Preliminary Requirements

Procedure

1. SUBTASK 72-42-61-350-055 Remove the Detail Parts from the Combustion Chamber Outer Liner

   1. Remove the liner segments, the combustion chamber retaining bolt bushings, the access cover, the fuel nozzle guides and the bulkhead segments.

      1. Refer to Repair, VRS3092 TASK 72-42-61-300-004 (REPAIR-004), Repair, VRS3094 TASK 72-42-61-300-006 (REPAIR-006), Repair, VRS3095 TASK 72-42-61-300-007 (REPAIR-007), Repair, VRS3096 TASK 72-42-61-300-008 (REPAIR-008) or Repair, VRS3540 TASK 72-42-61-300-015 (REPAIR-015).

2. SUBTASK 72-42-61-110-053 Clean the Damaged Combustion Chamber Outer Liner

   1. Refer to Figure.

   2. Mask the coated surfaces.

      1. Use CoMat 02-182 METAL FOIL TAPE.

   3. Moderately clean or vapor blast the liner to remove debris and fragments.

      1. Refer to the SPM TASK 70-11-03-300-503, SPM TASK 70-11-01-300-503 or SPM TASK 70-12-01-120-501.

3. SUBTASK 72-42-61-230-051 Examine the Damaged Combustion Chamber Outer Liner

   1. Fluorescent penetrant inspect the liner.

      1. Refer to the SPM TASK 70-23-03-230-501 or SPM TASK 70-23-08-230-501 and SPM TASK 70-23-05-230-501.

         Make sure you examine all surfaces in addition to the damaged areas.

         Cracks associated with the hood/bulkhead cooling holes are permitted as is up to 0.020 in. (0.508 mm) in length.

         Cooling holes are 0.042 in. (1.0668 mm) diameter reference.

   2. Remove the damage by machine.

   3. Fluorescent penetrant inspect again. Machine as necessary until the liner is acceptable by fluorescent penetrant inspection.

      1. All corners of the machined area must have a minimum radius of 0.062 in. (1.575 mm).

         Cracks associated with the hood/bulkhead cooling holes are permitted as is up to 0.020 in. (0.508 mm) in length.

         Cooling holes are 0.042 in. (1.0668 mm) diameter reference.

   4. Examine for the locations and dimensions of the areas where you removed material.

      1. If the areas are only in the hood/bulkhead and each area is less than 0.100 sq in. (65 sq mm), do the procedure in Step.

      2. If the areas are only in the hood/bulkhead and one or more areas are more than 0.100 sq in. (65 sq mm), do the procedure in Step.

      3. If the areas are only in the shell and each area is less than 0.070 sq in. (45 sq mm), do the procedure in Step.

      4. If the areas are only in the shell and one or more areas are more than 0.070 sq in. (45 sq mm), do the procedure in Step.

      5. If the areas are only in the rear seal and each area is less than 0.100 sq in. (65 sq mm), do the procedure in Step.

      6. If the areas are only in the rear seal and one or more areas are more than 0.100 sq in. (65 sq mm), contact your IAE representative for further disposition.

         NOTE

         A pre-weld heat treat enhances weldability.

      7. Optional: Solution heat treat of the combustion chamber liner.

         Solution heat treat the inner liner by SPM TASK 70-37-24-370-501 at operator discretion.

      8. If the areas cross the hood/bulkhead and the shell and each area is less than 0.070 sq in. (45 sq mm), do the procedure in Step.

      9. If the areas cross the hood/bulkhead and the shell and one or more areas are more than 0.070 sq in. (45 sq mm), do the procedure in Step.

      10. If the areas cross the shell and the rear seal and each area is less than 0.070 sq in. (45 sq mm), do the procedure in Step.

      11. If the areas cross the shell and the rear seal and one or more areas are more than 0.070 sq in. (45 sq mm), contact your IAE representative for further disposition.

4. SUBTASK 72-42-61-310-051 Weld Repair the Hood/Bulkhead

   1. Refer to Figure and Figure.

   2. Weld repair the prepared areas.

      1. Remove and apply the coating again if coating overlaps the area to be weld repaired.

         1. Refer to the SPM TASK 70-31-13-310-501, IAE 16-3.

         2. Use the applicable CoMat welding filler wire.

         3. Refer to Figure.

         4. The total area of all weld repairs must not be more than 2.5 sq in. (1613 sq mm). The contour of the welded areas must be in 0.020 in. (0.508 mm) on both sides of perfect form. Cold work of the hood/bulkhead to restore the form is not recommended.

   3. Locally stress-relieve the liner after weld repair.

      1. Refer to Step.

5. SUBTASK 72-42-61-310-054 Patch Weld Repair the Hood/Bulkhead

   1. Refer to Figure, Figure and Figure.

   2. Cut a patch for the area to be repaired.

      1. Use the applicable CoMat patch material.

         Refer to Figure.

