TASK 72-44-20-300-018 HPT Stage 1 Vane - Outer Diameter Rear Foot Plasma Spray Repair, Repair-018 (VRS3158)

DMC:V2500-A0-72-44-2000-03A-609A-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 72-44-20-300-018 HPT Stage 1 Vane - Outer Diameter Rear Foot Plasma Spray Repair, Repair-018 (VRS3158)

Effectivity

FIG/ITEM

PART NO.

01-240

2A0561

01-250

2A0091CL21

01-250

2A2591CL21

01-251

2A0091CL22

01-251

2A2591CL22

01-252

2A0091CL23

01-252

2A2591CL23

01-253

2A0091CL24

01-253

2A2591CL24

01-254

2A0091CL25

01-254

2A2591CL25

01-255

2A0091CL26

01-255

2A2591CL26

01-256

2A0091CL27

01-256

2A2591CL27

01-257

2A0091CL28

01-257

2A2591CL28

01-258

2A0091CL29

01-258

2A2591CL29

01-259

2A0091CL30

01-259

2A2591CL30

01-260

2A0091CL31

01-250

2A2591CL31

01-261

2A0091CL32

01-261

2A2591CL32

01-262

2A0091CL33

01-262

2A2591CL33

01-263

2A0091CL34

01-263

2A2591CL34

01-264

2A0091CL35

01-264

2A2591CL35

01-265

2A0091CL36

01-265

2A2591CL36

01-266

2A0091CL37

01-266

2A2591CL37

01-267

2A0091CL38

01-267

2A2591CL38

01-268

2A0091CL39

01-268

2A2591CL39

01-269

2A0091CL40

01-269

2A2591CL40

01-270

2A0091CL41

01-270

2A2591CL41

01-271

2A0091CL42

01-271

2A2591CL42

01-272

2A0091CL43

01-272

2A2591CL43

01-273

2A0091CL44

01-273

2A2591CL44

01-274

2A0091CL45

01-274

2A2591CL45

01-275

2A0091CL46

01-275

2A2591CL46

01-276

2A0091CL47

01-276

2A2591CL47

01-277

2A0091CL48

01-277

2A2591CL48

01-278

2A0091CL48-5

01-279

2A0091CL49

01-279

2A2591CL49

01-280

2A0091CL49-5

01-284

2A2591CL50

01-286

2A2591CL51

Material of component

RR

DESCRIPTION

SYMBOL

MATERIAL

Stage 1 HPT vane cluster assembly -

Nickel alloy

Stage 1 HPT vane assembly -

Nickel alloy

General

Price and availability - refer to IAE

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

NOTE

To identify the consumable materials, refer to the PCI

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Workshop inspection equipmentLOCALWorkshop inspection equipment
Portablegrinding equipmentLOCALPortable grinding equipment

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-243 WELDING FILLER WIRELOCALCoMat 03-243

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-44-20-320-051-A00 Remove the Coating from the Rear Foot of the Stage 1 HPT Vane Cluster Assembly (PN 2A0091 or 2A2591)

      1. CAUTION

        KEEP THE CAVITIES OF THE LEADING AND TRAILING EDGES AND THE AIRFOIL SURFACE CLEAN OF GRINDING DEBRIS.

        Grind the rear face of the foot to remove the coating.

      1. Refer to Figure.

      2. Remove the coating so the foot thickness is 0.182 to 0.188 in. (4.623 to 4.775 mm).

      2. Visually inspect the repair area to make sure you removed all of the coating.

      1. If you did not remove all of the coating, grind the area again until you remove all of the coating.

    2. SUBTASK 72-44-20-320-051-B00 Remove the Coating from the Rear Foot of the Stage 1 HPT Vane Assembly (PN 2A0561)

      1. CAUTION

        KEEP THE CAVITIES OF THE LEADING AND TRAILING EDGES AND THE AIRFOIL SURFACE CLEAN OF GRINDING DEBRIS.

        Grind the rear face of the foot to remove the coating.

      1. Refer to Figure.

      2. Remove the coating so the foot thickness is 0.190 to 0.196 in. (4.826 to 4.978 mm).

      2. Visually inspect the repair area to make sure you removed all of the coating.

      1. If you did not remove all of the coating, grind the area again until you remove all of the coating.

    3. SUBTASK 72-44-20-220-086-A00 Examine the Thickness of the Rear Foot of the Stage 1 HPT Vane Cluster Assembly (PN 2A0091 or 2A2591)

      1. Examine the thickness of the foot.

      1. Refer to Figure.

      2. If the thickness of the foot is less than 0.182 in. (4.623 mm), do the plasma spray procedure given in Step or the weld and plasma spray procedure given in Step.

