TASK 72-41-31-300-005 HPC Stage 3 Rotor Path Segment - Replace The Lining, Repair-005 (VRS6242)

DMC:V2500-A0-72-41-3113-00A-920A-C|Issue No:002.00|Issue Date:2015-08-01

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 72-41-31-300-005 HPC Stage 3 Rotor Path Segment - Replace The Lining, Repair-005 (VRS6242)

Effectivity

FIG/ITEM PART NO.

01-685

6A3758

Material of component

PART IDENT

SYMBOL

MATERIAL

HP compressor Stage 3 Rotor Path Segment

LAH

Aluminum alloy

General

This Repair must only be done when the instruction to do so is given in 72-41-31 Inspection-XXX.

The practices and processes referred to in the procedure by the TASK/SUBTASK numbers are in the SPM.

Price and availability - not required

NOTE

Equivalent equipment can be used.
More equipment and materials necessary to do this Repair are in TASKS given below:
SPM TASK 70-33-59-300-503
SPM TASK 70-12-02-120-501
SPM TASK 70-23-01-230-501
SPM TASK 70-11-01-300-503
SPM TASK 70-34-01-340-501
SPM TASK 70-09-00-400-501

NOTE

To identify the consumable materials, refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
LatheLOCALLathe
Standard workshop toolsLOCALStandard workshop tools
Abrasive blast equipmentLOCALAbrasive blast equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Degreasing equipmentLOCALDegreasing equipment
FixtureLOCALFixture

Locally made

Metal spray equipmentLOCALMetal spray equipment
Hardness testerLOCALHardness tester
Vibrating marking pencilLOCALVibrating marking pencil
IAE 3R18733 Turning fixture0AM53IAE 3R187331

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADELOCALCoMat 01-025
CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADELOCALCoMat 05-001
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001
CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOILK0993CoMat 02-006
CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5)IE200CoMat 03-038
CoMat 03-089 METAL SPRAYING POWDER Ni/Al (95/5)00741CoMat 03-089
CoMat 03-090 METAL SPRAYING POWDER Ni/Al (95/5)0AM53CoMat 03-090
CoMat 03-036 METAL SPRAYING WIRE, Ni,AlLOCALCoMat 03-036
CoMat 03-057 ALUMINIUM ALLOY/POLYESTERCOMPOSITELOCALCoMat 03-057

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-31-325-051 Remove the Abradable Lining

    1. Refer to Figure.

      2. Assemble the fixture on the lathe.

      1. Attach to the lathe and set correctly.

      3. Assemble the segments on the fixture.

      1. Install the clamp plate loosely.

        Set the clamp plate correctly.

        Tighten the clamp nuts.

      4. Machine to remove abradable lining.

      1. Do not remove material of ring segment.

    2. SUBTASK 72-41-31-350-111 Remove the Remaining Lining

      1. Remove the remaining lining.

      1. Use standard workshop tools.

    3. SUBTASK 72-41-31-330-055 Loosen the Bond Coat

      1. Loosen the bond coat.

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

        Put ring segments fully into CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE until bubbles from the gas stops.

    4. SUBTASK 72-41-31-120-055 Remove the Remaining Bond Coat

      1. Remove the bond coat.

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

    5. SUBTASK 72-41-31-220-137 Examine the Stage 3 Rotor Path Ring Segments

    1. Refer to Figure and Figure.

    2. Visually examine and measure the dimensions.

    6. SUBTASK 72-41-31-230-126 Do a Crack Test

      1. Crack test.

      1. Refer to the SPM TASK 70-23-01-230-501.

        Use penetrant crack test equipment.

    7. SUBTASK 72-41-31-110-068 Clean the Stage 3 Rotor Path Ring Segment

      1. Remove the grease.

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

        Use degreasing equipment.

    8. SUBTASK 72-41-31-350-068 Apply Masking Tape to Areas not to be Repaired

      1. Apply masking tape.

      1. Use CoMat 02-001 ADHESIVE TAPE (MASKING) or locally made fixture.

    9. SUBTASK 72-41-31-120-056 Prepare the Areas to be Repaired

    1. Refer to Figure.

      2. CAUTION

        DO NOT TOUCH AREAS TO BE REPAIRED WHEN CLEANED.

        Clean with abrasive.

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

    3. Remove masking tape.

    10. SUBTASK 72-41-31-350-069 Apply Masking Tape to Areas to be Repaired

      1. Apply masking tape.

      1. Use CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL or locally made fixture.

    11. SUBTASK 72-41-31-340-053 Apply the Abradable Lining

    1. Refer to Figure.

      2. Apply the bond coat.

      1. Refer to the SPM TASK 70-34-01-340-501.

        Alternatively for the wire feed combustion spraying, use CoMat 03-036 METAL SPRAYING WIRE, Ni,Al.

        Preheat the seal ring to 221 to 257 deg F (105 to 125 deg C).

        Use the spray gun with the powder feed off.