         The contour of the patch must be in 0.020 in. (0.508 mm) on both sides of perfect form.

         Refer to Figure.

   3. Make sure there is a gap of 0.015 in. (0.381 mm) maximum at the edge when you put the patch into the repair area.

   4. Tack the patch in place and weld.

      1. Refer to the SPM TASK 70-31-13-310-501, IAE 16-3.

         Use the applicable CoMat welding filler wire.

         Refer to Figure.

         Refer to Figurefor weld areas. Cold work of the hood/bulkhead to restore the form is not recommended.

   5. Locally stress-relieve the liner after weld repair.

      1. Refer to Step.

6. SUBTASK 72-42-61-310-055 Weld Repair the Shell

   1. Refer to Figure and Figure.

   2. Weld repair the prepared areas.

      1. Refer to the SPM TASK 70-31-13-310-501, IAE 16-3.

      2. Use the applicable CoMat welding filler wire.

      3. Refer to Figure.

      4. The total area of all weld repairs must not be more than 1.0 sq in. (645 sq mm). The contour of the welded areas must be in 0.020 in. (0.508 mm) on both sides of perfect forms.

   3. Finish the weld on the inside in 0.010 in. (0.254 mm) above or 0.005 in. (0.127 mm) below the base material. Finish the weld on the outside in 0.010 in. (0.254 mm) above the base metal.

      1. Refer to Figure.

   4. Locally stress-relieve the liner after weld repair.

      1. Refer to Step.

   5. Cold work the shell to restore the form if necessary.

      Stress-relieve the entire liner again if you cold worked the liner.

      1. Refer to Step.

         Make sure that all details are removed. It is recommended that the mount pins, the front seal and the rear seal be held in a fixture to prevent distortion.

7. SUBTASK 72-42-61-310-056 Patch Weld Repair the Shell

   1. A maximum of 15 patches can be installed in the shell of a combustion chamber outer liner, with a maximum of 7 patches per liner row. There must be a minimum of 1.500 in. (38.100 mm). of undamaged material between adjacent patches.

      NOTE

      Use precaution to keep distortion to a minimum.

   2. Cut a patch for the area to be repaired.

      1. Refer to Figure and Figure for weld areas.

      2. Refer to Figure for the applicable CoMat patch material and part number grouping.

      3. It is permissible to use sheet stock, or obtain replacement patch from a donor shell.

      4. Sheet stock may not be used to patch repair across liner rows.

      5. Replacement patch obtained must be from the same liner row as the repair area. The same pattern of cooling holes, attachment stud holes, and dilution holes, must be maintained. Size and separation of the holes on the replacement patch must be consistent with that of the adjacent unrepaired area of the salvaged part.

      6. The contour of the patch must be in 0.020 in. (0.51 mm) on both sides of perfect form.

   3. Make sure there is a gap of 0.015 in. (0.38 mm) maximum at the edge when you put the patch into the repair area.

   4. Use rotary austenitic stainless steel wire brush or silicon carbide abrasive wheels to remove oxides and prepare the repair area and patch for weld.

      1. Refer to SPM TASK 70-31-13-310-501.

   5. Clean the repair area and patch.

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

   6. Tack the patch in place and weld.

      1. Refer to the SPM TASK 70-31-13-310-501, IAE 16-3.

      2. Use the manual gas tungsten arc welding method (GTAW-MA).

      3. Refer to Figure for welding filler wire and part number requirements.

   7. Finish the weld on the inside in 0.010 in. (0.25 mm) above or 0.005 in. (0.13 mm) below the base material. Finish the weld on the outside in 0.010 in. (0.25 mm) above the base material.

      1. Refer to Figure.

      2. Evidence of tack-welding after finishing is acceptable.

   8. Clean the repair area

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

   9. Dimensionally examine the area that you welded

      1. If the minimum spacing between any two cooling holes is found to be less than 0.020 in. (0.508 mm), weld close both cooling holes and drill a new cooling hole of the same size, equidistant to the adjacent holes.

      2. Refer to Step , Step and Step.

   10. Stress-relieve the liner after weld repair.

       1. Refer to Step.

   11. Cold work the shell to restore the form if necessary.

   12. Stress-relieve the entire liner again if you cold worked the liner.

       1. Refer to Step.

          Make sure that all details are removed. It is recommended that the mount pins, the front seal and the rear seal be held in a fixture to prevent distortion.

   13. Fluorescent penetrant inspect the part.

       1. Refer to Step.

8. SUBTASK 72-42-61-310-057 Weld Repair the Rear Seal Land

   1. Refer to Figure and Figure.

   2. Remove the coating from the rear seal land.

      1. Refer to Repair, VRS3100 TASK 72-42-61-300-010 (REPAIR-010).

   3. Weld repair the prepared areas.

      1. Refer to the SPM TASK 70-31-13-310-501, IAE 16-3.

         Use the applicable CoMat welding filler wire.

