Preliminary Requirements

Procedure

1. Repair Facilities

   1. The source demonstration requirements of this repair means that the facility not authorised to accomplish this repair either utilise the Authorised 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. Authorised Repair Vendors for repair VRS6670 are listed below:

      ROLLS-ROYCE AERO REPAIR AND OVERHAUL

      East Kilbride

      Glasgow

      G74 4PY

      SCOTLAND

      MTU MAINTENANCE ZHUHAI

      1 Tianke Road

      Free Trade Zone

      Zhuhai, Guangdong

      519030

      P.R. CHINA

      MTU MAINTENANCE HANNOVER Gmbh

      Muenchner Str.31

      30855 Langenhagan

      GERMANY

      IHI CORPORATION

      229 Tonogaya Mizuho-Machi

      Nishitama-Gun

      Tokyo 190-12

      JAPAN

      LUFTHANSA TECHNIK AG

      HAM WR 420

      PO Box 63 03 00

      D-22313 Hamburg-Airport

      GERMANY

      PRATT AND WHITNEY COLUMBUS ENGINE CENTER

      8801 Macon Road

      M/S 906-05

      Columbus

      GA31908

      USA

      PRATT AND WHITNEY AIR NEW ZEALAND SERVICES

      PO Box 14005

      634 Memorial Avenue

      Christchurch International Airport

      Christchurch 8053

      NEW ZEALAND

      Rolls-Royce Inchinnan

      Inchinnan Drive

      Inchinnan Business Park

      Inchinnan, PA4 9AF

      Scotland

      Asian Compressor Technology Services Co., Ltd.

      1, Industrial 3rd Rd., Kuanyin Industrial Park, Kuanyin Dist.,

      Taoyuan City

      Taiwan 32853

      MTU Aero Engines AG

      Dachauer Strasse 665

      80995 Muenchen

      Germany

   3. The designation by IAE of an Authorised 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 the work that may be carried out by a Repair Vendor other than when IAE is listed as the Repair Vendor. Authorised Repair Vendors do not act as agents or representatives of IAE.

2. SUBTASK 72-41-31-110-133 Chemically Clean

   1. Chemically clean.

      1. Refer to TASK 72-41-31-100-000 (CLEANING-000).

         Use chemical cleaning equipment.

3. SUBTASK 72-41-31-330-061 Chemically Remove the Abradable Lining

   1. Refer to Figure and Figure.

   2. NOTE

      Step and Step are alternatives to:

      Step and Step or Step and Step.

   3. Chemically remove the abradable lining.

      1. Refer to the SPM TASK 70-33-59-300-503, SUBTASK 70-33-59-300-003.

         Use CoMat 01-041 ALKALINE RUST REMOVER with chemical cleaning equipment.

4. SUBTASK 72-41-31-330-062 Chemically Remove the Bond Coat

   1. Refer to Figure and Figure.

   2. Chemically remove the bond coat.

      1. Refer to the SPM TASK 70-33-59-300-503, SUBTASK 70-33-59-300-002.

         Use CoMat 01-025 NITRIC ACID HNO3, TECHNICAL GRADE with chemical cleaning equipment.

         Put the assembly into the nitric acid and keep below the surface.

         Stripping is complete when gassing stops.

         Remove assembly from the acid immediately after gassing stops.

5. SUBTASK 72-41-31-320-002 Machine the Abradable Lining

   1. Refer to Figure and Figure.

   2. NOTE

      Step and Step are alternatives to either:

      Step and Step or Step and Step.

   3. Assemble the fixture on the machine.

      1. Use a locally manufactured turning fixture with a lathe.

         Set to turn correctly.

         Use a dial test indicator.

   4. Assemble the rotor path ring on to the turning fixture and machine to remove the abradable lining.

      1. Turn to remove the abradable lining.

         You must not remove material from the ring.

6. SUBTASK 72-41-31-320-003 Grind the Remaining Lining Material

   1. Refer to Figure and Figure.

   2. Remove the remaining lining material.

      1. Use an air operated grinder with a rotary burr or applicable alternatives.

         You must not remove material from the ring.

7. SUBTASK 72-41-31-330-064 Remove the Abradable Lining by Ultra High Pressure Water-Jet

   1. Refer to Figure and Figure.

   2. NOTE

      Step and Step are alternatives to either:

      Step and Step or Step and Step.

   3. Install the part in an ultra high pressure water-jet machine fixture.

      1. Use locally manufactured tooling.

   4. Remove the abradable lining.

      1. Refer to the SPM TASK 70-15-01-160-501.

         Use an ultra high pressure water-jet machine.

         Make sure that the abradable lining and old bond coat are removed.

8. SUBTASK 72-41-31-120-065 Abrasive Blast to Remove the Remaining Bond Coat

   1. Refer to Figure and Figure.

   2. Abrasive blast to remove the bond coat that remains.

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

         Use CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADE with abrasive blast equipment.

