TASK 72-41-32-300-011 HPC Stage 6 Variable Stator Vane - Weld Repair The Airfoil By Weld, Repair-011 (VRS6059)

DMC:V2500-A0-72-41-3206-00A-627A-C|Issue No:001.00|Issue Date:2013-11-01

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 72-41-32-300-011 HPC Stage 6 Variable Stator Vane - Weld Repair The Airfoil By Weld, Repair-011 (VRS6059)

Effectivity

FIG/ITEM

PART NO.

Assembly

05-500

6A3699

A

05-500

6A3763

B

05-600

6A3752

C

05-600

6A3764

D

General

This repair must only be done when the instruction to do so is given in TASK 72-41-32Inspection/Check.

This repair restores the H.P compressor stage 6, variable stator vane tip length by welding.

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

This is a Source Demonstration Repair which can only be done by approved vendors.

Sermatech Repair Services Ltd. are approved for assembly B and Assembly D Part numbers only.

IHI Heavy Industries Co. Ltd. are approved for Assembly B and Assembly D Part Numbers only.

Airfoil Services Sdn Bhd are approved for Assembly B and Assembly D Part Numbers only.

To keep the H.P compressor efficiency, the stage 6 variable stator vane is repaired as near to the new vane condition as possible.

Variable stator vanes must be repaired as soon as damage or wear is monitored, to get back H.P compressor efficiency and extend the stage 6 variable stator vane life.

This repair can be done again to the welded stage 6 variable stator vane if:

- The minimum airfoil dimensions are as given in TASK 72-41-32 Inspection/Check.

- The airfoil surface has been polished up to two times, refer to VRS6044, TASK 72-41-32-300-018.

DESCRIPTION SYMBOL MATERIAL

H.P Compressor - Stage 6

EAX

Creep resisting -

variable stator vane

Ferritic steel -

Assembly A and Assembly C

Vacuum melted

or

Assembly B and Assembly D

QMP

52 percent Nickel

19 percent Chromium

18 percent Iron and

5 percent Niobium

Price and Availability

Refer to International Aero Engines

Related Repairs

H.P compressor stage 6 variable stator vane - Restore airfoil surface finish. Refer to repair VRS6044, TASK 72-41-32-300-018 (REPAIR-018).

Repair Facilities

The Source Demonstration requirements of this repair means that any facility not authorized to accomplish this repair either, utilize the Authorized 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 
C/O Rolls-Royce Plc.
P.O. Box 31
Derby De 24 8BJ
England
Attn: Manager technical Services

Authorized Repair Vendors for Repair VRS6059 are listed below:

Chromalloy Dallas
14042 Distribution Way,
Dallas,
Texas 75234
U.S.A.

MTU Maintenance GmbH
Flughafen Hannover,
Muncher Strasse 31,
30855 Langenhagen
GERMANY

Rolls-Royce Aero-Engine Services Ltd
Component Refurbishment,
Mavor Avenue,
Nerston,
East Kilbride,
Glasgow, G74 4PY
SCOTLAND

Airfoil Technologies International (ATI)
High Holborn Road
Codnor
Ripley
Debyshire DE5 3NW
ENGLAND

Ishikawajima-Harima Heavy Industries Co. Ltd.
229 Tonogaya, Mizuho-Machi
Nishitama-Gun
Tokyo 190-1297
JAPAN

Airfoil Services Sdn Bhd (ASSB)
No.12 Jalan Teknologi
Taman Sains Selangor 1
Kota Damansara PJU5
47810 Petailing Jaya
Selangor Darul Ehsan
MALAYSIA

The designation by IAE of an Authorized 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 of the Repair Vendors to carry out the repair work, and accepts no responsibility whatsoever for any work that may be carried out by a Repair Vendor other than when IAE is listed as the Repair Vendor. Authorized Repair Vendors do not act as agents or representatives of IAE.

NOTE

More equipment and materials necessary to do this repair are in the SPM TASKS given below:
SPM TASK 70-09-00-400-501
SPM TASK 70-11-01-300-503
SPM TASK 70-12-01-120-501
SPM TASK 70-23-04-230-501
SPM TASK 70-31-02-310-501-001

NOTE

To identify the consumable materials refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Chemical cleaning equipmentLOCALChemical cleaning equipment
Penetrant Crack Test EquipmentLOCALPenetrant crack test equipment
Abrasive blast equipmentLOCALAbrasive blast equipment
Welding equipmentLOCALWelding equipment

Argonarc

Heat treatment equipmentLOCALHeat treatment equipment
Hardness testerLOCALHardness tester
Grinding machineLOCALGrinding machine
Hand toolsLOCALTools, hand
Radiographic equipmentLOCALRadiographic equipment
Vibrating marking pencilLOCALVibrating marking pencil

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001
CoMat 03-181 WELDING WIRE 12% Cr. STEELLOCALCoMat 03-181
CoMat 03-284 WELDING FILLER WIRE, NiBASELOCALCoMat 03-284
CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADELOCALCoMat 05-003

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-41-32-110-064 Clean the Stage 6 Variable Stator Vanes

      1. Chemically clean the vanes.

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

        Use chemical cleaning equipment.