      3. If the thickness of the foot is a minimum of 0.182 in. (4.623 mm), do the plasma spray procedure given in Step.

    4. SUBTASK 72-44-20-220-086-B00 Examine the Thickness of the Rear Foot of the Stage 1 HPT Vane Assembly (PN 2A0561)

      1. Examine the thickness of the foot.

      1. Refer to Figure.

      2. If the thickness of the foot is less than 0.190 in. (4.826 mm), do the plasma spray procedure given in Step or the weld and plasma spray procedure given in Step.

      3. If the thickness of the foot is a minimum of 0.190in. (4.826 mm) do the plasma spray procedure given in Step.

    5. SUBTASK 72-44-20-340-052-A01 Plasma Spray the Rear Foot of the Stage 1 HPT Vane Cluster Assembly (PN 2A0091 or 2A2591)

      1. NOTE

        Do this procedure if the thickness of the rear foot is less than 0.182in. (4.623 mm).

        Plasma spray the repair area of the rear foot.

      1. Refer to Figure and the SPM TASK 70-34-03-340-501, IAE 53-18 or IAE 271-47.

      2. Apply coating to a thickness of 0.003 to 0.015 in. (0.08 to 0.38 mm).

      2. NOTE

        Build up the flange thickess to the upper end of the tolerance so that the thickess of IAE 53-15 will not be more than the maximum limit of 0.015 in. (0.381 mm).

        Plasma spray the repair area of the rear foot.

      1. Refer to Figure and the SPM TASK 70-34-03-340-501, IAE 53-15.

      2. Apply coating to a thickness of 0.015 in. (0.381 mm) maximum.

    6. SUBTASK 72-44-20-340-052-A02 Weld Build-Up and Plasma Spray the Rear Foot of the Stage 1 HPT Vane Cluster Assembly (PN 2A0091 or 2A2591)

      1. NOTE

        You can do this procedure if the thickness of the rear foot is between 0.164in. (4.166 mm) and 0.182in. (4.623 mm).

        Weld the rear foot to build up the thickness.

      1. Refer to Figure.

      2. Build up the foot to a sufficient thickness so that the thickness of the foot after machining will be a minimum of 0.182 in. (4.623 mm).

      3. Use the gas tungsten arc or plasma weld method and CoMat 03-243 WELDING FILLER WIRE.

      2. Machine the weld area to 0.182 in. (4.623 mm) minimum.

      1. Refer to Figure.

      3. Stress-relieve the vane.

      1. Refer to the SPM TASK 70-37-14-370-501.

      4. Fluorescent penetrant inspect the vane.

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

      2. No cracks are permitted.

      5. Plasma spray the repair area of the rear foot.

      1. Refer to Figure and the SPM TASK 70-34-03-340-501, IAE 53-15.

      2. Apply coating to a thickness of 0.015 in. (0.381 mm) maximum.

    7. SUBTASK 72-44-20-340-053-A00 Plasma Spray the Rear Foot of the Stage 1 HPT Vane Cluster Assembly (PN 2A0091 or 2A2591)

      NOTE

      Do this procedure if the thickness of the rear foot is a minimum of 0.182 in. (4.623 mm).

      1. Plasma spray the repair area of the rear foot.

      1. Refer to Figure and the SPM TASK 70-34-03-340-501, IAE 53-15.

      2. Apply coating to a thickness of 0.020 in. (0.508 mm) maximum.

    8. SUBTASK 72-44-20-340-054-B01 Plasma Spray the Rear Foot of the Stage 1 HPT Vane Assembly (PN 2A0561)

      1. NOTE

        Do this procedure if the thickness of the rear foot is less than 0.190 in. (4.826 mm).

        Plasma spray the repair area of the rear foot.

      1. Refer to Figure and the SPM TASK 70-34-03-340-501, IAE 53-18 or IAE 271-47.

      2. Apply coating to a thickness of 0.003 to 0.015 in. (0.08 to 0.38 mm).

      2. NOTE

        Build up the flange thickness to the upper end of the tolerance so that the thickness of IAE 53-15 will not be more than the maximum limit of 0.015 in. (0.381 mm).