         Make sure the old bond coat and abradable lining have been removed.

9. SUBTASK 72-41-31-110-134 Cold Ferric Chloride Etch

   1. Refer to Figure and Figure.

   2. Swab etch the repair area(s).

      1. Refer to the SPM TASK 70-11-39-300-503, SUBTASK 70-11-39-300-001.

         Use a polythene bottle.

10. SUBTASK 72-41-31-220-267 Examine the Stage 6 Rotor Path Ring Assembly

    1. Refer to Figure and Figure.

    2. Do a visual and dimensional inspection of the repair area(s).

       1. Use workshop inspection equipment.

11. SUBTASK 72-41-31-230-128 Do a Local Crack Test

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

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

          Use CoMat 06-063 FLUORESCENT PENETRANT (POST-EMULSIFIED MEDIUM SENSITIVITY) with penetrant crack test equipment.

          Cracks are not permitted.

12. SUBTASK 72-41-31-110-135 Clean the Stage 6 Rotor Path Ring

    1. Chemically clean.

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

          Use chemical cleaning equipment.

13. SUBTASK 72-41-31-350-113 Seal the Areas Not to be Sprayed

    1. Refer to Figure, Figure and Figure.

    2. Seal the areas not to be sprayed.

       1. Use CoMat 02-198 ADHESIVE TAPE (MASKING METAL SPRAY) or locally made fixture.

    3. NOTE

       The adhesive tape permits the blasting and the sprayed coating to be done in one operation.

14. SUBTASK 72-41-31-120-066 Abrasive Blast the Areas to be Sprayed

    
    CAUTION
    DO NOT TOUCH THE SURFACE, WHICH IS CLEANED FOR REPAIR. YOU MUST NOT DO THIS TO PREVENT THE CONTAMINATION.
    
    CAUTION
    DO NOT DWELL IN ANY ONE AREA, USE CONTINUOUS MOTION. YOU MUST PREVENT THE EXTENDED DURATION OF ABRASIVE BLASTING. IF YOU DO NOT DO THIS, IT CAN CAUSE DETERIORATION OF THE PREPARED SURFACE CONDITION.

    1. Abrasive blast.

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

          Use CoMat 05-001 ABRASIVE MEDIUM, ALUMINIUM OXIDE, 20/30 GRADE with abrasive blast equipment.

15. SUBTASK 72-41-31-110-136 Clean the Stage 6 Rotor Path Ring

    1. Chemically clean.

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

          Use chemical cleaning equipment.

16. SUBTASK 72-41-31-340-059 Apply the Abradable Lining to the Repaired Part and Test Piece

    1. Refer to Figure and Figure.

    2. Apply the bond coat.

       1. Refer to the SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-025 or SUBTASK 70-34-01-340-010.

          For powder feed plasma spray gun, use CoMat 03-038 METAL SPRAYING POWDER NICKEL ALUMINIUM (95/5), CoMat 03-089 METAL SPRAYING POWDER Ni/Al (95/5) or CoMat 03-090 METAL SPRAYING POWDER Ni/Al (95/5).

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

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

          Use metal spray equipment.

          Apply bond coat to a test piece.

    3. Apply the abradable lining.

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

          Use CoMat 03-457 METAL SPRAY POWDER with metal spray equipment.

          Spray sufficient thickness to let it for machining.

          Also spray a test piece to check the spray hardness.

          Apply abradable lining to a test piece to check the spray hardness.

    4. Remove the masking tape.

17. SUBTASK 72-41-31-220-272 Examine the Stage 6 Rotor Path Lining

    1. Refer to Figure and Figure.

    2. Visually examine the sprayed coating on the ring.

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

    3. Measure the dimensions of the repaired area.

       1. Use workshop inspection equipment.

    4. Test the hardness of the sprayed coating on the test piece.

       1. Refer to the SPM TASK 70-34-01-340-501, SUBTASK 70-34-01-340-004.

          Use hardness testing equipment.

          Average hardness must be 45 to 70 R15Y, outer limits 35 minimum, 80 maximum.

          If the hardness value is outside these limits, reject the assembly and do the repair again.

18. SUBTASK 72-41-31-350-114 Remove the Overspray

    1. Refer to Figure and Figure.

    2. Remove the overspray.

       1. Use standard workshop equipment.

    3. Reform the chamfers.

       1. Use standard workshop equipment.

19. SUBTASK 72-41-31-220-269 Examine the Stage 6 Rotor Path Lining

    1. Refer to Figure and Figure.

    2. Visually examine and measure the dimensions of the sprayed area.

       1. Use workshop inspection equipment.

20. SUBTASK 72-41-31-330-063 Identify the Repair

    1. Refer to Figure.

    2. Make a mark VRS6670 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.

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