      2. Degrease the dressed area.

    10. SUBTASK 72-41-23-350-125 Heat Treat the Part

    1. Refer to Figure and Figure.

      2. Locally heat treat the repaired areas only.

      1. Refer to SPM TASK 70-31-02-310-501-001, SUBTASK 70-31-02-370-001.

      2. Heat treat locally the area shown to a temperature between 392 and 482 deg F (200 and 250 deg C).

      3. When the part is at the specified temperature, weld the part immediately in accordance with SPM TASK 70-31-02-310-501-001, SUBTASK 70-31-02-370-001.

      4. Use thermal blankets.

    11. SUBTASK 72-41-23-350-126 Weld Build-up the Damaged Area

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

      2. Weld build-up dressed area.

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

      3. Make sure sufficient weld is applied to get back the drawing dimensions.

      4. Use TIG welding equipment.

    3. NOTE

      1. Use copper chills to minimize distortion.

      2. 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 minimise distortion.

    12. SUBTASK 72-41-23-350-127 Heat Treat the Part

      2. Locally heat treat the repaired areas only.

      2. Heat to a temperature of 1130 deg F (610 deg C) for 60 minutes.

      3. Use thermal blankets.

    13. SUBTASK 72-41-23-350-128 Restore the Casing Contour

      2. Restore the casing contour.

      1. Refer to SPM TASK 70-35-03-300-501.

      2. Dress to remove unwanted weld.

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

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

      6. Use applicable hand tools.

    14. SUBTASK 72-41-23-350-129 Machine the Holes

      2. Machine to make the holes again.

      1. Drill, counter bore and chamfer.

    3. Break burrs and remove sharp edges.

    15. SUBTASK 72-41-23-110-098 Chemically Clean

      1. Locally clean the repaired areas.

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

      2. Use chemical cleaning equipment.

    16. SUBTASK 72-41-23-220-200 Examine the HP Compressor Rear Outer Case

      2. Visually and dimensionally examine the repaired area.

      1. Visually and dimensionally examine the repaired and dressed area.

      2. Make sure all unwanted weld materials are removed.

      3. Make sure all surfaces are smooth and agree with the adjacent material.

      4. Make sure all original conditions are restored.

      5. Use workshop inspection equipment.

    17. SUBTASK 72-41-23-230-098 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.

      3. Cracks are not permitted.

    18. SUBTASK 72-41-23-350-130 Identify the Repair

      1. Mark VRS6530/ and the number of repairs adjacent to the part number.

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

      2. Use vibro-engraving equipment.

    19. SUBTASK 72-41-23-350-134 Reapply the Surface Protection

      1. Locally touch-up missing surface protection as necessary including identity marking.

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

    20. SUBTASK 72-41-23-350-131 Replace the Shank Nuts

      1. Replace the inserts as necessary.

      1. Refer to Repair, VRS6279 TASK 72-41-23-300-011 (REPAIR-011).

    21. Figure: Repair Details and Dimensions - Assembly A

    Repair Details and Dimensions - Assembly A

    Figure: Repair Details and Dimensions - Assembly A

    Repair Details and Dimensions - Assembly A

    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 B

    Repair Details and Dimensions - Assembly B

    Figure: Repair Details and Dimensions - Assembly B

    Repair Details and Dimensions - Assembly B

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedure to add PN 6B1427 information and updated figures. (10VR949A)

Manufacturer Code:06565
Enterprise Name:SAINT-GOBAIN ABRASIVES
BU Name:SAINT-GOBAIN ABRASIVES
P.O. Box:808
City:TROY
State:NY
Zip Code:12181
Country:USA
Phone Number:1-518-266-2200
Fax Number:1-518-266-2342
Internet:www.saintgobain.com
Manufacturer Code:IE304
Enterprise Name:DELETED
BU Name:DELETED,SEE CAGE CODE 0V6W9
Manufacturer Code:K6835
Enterprise Name:MED-LAB LTD
BU Name:MED-LAB LTD
Street:COPELAND ST
City:DERBY
Zip Code:DE1 2PU
Country:GREAT BRITAIN
Phone Number:44-1332-349094
Fax Number:44-1332-371237
Email:sales@med-lab.co.uk
Internet:www.med-lab.co.uk
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:K6835
Supply Number:CoMat 05-106
Type:sp01
Supply Short Name:CoMat 05-106 ABRASIVE STONE
Supply Name:CoMat 05-106 ABRASIVE STONE
Specification Groups:
Doc NumberType
(SS-S-736/2/26) (A-A-3068/2-26)SQUARE FINE SS-S-736 TYPE II CLASS A1
Suppliers:
ManufacturerRemarks
K6835
KC1D9
Manufacturer Code:44197
Supply Number:CoMat 05-111
Type:sp01
Supply Short Name:CoMat 05-111 EMERY POLISHING PAPER
Supply Name:CoMat 05-111 EMERY POLISHING PAPER
Specification Groups:
Doc NumberType
FEPA GRIT SIZE P280 OR P240 EMERY POLISHING PAPER OR ALUMINUM OXIDE ABRASIVE PAPER
Suppliers:
ManufacturerRemarks
44197
K6835
KC1D9
LOCAL
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:TIG welding equipment
Tool Name:TIG welding 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