         Refer to Figure.

         The total area of all weld repairs must not be more than 1.0 sq in. (645 sq mm). The contour of the welded areas must be in 0.020 in. (0.508 mm) on both sides of perfect form.

   4. Finish the weld on the inside in 0.010 in. (0.254 mm) above or 0.005 in. (0.127 mm) below the base material. If the weld goes into the seal surface, machine the entire surface to a diameter of 26.114 to 26.120 in. (663.296 to 663.448 mm).

      1. Refer to Figure.

   5. Stress-relieve the liner after weld repair.

      1. Refer to Step.

   6. If necessary, resize the seal land diameter.

      1. Refer to Repair, VRS3099 TASK 72-42-61-300-009 (REPAIR-009).

   7. Restore the coating.

      1. Refer to Repair, VRS3100 TASK 72-42-61-300-010 (REPAIR-010).

         If the area you repaired goes into the OD seal surface, a coating thickness of 0.003 to 0.006 in. (0.077 to 0.152 mm) must be maintained.

9. SUBTASK 72-42-61-310-058 Weld Repair Across the OEM Weld Line Between the Hood/Bulkhead and the Shell

   1. Refer to Figure, Figure and Figure.

   2. Weld repair the prepared areas.

      1. Refer to the SPM TASK 70-31-13-310-501,IAE 16-3.

      2. Use the applicable CoMat welding filler wire.

      3. Refer to Figure.

      4. The total area of all weld repairs must not be more than 1.0 sq in. (645 sq mm). The contour of the welded areas must be in 0.020 in. (0.508 mm) on both sides of perfect form. Cold work of the hood/bulkhead and the shell to restore the form is not recommended.

   3. Locally stress-relieve the liner after weld repair.

      1. Refer to Step.

10. SUBTASK 72-42-61-310-059 Patch Weld Repair Across the OEM Weld Line Between the Hood/Bulkhead and the Shell

    1. Refer to Figure, Figure and Figure.

    2. Cut and form two patches for the prepared areas of both the hood/bulkhead and the shell.

       1. Use the applicable patch material for the patches, or obtain replacement patch material from a donor shell.

       2. Refer to Figure.

       3. The contour of the patches must be in 0.020 in. (0.508 mm) on both sides of perfect form.

    3. (Optional) Cut, form and machine a single patch.

       1. Use CoMat 03-334 IN 625 SHEET STOCK, or obtain replacement patch material from a donor shell for the full area to be repaired.

          1. The contour of the patch must be in 0.020 in. (0.508 mm) on both sides of perfect form.

    4. Make sure there is a gap of 0.015 in. (0.381 mm) maximum at all edges when you put the patch into the repair area.

       1. Refer to Figure.

    5. If you use two patches, tack weld them together.

       1. Refer to the SPM TASK 70-31-13-310-501, IAE 16-3.

          Trim the patches as necessary so that there is a 0.015 in. (0.381 mm) gap maximum from all edges.

    6. If the single optional patch is used, weld the patch to the prepared area.

       1. Refer to the SPM TASK 70-31-13-310-501, IAE 16-3.

       2. Use CoMat 03-287 WELDING FILLER WIRE.

    7. Finish the weld on the inside in 0.010 in. (0.254 mm) above or 0.005 in. (0.127 mm) below the base material. Finish the weld on the outside in 0.010 in. (0.254 mm) above the base material.

       1. Refer to Figure.

    8. Locally stress-relieve the liner after weld repair.

       1. Refer to Step.

          Cold working of the hood/bulkhead and shell to restore the form is not recommended.

11. SUBTASK 72-42-61-310-060 Weld Repair Across the OEM Weld Line Between the Shell and the Rear Seal

    1. Refer to Figure, Figure and Figure.

    2. Remove the coating.

       1. Refer to Repair, VRS3100 TASK 72-42-61-300-010 (REPAIR-010).

    3. Weld repair the prepared areas.

       1. Refer to the SPM TASK 70-31-13-310-501, IAE 16-3.

       2. Use applicable welding filler wire.

       3. Refer to Figure.

       4. The total area of all weld repairs must not be more than 1.0 sq in. (645 sq mm). The contour of the welded areas must be in 0.020 in. (0.508 mm) on both sides of perfect form.

    4. Finish the weld on the inside in 0.010 in. (0.254 mm) above or 0.005 in. (0.127 mm) below the base material. If the weld goes into the seal surface, machine the entire surface to a diameter of 26.114 to 26.120 in. (663.296 to 663.448 mm).

       1. Refer to Figure.

    5. Locally stress-relieve the liner after weld repair.

       1. Refer to Step.

    6. If necessary, resize the seal land diameter.

       1. Refer to Repair, VRS3099 TASK 72-42-61-300-009 (REPAIR-009).

    7. Restore the coating.

       1. Refer to Repair, VRS3100 TASK 72-42-61-300-010 (REPAIR-010).

          If the area you repaired goes into the OD seal surface, a coating thickness of 0.003 to 0.006 in. (0.077 to 0.152 mm) must be maintained.

12. SUBTASK 72-42-61-370-051 Stress-Relieve the Outer Liner

    NOTE

    Stress-relief at temperatures higher than 1200 deg F (648.9 deg C) of finish machined steel, nickel and cobalt alloy parts must be done in a suitable protective atmosphere or must be followed by a suitable acid cleaning or descaling. Cooling rates must be selected to minimize distortion.
    1. 
       CAUTION
       HYDROGEN ATMOSPHERE IS NOT PERMITTED IF PWA 53-5 COATING IS NOT REMOVED FROM THE PART.

       Put the part in a cool, 500 deg F (260 deg C) maximum furnace.

       1. Refer to the SPM TASK 70-37-04-370-501 for the atmosphere.

    2. Heat to 600 deg F (315.6 deg C) and hold it for 30 minutes.

    3. Heat to 900 deg F (482.2 deg C) and hold it for 30 minutes.

    4. Heat to 1200 deg F (648.9 deg C) and hold it for 30 minutes.

    5. Heat to 1500 deg F (815.6 deg C) and hold it for 30 minutes.

    6. Heat to 1775 to 1825 deg F (968 to 996 deg C) and hold it for one hour.

    7. Slowly decrease the temperature at a rate of 100 deg F (55.5 deg C) each 15 minutes to a maximum of 500 deg F (260 deg C).

       NOTE

       Air cooling or faster is permitted if the dimensional requirements are met.

    8. It is permitted to stress relieve the outer liner. This stress relief may be done instead of the stress relief requirements in steps 15.A. to 15.G. above.

       1. Use SPM TASK 70-37-24-370-501.

13. SUBTASK 72-42-61-350-080-001 Install Cooling and Segment Attachment Holes (Manual Method)

    1. Use existing holes as a reference to locate the holes.

       1. Use CoMat 06-072 DYE to mark the locations of the hole rows and the angular locations.

    2. Use usual machining techniques to install the holes.

14. SUBTASK 72-42-61-350-080-002 Install Cooling and Segment Attachment Holes (Automatic Method)

    1. Install the weld repaired assembly onto a NC laser drill, bore mill or Omnimill.

       1. Put the part in a fixture to make sure it is centered and flat. Use the existing row of holes to establish a machining datum for NC or machine operator reference.

    2. Install the holes and racetracks.

       1. Use an existing row of holes for reference.

15. SUBTASK 72-42-61-220-132 Examine the Combustion Chamber Outer Liner After Repair

    1. Examine the areas that you welded.

       1. Refer to the SPM TASK 70-21-01-220-501.

    2. Examine the dimensions of the outer liner.

       1. Refer to TASK 72-42-61-200-000 (INSPECTION/CHECK-000).

16. SUBTASK 72-42-61-230-054 Fluorescent Penetrant Inspect the Combustion Chamber Outer Lining

    1. Fluorescent penetrant inspect the entire part.

       1. Refer to the SPM TASK 70-23-03-230-501 or SPM TASK 70-23-08-230-501.

17. SUBTASK 72-42-61-220-133 Examine the Hardcoat on the Front Inside Diameter Seal and the Rear Outside Diameter Seal of the Combustion Chamber Outer Liner

    1. Inspect the hardcoat of the front inside diameter seal and the rear outside diameter seal.

       1. Refer to TASK 72-42-61-200-000 (INSPECTION/CHECK-000).

18. SUBTASK 72-42-61-350-056 Install the Detail Parts to the Combustion Chamber Outer Liner

    1. Install the liner segments, the combustion chamber retaining bolt bushings, the access cover, the fuel nozzle guides and the bulkhead segments.

       1. Refer to Repair, VRS3092 TASK 72-42-61-300-004 (REPAIR-004), Repair, VRS3094 TASK 72-42-61-300-006 (REPAIR-006), Repair, VRS3095 TASK 72-42-61-300-007 (REPAIR-007), Repair, VRS3096 TASK 72-42-61-300-008 (REPAIR-008) or Repair, VRS3450 TASK 72-42-61-300-015 (REPAIR-015).

          NOTE

          If you patch repaired the shell, inspect for distortion between the segments after you install the segments. Refer to TASK 72-42-61-200-000.

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



Repair Details and Dimensions



Figure: Repair Details and Dimensions

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



Repair Details and Dimensions



Figure: Repair Details and Dimensions

Repair Details and Dimensions



Repair Details and Dimensions



Repair Details and Dimensions



Repair Details and Dimensions