        Plasma spray the repair area of the rear foot.

      1. Refer to Figure and the SPM TASK 70-34-03-340-501, IAE 53-15.

      2. Apply coating to a thickness of 0.015 in. (0.381 mm) maximum.

    9. SUBTASK 72-44-20-340-054-B02 Weld Build-Up and Plasma Spray the Rear Foot of the Stage 1 HPT Vane Assembly (PN 2A0561)

      NOTE

      You can do this procedure if the thickness of the rear foot is between 0.172 in. (4.369 mm) and 0.190 in. (4.826 mm).

      1. Weld the rear foot to build up the thickness.

      1. Refer to Figure.

      2. Build up the foot to a sufficient thickness so that the thickness of the foot after machining will be a minimum of 0.190 in. (4.826 mm).

      3. Use the gas tungsten arc or plasma weld method and CoMat 03-243 WELDING FILLER WIRE.

      2. Machine the weld area to 0.190 in. (4.826 mm) minimum.

      1. Refer to Figure.

      3. Stress-relieve the vane.

      1. Refer to the SPM TASK 70-37-14-370-501.

      4. Fluorescent penetrant inspect the vane.

      1. No cracks are permitted.

      5. Plasma spray the repair area of the rear foot.

      1. Refer to Figure and the SPM TASK 70-34-03-340-501, IAE 53-15.

      2. Apply coating to a thickness of 0.015 in. (0.381 mm) maximum.

    10. SUBTASK 72-44-20-340-053-B00 Plasma Spray the Rear Foot of the Stage 1 HPT Vane Assembly (PN 2A0561)

      1. NOTE

        Do this procedure if the thickness of the rear foot is a minimum of 0.190 in. (4.826 mm).

        Plasma spray the repair area of the rear foot.

      1. Refer to Figure and the SPM TASK 70-34-03-340-501, IAE 53-15.

      2. Apply coating to a thickness of 0.020 in. (0.508 mm) maximum.

    11. SUBTASK 72-44-20-320-052-A00 Machine the Rear Foot of the Stage 2 HPT Vane Cluster Assembly after Plasma Spray (PN 2A0091 and 2A2591)

      1. Set up and finish machine the rear foot after plasma spray.

      1. Refer to Figure.

      2. Machine the foot to a thickness of 0.192 to 01.98 in. (4.877 to 5.029 mm).

      3. The minimum thickness of the coating after machining is 0.003 in. (0.076 mm).

      4. Break the edges 0.015 to 0.025 in. (0.38 to 0.64 mm).

    12. SUBTASK 72-44-20-320-052-B00 Machine the Rear Foot of the Stage 1 HPT Vane Assembly after Plasma Spray (PN 2A0561)

      1. Set up and finish machine the rear foot after plasma spray.

      1. Refer to Figure.

      2. Machine the foot to a thickness of 0.200 to 0.206 in. (5.080 to 5.232 mm).

      3. The minimum thickness of the coating after machining is 0.003 in. (0.076 mm).

      4. Break the edges 0.015 to 0.025 in. (0.38 to 0.64 mm).

    13. SUBTASK 72-44-20-220-087 Examine the Repair

      1. Examine the repair.

      1. Refer to TASK 72-44-20-200-000 (INSPECTION-000).

    14. Figure: Stage 1 HPT vane cluster assembly (PN 2A0091 and 2A2591) outer diameter rear foot plasma spray repair

    Stage 1 HPT vane cluster assembly (PN 2A0091 and 2A2591) outer diameter rear foot plasma spray repair

    Figure: Stage 1 HPT vane assembly (PN 2A0561) outer diameter rear foot plasma spray repair

    Stage 1 HPT vane assembly (PN 2A0561) outer diameter rear foot plasma spray repair

Requirements After Job Completion

Follow-On Conditions

NONE
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 03-243
Type:sp01
Supply Short Name:CoMat 03-243 WELDING FILLER WIRE
Supply Name:CoMat 03-243 WELDING FILLER WIRE
Specification Groups:
Doc NumberType
HAYNES 188AMS 5801
Suppliers:
ManufacturerRemarks
LOCAL
IE508
0ZDB5
2R602
07098
36346
55596
57965
58401
80357
Manufacturer Code:LOCAL
Tool Number:Portable grinding equipment
Tool Name:Portablegrinding equipment
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment