TASK 72-41-31-300-028 HPC Front Cases - Stage 6 Rotor Path Ring Slots And Forward Location Face, Metal Spray, Repair-028 (VRS6634)

DMC:V2500-A0-72-41-3101-01A-609A-C|Issue No:007.00|Issue Date:2020-02-01

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 72-41-31-300-028 HPC Front Cases - Stage 6 Rotor Path Ring Slots And Forward Location Face, Metal Spray, Repair-028 (VRS6634)

Effectivity

FIG/ITEM

PART NO.

ASSEMBLY

01-400

6A3462

A

01-400

6A3675

A

01-400

6A5470

A

01-400

6A4439

B

Material of component

PART IDENT

MATERIAL

HP Compressor Front Case

Titanium Alloy

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 72-41-31.

The maximum slot width before repair must not be more than 0.165 in. (4.191 mm). The maximum depth of damage on the forward location face before repair must not be more than 0.050 in. (1.27 mm).

Preliminary Requirements

Pre-Conditions

Action/ConditionData Module/Technical Publication
Make sure that all the cleaning and inspection procedures are done before this repair.

Support Equipment

NONE

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
DELETEDX111XDELETED
CoMat 03-248 METAL SPRAY POWDERLOCALCoMat 03-248
CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADELOCALCoMat 05-001

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-31-220-240 Examine the HP Compressor Front Case Assembly

      1. Examine the HP Compressor - Front Case Assembly to see if VRS6634 has been carried out before.

        1. If yes, refer to Step.

        1. If no, refer to Step.

    2. SUBTASK 72-41-31-110-114 Remove the Metal Spray from the HP Compressor Front Case Stage 6 Rotor Path Ring Slots and Forward Location Face

      2. Remove the metal spray from the HP compressor front case stage 6 rotor path ring slots and forward location face only.

      1. Refer to SPM TASK 70-33-59-300-503.

      2. Make sure that all metal spray has been removed from the slots and forward location face. It is possible that metal spray exists on other locations of the front case. Make sure all other metal spray locations are sufficiently masked.

    3. SUBTASK 72-41-31-350-097 Remove Damaged Area(s) from the HP Compressor Front Case Stage 6 Rotor Path Ring Slots and Forward Location Face by Blending

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

      2. Blend to remove damage.

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

      2. Blend damage to depth, remove no more material than is necessary to make sure a smooth surface.

        NOTE

        The maximum amount of material removal permitted from the forward location face is 0.050 in. (1.27 mm).

    4. SUBTASK 72-41-31-350-001 Remove Damaged Area(s) from the HP Compressor Front Case Stage 6 Rotor Path Ring Slots and/or Forward Location Face

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

      2. Machine the rotor path ring slots to remove damage.

      1. Use a locally made fixture.

      2. Remove no more material than is necessary to remove the damage.

      3. The maximum slot width after machining must not be more than 0.165 in. (4.191 mm).

      3. Machine the rotor path ring slot forward location face to remove damage.

      1. Use a locally made fixture.

      2. Remove no more material than is necessary to remove the damage.

      3. The maximum amount of material removal permitted is 0.050 in. (1.27 mm).

      4. Visually and dimensionally examine the area(s) of material removal.

      1. Make sure all traces of damage are removed.

      2. Ensure the maximum material removal limits are not exceeded.

    5. SUBTASK 72-41-31-220-001 Examine the HP Compressor Front Case Stage 5 VSV Borescope Hole

      2. Visually examine.

      1. Visually examine the wall section between the borescope hole and forward location face of the stage 6 ring slot.

      2. If cracked or broken thru, remove the damage.

      3. Use 10X magnification.

    6. SUBTASK 72-41-31-350-002 Remove Damaged Area from the HP Compressor Front Case Borescope Hole

      NOTE

      This SUBTASK is only necessary if the borescope hole was repaired in Step.

      2. Blend to remove damage from the borescope hole.

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

      2. Blend the damaged wall section of the borescope hole, remove no more material than is necessary to remove the damage.

      3. Blend the area to make sure that all sharp edges and burrs are removed.

    7. SUBTASK 72-41-31-110-132 Do a Swab Etch

      1. Chemically clean the area(s) of material removal.

      1. Refer to SPM TASK 70-11-08-300-503, SUBTASK 70-11-08-300-001.

      2. Swab etch the area(s) of material removal.

      1. Refer to SPM TASK 70-11-08-300-503, SUBTASK 70-11-08-300-002.

    8. SUBTASK 72-41-31-230-111 Do a Crack Test

      1. Do a local penetrant crack test on the area(s) of material removal using medium sensitivity penetrant.

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

      2. Cracks are not permitted.

    9. SUBTASK 72-41-31-120-064 Abrasive Blast the Surface to be Repaired

    1. CAUTION

      TO PREVENT CONTAMINATION, DO NOT TOUCH THE SURFACE WHICH IS CLEANED FOR REPAIR.

      CAUTION

      TOO MUCH ABRASIVE BLAST CAN CAUSE DETERIORATION OF THE PREPARED SURFACE CONDITION AND MUST BE PREVENTED.

      2. Abrasive blast the surface to be repaired. Abrasive blast out of repair area is not permitted. Use Mask.

      1. Refer to SPM TASK 70-12-02-120-501.

    10. SUBTASK 72-41-31-340-058 Metal Spray the HP Compressor Front Case Stage 6 Rotor Path Ring Slots and Forward Location Face

      2. Apply metal spray.

      1. Refer to SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-021.

        3. Apply sufficient metal spray to get the final machining dimensions.

        1. You must apply the metal spray at an angle as close to 45 degrees as possible to get maximum coverage.

        2. A secondary spray at an angle of between 45 and 30 degrees is permissible to get full coverage.

      3. After metal spray is applied and the part is cooled, remove the masking and any tape residue.

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

      2. The borescope hole masking must stay until the final machining is complete.

    11. SUBTASK 72-41-31-320-001 Machine the HP Compressor Front Case Stage 6 Rotor Path Ring Slots and Forward Location Face

    2. Install the front case on to the locally made fixture.

    3. Machine front case stage 6 rotor path ring slots and forward location face.

    4. Remove any remaining masking.

      5. Remove burrs.

      1. Chipping or detachment of the metal spray is not permitted.

    12. SUBTASK 72-41-31-350-003 Remove Metal Spray from the HP Compressor Front Case Borescope Hole Area

      NOTE

      This SUBTASK is only necessary if the borescope hole was repaired in Step.

      2. Blend to remove the metal spray.

      1. If there is metal spray wall section between the borescope hole and the forward location face, remove it.

      2. Make sure that the metal spray is blended back smoothly.

      3. Remove burrs and sharp edges.

      3. Visually examine the borescope hole.

      1. Make sure that you do not see metal spray in the borescope hole.

    13. SUBTASK 72-41-31-110-116 Clean the HP Compressor Front Case

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

    14. SUBTASK 72-41-31-220-241 Examine the HP Compressor Front Case

      2. Visually examine.

      1. Chipping or detachment of metal spray is not permitted. You must remove the metal spray and do the repair again.

      3. Measure the dimensions of the stage 6 forward location face.

      1. Measure the dimensions to make sure they are in the limits given.

      2. If you do not get the given dimensions, you must remove the metal spray and do the repair again.

      4. Measure the dimensions of the stage 6 rotor path ring slots.

      1. Measure the dimensions to make sure they are in the given limits.

        NOTE

        It is possible that localized areas exist where the slot width more than the final machining dimensions given. This is permitted to a maximum of 0.007 in. (0.18 mm) above a localized arc of not more than 3.00 in. (76.20 mm) at not more than three locations in each half casing.

    15. SUBTASK 72-41-31-350-099 Identify the Repair

      1. Vibration peen VRS6634 adjacent to the part number.

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

    16. 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 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

    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:

Reinstate surface preperation (REA19VC573)

Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X111X
Enterprise Name:N/A – DELETED CONSUMABLE MATERIAL
Manufacturer Code:LOCAL
Supply Number:CoMat 03-248
Type:sp01
Supply Short Name:CoMat 03-248 METAL SPRAY POWDER
Supply Name:CoMat 03-248 METAL SPRAY POWDER
Specification Groups:
Doc NumberType
MSRR9507/35METCO 447 NS
OMAT:3/179MIL-P-85856/27
Suppliers:
ManufacturerRemarks
LOCAL
39918
K1030
K6835
IE103
IE195
IE200
Manufacturer Code:LOCAL
Supply Number:CoMat 05-001
Type:sp01
Supply Short Name:CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADE
Supply Name:CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADE
Specification Groups:
Doc NumberType
Use one of the CoMat 05-001 letter suffix alternatives.
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:LOCAL
Supply Number:DELETED
Type:sp01
Supply Short Name:DELETED
Supply Name:DELETED
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
LOCAL