    2. SUBTASK 72-41-32-220-114-001 Examine the Stage 6 Variable Stator Vanes

      NOTE

      This SUBTASK only applies to Assembly A and Assembly B.

      2. Examine the vanes to make sure the vanes can be repaired.

      1. Refer to TASK 72-41-32-200-000 (INSPECTION/CHECK-000) for Inspection Standards.

        The vanes must be easily identified to allow dimensions before and after repair to be checked.

        Record the vane length.

    3. SUBTASK 72-41-32-220-114-002 Examine the Stage 6 Variable Stator Vanes

    1. NOTE

      This SUBTASK only applies to Assembly C and Assembly D.

      2. Examine the vanes to make sure the vanes can be repaired.

      1. Refer to TASK 72-41-32-200-000 (INSPECTION/CHECK-000) for inspection standards.

        The vanes must be easily identified to allows dimensions before and after repair to be checked.

        Record the vane length.

    4. SUBTASK 72-41-32-230-062 Do a Crack Test

      1. Do a penetrant crack test.

      1. Refer to the SPM TASK 70-23-04-230-501.

        Use penetrant crack test equipment.

        Discard any cracked vanes.

    5. SUBTASK 72-41-32-120-051-001 Vapour Blast the Stage 6 Variable Stator Vanes

    1. NOTE

      This SUBTASK only applies to Assembly A and Assembly B.

      2. Mask areas of the vane, not to be welded.

      3. Vapour blast areas of the vane to be welded.

      1. Refer to the SPM TASK 70-12-01-120-501.

    4. Remove the masking tape.

    6. SUBTASK 72-41-32-120-051-002 Vapour Blast the Stage 6 variable Stator Vanes

    1. NOTE

      This SUBTASK only applies to Assembly C and Assembly D.

      2. Mask areas of vane not to be welded.

      3. Vapour blast areas of vane to be welded.

      1. Refer to the SPM TASK 70-12-01-120-501.

    4. Remove the masking tape.

    7. SUBTASK 72-41-32-110-065 Clean the Stage 6 Variable Stator Vanes

      1. Chemically clean the vanes.

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

        Use chemical cleaning equipment.

    8. SUBTASK 72-41-32-310-051-001 Weld the Stage 6 Variable Stator Vane Tip

      NOTE

      This SUBTASK only applies to Assembly A.

      2. Build up the vane tip with weld to restore the length.

      1. Refer to the SPM TASK 70-31-02-310-501-001.

        Use CoMat 03-181 WELDING WIRE 12% Cr. STEEL, with argonarc welding equipment.

      3. Weld Data.

      1. Refer to approved vendor in 4. Repair Facilities, Para. B, for weld parameters.

      4. Apply sufficient weld to get the necessary vane length.

      1. Identify a sample stage 6 variable stator vane and repair along with each repair batch.

        NOTE

        An increase in vane length of up to a maximum of 0.060in. (1.52 mm) is permitted by this Repair.

    9. SUBTASK 72-41-32-310-051-002 Weld the Stage 6 Variable Stator Vane Tip

      NOTE

      This SUBTASK only applies to Assembly B.

      2. Build up the vane tip with weld to restore the length.

      1. Use CoMat 03-284 WELDING FILLER WIRE, NiBASE, with argonarc welding equipment.

      3. Weld Data.

      1. Refer to approved vendor in 4. Repair Facilities, Para. B, for weld parameters.

      4. Apply sufficient weld to get the necessary vane length.

      1. Identify a sample stage 6 variable stator vane and repair along with each repair batch.

        NOTE

        An increase in vane length of up to a maximum of 0.060in. (1.52 mm) is permitted by this Repair.

    10. SUBTASK 72-41-32-310-051-003 Weld the Stage 6 variable Stator Vane Tip

    1. NOTE

      This SUBTASK only applies to Assembly C.

      2. Build up the vane tip with weld to restore the length.

      1. Refer to the SPM TASK 70-31-02-310-501-001.

        Use CoMat 03-181 WELDING WIRE 12% Cr. STEEL, with argonarc welding equipment.

      3. Weld Data.

      1. Refer to approved vendor in 4. Repair Facilities, Para. B, for weld parameters.

      4. Apply sufficient weld to get necessary vane length.

      1. Identify a sample stage 6 variable stator vane and repair along with each batch.

        NOTE

        An increase in vane length of up to a maximum of 0.060in. (1.52 mm) is permitted by this Repair.