        Use metal spray facility.

      3. Apply the abradable lining.

      1. Refer to the SPM TASK 70-34-01-340-501.

        Spray a sufficient thickness to allow for machining.

        The machining will be done in the assembly.

        Remove masks when spraying is completed.

      4. Spray Data.

        1. Parameters for Metco 3MB powder feed plasma spray gun.

        1. Bond coat.

          Gun . . . . .

          Metco 3MB

          Cathode . . . .

          3M11A

          Nozzle . . . .

          3M7AGH

          Distribution ring . .

          3A275A

          Powder port . . .

          No.2

          Primary gas flow tube .

          2M164

          Secondary gas flow tube .

          2M166

          Gases:

          Arc primary . . .

          Argon

          Pressure . . . .

          100 PSI

          Arc secondary . . .

          Hydrogen

          Pressure . . . .

          50 PSI

          Operating conditions:

          Gas flow Metco flow meter

          setting:

          Primary . . . .

          80

          Secondary . . .

          15

          Power settings:

          Current . . . .

          500 amps

          Powder control:

          Carrier gas flow meter

          setting . . . .

          37

          Powder feed rate . .

          67 to 69 gms/min

          Spray distance . .

          4 to 7 ins

          Deposition per pass .

          0.0001 ins

          Spray thickness . .

          0.003 to 0.005 ins

        2. Abradable coat.

          Gun . . . . .

          Metco 3MB

          Cathode . . . .

          3M11A

          Nozzle . . . .

          3M7AGP

          Distribution ring . .

          3A275A

          Powder port . . .

          No.1

          Primary gas flow tube .

          2M164

          Secondary gas flow tube .

          2M164

          Gases:

          Arc primary . . .

          Argon

          Pressure . . . .

          100 PSI

          Arc secondary . . .

          Hydrogen

          Pressure . . . .

          50 PSI

          Operating conditions:

          Gas flow Metco flow meter

          setting:

          Primary . . . .

          180 to 190

          Secondary . . .

          5

          Power settings:

          Current

          500 amps

          Powder control:

          Carrier gas flow meter

          setting . . . .

          50

          Powder feed rate . .

          23 to 27 gms/min

          Spray distance . .

          2 to 3.5 ins

          Deposition per pass .

          0.003 ins

          Spray thickness . .

          See illustrations

        2. Parameters for plasma technik F4 plasma burner.

        1. Bond coat.

          Gun . . . . .

          Plasma Technik

          F4

          Nozzle dia . . .

          6 mm

          Power injection dia .

          1.8 mm

          Injector angle . .

          90 deg

          Powder gauge . . .

          6 mm

          Arc primary gas . .

          Argon

          Flow rate litres/min .

          55

          Arc secondary gas . .

          Hydrogen

          Wire diameter . . .

          0.125 ins

          Deposition per pass .

          0.001 ins

          Spray thickness . .

          0.004 to 0.007 ins

    12. SUBTASK 72-41-31-220-138 Examine the Lining

    1. Refer to Figure.

      2. Visually examine the lining.

      1. Refer to the SPM TASK 70-34-01-340-501.

      3. Measure the depth of lining.

      1. Make sure lining thickness is sufficient.

      4. Do a hardness test of lining on the test piece.

      1. The hardness value must be between 55 and 85 R15Y.

        Outer limits are 50 minimum and 90 maximum.

        Use Rockwell Hardness Tester.

    13. SUBTASK 72-41-31-350-070 Dress the Repaired Area

      1. Remove unwanted material.

      1. Use standard workshop tools.

      2. Put back the chamfers again.

      1. Use standard workshop tools.

    14. SUBTASK 72-41-31-325-052 Machine the Abradable Lining

      NOTE

      Final machining of the abradable lining in this SUBTASK is optional to the final machining of the lining in the forward case in TASK 72-41-30-440-002-A00, SUBTASK 72-41-30-324-052-A00.

    1. Refer to Figure.

      2. Assemble the fixture on the lathe.

      1. Attach to the lathe and set correctly.

      3. Assemble the segments on the fixture.

      1. Install the clamp plate loosely.

        Set the clamp plate correctly.

        Tighten the clamp nuts.

    4. Machine the lining to dimensions shown.

      5. Remove sharp corners.

      1. Use standard workshop tools.

    15. SUBTASK 72-41-31-220-139 Examine the Stage 3 Rotor Path Ring Segments

    1. Refer to Figure and Figure.

      2. Visually examine and measure the dimensions.

      1. Refer to the SPM TASK 70-34-01-340-501.

    16. SUBTASK 72-41-31-350-071 Identify the Repair

    1. Refer to Figure.

      2. Vibro-engrave VRS6242 adjacent to the part number.

      1. Refer to the SPM TASK 70-09-00-400-501.

        SUBTASK 70-09-00-400-001.

        Use vibro-engraving equipment.

