TASK 72-44-50-300-011 HPT Stage 1 Cooling (TOBI) Duct - Weld Repair Cracks And/Or Burns on The Outer Flange, Repair-011 (VRS3558)

DMC:V2500-A0-72-44-5001-00A-627A-C|Issue No:002.00|Issue Date:2020-08-01

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 72-44-50-300-011 HPT Stage 1 Cooling (TOBI) Duct - Weld Repair Cracks And/Or Burns on The Outer Flange, Repair-011 (VRS3558)

Effectivity

FIG/ITEM

PART NO.

01-010

2A0008-01

01-010

2A1997-01

01-010

2A1997-001

01-010

2A1997-002

01-010

2A1997-003

01-010

2A2141-01

01-010

2A3180-01

01-010

2A3329-01

01-010

2A3487-01

01-010

2A3487-001

01-010

2A3491-01

01-010

2A3914-01

01-010

2A3914-001

01-010

2A4086

Material of component

PART IDENT

SYMBOL

MATERIAL

Stage 1 HPT cooling duct

Nickel alloy

General

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

NOTE

To identify the consumable materials, refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

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

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-284 WELDING FILLER WIRE, NiBASELOCALCoMat 03-284
CoMat 05-146 WHEEL, SILICON CARBIDE ABRASIVE COAT DELETED0AM53CoMat 05-146

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Locating Pin2A0869AR

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-44-50-350-077 Remove the Locating Pin from the Stage 1 HPT Cooling Duct

    1. Refer to Figure.

    2. Drill out the flared shank with a bit that is slightly smaller than 0.182 in. (4.6228 mm) diameter.

    3. Use a drift to push out the remaining part of the locating pin that is in the hole.

    2. SUBTASK 72-44-50-350-078 Remove Cracks or Burns in the Flange before Weld Repair and Weld Preparation

    1. Rout out cracks or burns in areas to be welded.

      3. Prepare the part for weld.

      1. Refer to the SPM TASK 70-31-02-310-501-011.

    3. SUBTASK 72-44-50-230-065 Fluorescent Penetrant Inspect the Stage 1 HPT Cooling Duct

      1. Fluorescent penetrant inspect the repair area. No cracks permitted.

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

      2. Use fluorescent penetrant (medium post-emulsified).

    4. SUBTASK 72-44-50-120-051 Clean the Area to be Welded

      1. Clean the area to be welded.

      1. Refer to the SPM TASK 70-11-26-300-503.

    5. SUBTASK 72-44-50-310-052 Weld to Repair Damage in the Stage 1 HPT Cooling Duct

    1. Refer to Figure, Figure, Figure and Figure.

      2. It is recommended that you use a one inch (25.400 mm) thick steel plate as a fixture to minimize distortion during welding.

      1. Use all 40 larger bolt holes with work bolts to attach the plate to the flange rear surface.

      2. Refer to Figure for dimensional requirements for the duct flange.

      3. Weld to repair the cracks and burns you routed out.

      1. Use CoMat 03-284 WELDING FILLER WIRE, NiBASE and the manual gas tungsten arc weld method.

      2. Refer to the SPM TASK 70-31-02-310-501-011.

    6. SUBTASK 72-44-50-370-057 Optional, Fluorescent Penetrant Inspect the Stage 1 HPT Cooling Duct

      1. Do a fluorescent penetrant inspection of the repaired area. No cracks permitted.

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

      2. Use fluorescent penetrant (medium post-emulsified).

    7. SUBTASK 72-44-50-370-058 Solution Heat Treat and Precipitation Harden the Stage 1 HPT Cooling Duct

    1. Solution heat treat the duct at 1725 to 1775 deg F (940.555 to 968.333 deg C) for one hour in a protective atmosphere.

    2. Cool at 40 deg F (4.444 deg C) per minute or faster to 1300 to 1350 deg F (704.444 to 732.222 deg C).

    3. Precipitation heat treat the duct at 1300 to 1350 deg F (704.444 to 732.222 deg C) for eight hours.

    4. Furnace cool at a rate of 100 deg F (37.777 deg C) maximum per hour to 1125 to 1175 deg F (607.222 to 635 deg C).

    5. NOTE

      Solution heat treat may be done concurrent with honeycomb brazing cycle in VRS3179, TASK 72-44-50-300-003 (REPAIR-003).