    11. SUBTASK 72-41-32-310-051-004 Weld the Stage 6 variable Stator Vane Tip

    1. NOTE

      This SUBTASK only applies to Assembly D.

      2. Build up the vane tip with weld to restore the length.

      1. Refer to the SPM TASK 70-31-02-310-501-001.

        Use CoMat 03-284 WELDING FILLER WIRE, NiBASE, with argonarc welding equipment.

      3. Weld Data.

      1. Refer to approved vendor in 4. Repair Facilities, Para. B, for weld parameters.

      4. Apply sufficient weld to get necessary vane length.

      1. Identify a sample stage 6 variable stator vane and repair along with each batch.

        NOTE

        An increase in vane length of up to a maximum of 0.060in. (1.52 mm) is permitted by this Repair.

    12. SUBTASK 72-41-32-370-051-001 Heat-Treat the Stage 6 Variable Stator Vanes

      NOTE

      This SUBTASK only applies to Assembly A and Assembly C.

      1. Heat-treat the vanes in a vacuum or controlled atmosphere.

      1. Refer to the SPM TASK 70-31-02-310-501-001.

        Use heat treatment equipment.

      2. Heat-treat Data.

      1. Heat to a temperature of 1121 to 1139 deg F (605 to 615 deg C), and hold for 2 hours.

        Gas fan cool to 212 deg F (100 deg C) in argon.

        Air cool to room temperature.

    13. SUBTASK 72-41-32-370-051-002 Heat-Treat the Stage 6 Variable Stator Vanes

      NOTE

      This SUBTASK only applies to Assembly B and Assembly D.

      1. Heat-treat the vanes in a vacuum or controlled atmosphere.

      1. Refer to the SPM TASK 70-31-02-310-501-001.

        Use heat treatment equipment.

      2. Heat-treat Data.

      1. Heat to 1400 deg F (760 deg C) and hold for 2 hours.

        Furnace cool at a rate of 100 deg F (56 deg C) per hour to 1150 deg F (621 deg C) and hold for 4 hours.

        Cool to room temperature.

    14. SUBTASK 72-41-32-220-115-001 Do a Hardness Check

      NOTE

      This SUBTASK only applies to Assembly A and Assembly C.

      1. Do a hardness check on a longitudinal cross section of a sample vane.

      1. Refer to approved vendor in 4.

        Repair Facilities, Para. B.

        Do a hardness check across the weld material, heat affected zone and base material.

        The hardness value of the parent metal is 334 to 366 HV.

        The minimum hardness value of the weld area is 300 HV.

        The maximum variation from the parent metal is 30 HV.

        Use a hardness tester.

        NOTE

        If the hardness value is below 300 HV minimum, then additional sample vanes should be selected for metallurgical examination.

    15. SUBTASK 72-41-32-220-115-002 Do a Hardness Check

      NOTE

      This SUBTASK only applies to Assembly B and Assembly D.

      1. Do a hardness check on a longitudinal cross section of a sample vane.

      1. Refer to approved vendor in 4.

        Repair Facilities, Para. B.

        Do a hardness check across the weld material, heat affected zone and base material.

        The minimum hardness value should be 361 HV.

        Use a hardness tester.

        NOTE

        If the hardness value is below 361 HV minimum, then additional sample vanes should be selected for metallurgical examination.

    16. SUBTASK 72-41-32-350-068-001 Put the Shape Back on the Stage 6 Variable Stator Vane Contour and Height

      NOTE

      This SUBTASK only applies to Assembly A and Assembly B.

      2. Put the shape back on the vane contour.

      1. Refer to approved vendor in 4.

        Repair Facilities, Para. B., for special machines to make the vane contour.

        Hand methods are permitted to put the shape back on the vane contour.

      3. Grind the vane tip to the correct height.

      1. Use a grinding machine.

      4. Dress the vane tip to remove burrs.

      1. Use hand tools.

    17. SUBTASK 72-41-32-350-068-002 Put the Shape Back on the Stage 6 Variable Stator Vane Contour and Height

      NOTE

      This SUBTASK only applies to Assembly C and Assembly D.

      2. Put the shape back on the vane contour.

      1. Refer to approved vendor in 4.

        Repair Facilities, Para. B., for special machines to make the vane contour.

        Hand methods are permitted to put the shape back on the vane contour.

      3. Grind the vane tip to the correct height.

      1. Use a grinding machine.

      4. Dress the vane tip to remove burrs.

      1. Use hand tools.

    18. SUBTASK 72-41-32-220-116-001 Examine the Stage 6 Variable Stator Vanes

      NOTE

      This SUBTASK only applies to Assembly A and Assembly B.