    17. Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

    Figure: Repair details and dimensions

    Repair details and dimensions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised note to remove "materials or". (PSAF 15VC314)

Manufacturer Code:00741
Enterprise Name:Was BOC GASES
BU Name:DELETED, REFER TO SUPPLIER CODE 46AN7
Manufacturer Code:0AM53
Enterprise Name:IAE INTERNATIONAL AERO ENGINES AG
BU Name:NULL
Building:SUITE 400
Street:628 HEBRON AVENUE
City:GLASTONBURY
State:CT
Zip Code:06033
Country:USA
Manufacturer Code:IE200
Enterprise Name:DELETED, REFER TO CAGE CODE 00BB6
Manufacturer Code:K0993
Enterprise Name:3M (UK) PLC
BU Name:3M (UK) PLC
Street:3M CENTRE, CAIN ROAD
City:BRACKNELL
Zip Code:RG12 8HT
Country:UNITED KINGDOM
Phone Number:44-161-236-8500
Fax Number:44-161-237-6136
Internet:www.mmm.co.uk
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:5FCA4
Supply Number:CoMat 01-025
Type:sp01
Supply Short Name:CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE
Supply Name:CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE
Specification Groups:
Doc NumberType
orTECHNICAL GRADE SP.GR. 1.42 NITRIC ACID
orTECHNICAL GRADE 42 BAUME NITRIC ACID
TECHNICAL GRADE 67.5 WT% NITRIC ACID
Suppliers:
ManufacturerRemarks
5FCA4
K6835
LOCAL
U0PR4
U0SV8
U6726
V272V
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:K6835
Supply Number:CoMat 02-006
Type:sp01
Supply Short Name:CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL
Supply Name:CoMat 02-006 ADHESIVE TAPE ALUMINIUM FOIL
Specification Groups:
Doc NumberType
OMAT: 298 (RR REF)SCOTCH 425
Suppliers:
ManufacturerRemarks
K6835
52152
76381
LOCAL
Manufacturer Code:LOCAL
Supply Number:CoMat 03-036
Type:sp01
Supply Short Name:CoMat 03-036 METAL SPRAYING WIRE, Ni, Al
Supply Name:CoMat 03-036 METAL SPRAYING WIRE, Ni,Al
Specification Groups:
Doc NumberType
MSRR 9507/101METCO 405 NS
OMAT:3/90MIL-W-6712 NI80
JCR-019
Suppliers:
ManufacturerRemarks
LOCAL
IE103
IE195
IE200
K1030
K6835
39918
Manufacturer Code:00BB6
Supply Number:CoMat 03-038
Type:sp01
Supply Short Name:CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5)
Supply Name:CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5)
Specification Groups:
Doc NumberType
OMAT: 3/188 (RR REF)METCO 450NS
JCR-020 (JAEC REF)
Suppliers:
ManufacturerRemarks
00BB6
01FK3
0Y7E4
C1840
IE103
K0455
K6835
Manufacturer Code:LOCAL
Supply Number:CoMat 03-057
Type:sp01
Supply Short Name:CoMat 03-057 ALUMINIUM ALLOY/POLYESTERCOMPOSITE
Supply Name:CoMat 03-057 ALUMINIUM ALLOY/POLYESTERCOMPOSITE
Specification Groups:
Doc NumberType
MSRR9507/15METCO 601NS
OMAT:3/143MIL-P-85856/22
JCR-022MIL-P-85856/22
Suppliers:
ManufacturerRemarks
LOCAL
39918
IE103
IE195
IE200
K1030
K6835
Manufacturer Code:33870
Supply Number:CoMat 03-089
Type:sp01
Supply Short Name:CoMat 03-089 METAL SPRAYING POWDER Ni/Al (95/5)
Supply Name:CoMat 03-089 METAL SPRAYING POWDER Ni/Al (95/5)
Specification Groups:
Doc NumberType
PWA 1337 (PW REF)NI-109 or NI-970 or AI 1037
Suppliers:
ManufacturerRemarks
33870
Manufacturer Code:X111X
Supply Number:CoMat 03-090
Type:sp01
Supply Short Name:CoMat 03-090 METAL SPRAYING POWDER Ni/Al(95/5)
Supply Name:CoMat 03-090 METAL SPRAYING POWDER Ni/Al (95/5)
Specification Groups:
Doc NumberType
DELETED Use CoMat 03-089
Suppliers:
ManufacturerRemarks
X111X
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
Link not Found
Manufacturer Code:LOCAL
Tool Number:Degreasing equipment
Tool Name:Degreasing equipment
Manufacturer Code:LOCAL
Tool Number:Fixture
Tool Name:Fixture
Link not Found
Manufacturer Code:0AM53
Tool Number:IAE 3R18733
Tool Name:IAE 3R18733 Turning fixture
Manufacturer Code:LOCAL
Tool Number:Lathe
Tool Name:Lathe
Manufacturer Code:LOCAL
Tool Number:Metal spray equipment
Tool Name:Metal spray 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
Link not Found