      2. Visually examine the airfoil surface.

      1. Scratches or scores on the airfoil surface are not permitted.

    3. If scratches or scores are shown on the airfoil surface, do Step.

      4. Visually examine the vane contour.

      5. Dimensionally examine the vane height.

      1. Compare before and after repair dimensions, refer to SUBTASK 72-41-32-220-114.

        Welded material must be contained within given limits.

    19. SUBTASK 72-41-32-220-116-002 Examine the Stage 6 Variable Stator Vanes

      NOTE

      This SUBTASK only applies to Assembly C and Assembly D.

      2. Visually examine the airfoil surface.

      1. Scratches or scores on the airfoil surface are not permitted.

    3. If scratches or scores are shown on the airfoil surface, do Step.

      4. Visually examine the vane contour.

      5. Dimensionally examine the vane height.

      1. Compare before and after repair dimensions, refer to SUBTASK 72-41-32-220-114.

        Welded material must be contained within given limits.

    20. SUBTASK 72-41-32-350-069 Polish the Stage 6 Variable Stator Vane Airfoil Surface and Contour

    1. Refer to Figure and Figure.

      2. Polish the vane airfoil surface and contour.

      1. Refer to approved vendor in 4.

        Repair Facilities, Para. B., for special machines to make the vane contour.

        Hand methods are permitted to polish the vane contour.

    21. SUBTASK 72-41-32-110-103 Cold ferric Chloride Etch

      1. Swab etch the repaired area.

      1. Refer to the SPM TASK 70-23-04-230-501.

        Use penetrant crack test equipment.

        Discard any cracked vanes.

    22. SUBTASK 72-41-32-230-063 Do a Crack Test

      1. Do a penetrant crack test.

      1. Refer to the SPM TASK 70-23-04-230-501.

        Use penetrant crack test equipment.

        Discard any cracked vanes.

    23. SUBTASK 72-41-32-260-052 Radiographically Examine the Stage 6 Variable Stator Vanes

      1. Radiographically examine the welded vane tip.

      1. Cracks or unwanted material are not permitted.

        Pores larger than 0.006in. (0.15 mm) diameter are not permitted.

        Pores with a distance of less than 0.200in. (5.10 mm) between them, are not permitted.

        Surfaces broken by pores are not permitted.

        Pores are not permitted less than 0.040in. (1.00 mm) from the leading and trailing edges.

        Use radiographic equipment.

      2. Radiographic Data.

      1. Refer to approved vendor in 4. Repair Facilities, Para. B., for the appropriate data card, and Radiographic Examination parameters.

    24. SUBTASK 72-41-32-380-056 Restore the Airfoil Surface Finish

      1. Restore the airfoil surface finish.

      1. Refer to VRS6044, TASK 72-41-32-300-018 (REPAIR-018).

    25. SUBTASK 72-41-32-350-070 Identify the Repair

      CAUTION

      DO NOT VIBRO-ENGRAVE ON THE VANE AIRFOIL OR LOCATION FACES.

    1. Refer to Figure.

      2. Mark a code symbol adjacent to the assembly number.

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

        Use vibro-engraving equipment.

    26. 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 - Assembly A and Assembly B

    Repair details and dimensions - Assembly A and Assembly B

    Figure: Repair details and dimensions - Assembly C and Assembly D

    Repair details and dimensions - Assembly C and Assembly D

    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

    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
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
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: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:LOCAL
Supply Number:CoMat 03-284
Type:sp01
Supply Short Name:CoMat 03-284 WELDING FILLER WIRE, Ni BASE
Supply Name:CoMat 03-284 WELDING FILLER WIRE, NiBASE
Specification Groups:
Doc NumberType
INCONEL 718 AMS 5832 AWS 5.14 MSRR9500/220
INCONEL 718 AMS 5832 AWS 5.14CLASS ER NI FE Cr-2 OMAT:3/206
INCONEL 718 AMS 5832 AWS 5.14CLASS ER NI FE Cr-2
Suppliers:
ManufacturerRemarks
LOCAL
28553
IE137
08489
IE508
0ZDB5
2R602
55596
58401
80357
K6835
Manufacturer Code:X222X
Supply Number:CoMat 05-003
Type:sp01
Supply Short Name:CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE
Supply Name:CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE
Specification Groups:
Doc NumberType
Use one of the CoMat 05-003 letter suffix alternatives.
Suppliers:
ManufacturerRemarks
X222X
Link not Found
Manufacturer Code:LOCAL
Tool Number:Chemical cleaning equipment
Tool Name:Chemical cleaning equipment
Link not Found
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Penetrant crack test equipment
Tool Name:Penetrant Crack Test Equipment
Link not Found
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:Welding equipment
Tool Name:Welding equipment