      Hold at 1125 to 1175 deg F (607.222 to 635 deg C) for eight hours.

    6. Air cool to room temperature.

    8. SUBTASK 72-44-50-230-067 Fluorescent Penetrant Inspect the Stage 1 HPT Cooling Duct

      1. Do a fluorescent penetrant inspection of the part. No cracks permitted.

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

      2. Use fluorescent penetrant (medium post-emulsified).

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

    9. SUBTASK 72-44-50-220-077 Examine the Stage 1 HPT Cooling Duct for Hardness

    1. Refer to Figure.

      2. Examine the surfaces of the duct for hardness.

      1. Surfaces N and M must be 34 HRC minimum.

      2. Hardness requirement is waived on parts AF and AG.

    10. SUBTASK 72-44-50-320-077 Machine the Bolt Holes and Flange of the Stage 1 HPT Cooling Duct

    1. Refer to Figure, Figure and Figure.

      2. Finish machine the bolt holes and flange.

      1. Refer to the dimensions given in the figure and TASK 72-44-50-200-000 (INSPECTION-000).

    11. SUBTASK 72-44-50-220-108 Examine the Repair

      1. Examine the repair.

      1. Refer to TASK 72-44-50-200-000 (INSPECTION-000).

    12. SUBTASK 72-44-50-350-070 Install a New Locating Pin to the Stage 1 HPT Cooling Duct

    1. Refer to Figure.

      2. Install a new locating pin to the duct in the correct position in the flange hole.

      1. Use an applicable flaring tool to flare the locating pin to install it tightly.

    13. SUBTASK 72-44-50-350-079 Remove the Locating Pin from the Stage 1 HPT Cooling Duct

    1. Refer to Figure.

    2. Remove the locating pin.

    14. SUBTASK 72-44-50-310-056 Weld to Repair Damage in the Stage 1 HPT Cooling Duct

    1. Refer to Figure, Figure, Figure and Figure.

      2. It is recommended that you use a one inch (25.400 mm) thick steel plate as a fixture to minimize distortion during welding.

      1. Use all 40 larger bolt holes with work bolts to attach the plate to the flange rear surface.

      2. Refer to Figure for dimensional requirements for the duct flange.

      3. Weld to repair the cracks and burns you routed out.

      1. Use CoMat 03-284 WELDING FILLER WIRE, NiBASE and the manual gas tungsten arc method.

    15. SUBTASK 72-44-50-220-077 Examine the Stage 1 HPT Cooling Duct for Hardness

    1. Refer to Figure.

    2. Examine the surfaces of the duct for hardness.

    3. Surfaces N and M must be 34 HRC minimum.

    4. Hardness requirement is waived on parts AF and AG.

    16. SUBTASK 72-44-50-230-069 Fluorescent Penetrant Inspect the Stage 1 HPT Cooling Duct after Heat Treat

      1. Fluorescent penetrant inspect the duct for stress cracks in the welded areas and the flange areas adjacent to the welds. No cracks are permitted.

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

    17. SUBTASK 72-44-50-320-078 Machine the Bolt Holes and Flange of the Stage 1 HPT Cooling Duct

    1. Refer to Figure, Figure and Figure.

      2. Finish machine the bolt holes and flange.

      1. Refer to the dimensions given in the figure and TASK 72-44-50-200-000 (INSPECTION-000).

    18. SUBTASK 72-44-50-350-080 Install a New Locating Pin to the Stage 1 HPT Cooling Duct

    1. Refer to Figure.

    2. Install a new locating pin to the duct.

    19. Figure: Repair Details and Dimensions (for all PNs except 2A3487-001)

    Sheet 1

    Legend
    Repair Details and Dimensions (for all PNs except 2A3487-001)

    Sheet 1

    Close

    Figure: Repair Details and Dimensions (for PN 2A3487-001)

    Sheet 2

    Legend
    Repair Details and Dimensions (for PN 2A3487-001)

    Sheet 2

    Close

    Figure: Repair Details and Dimensions

    Sheet 3

    Legend
    Repair Details and Dimensions

    Sheet 3

    Close

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedural step. (18VC436)

Link not Found
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:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Link not Found
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:0AM53
Supply Number:CoMat 05-146
Type:sp01
Supply Short Name:CoMat 05-146 WHEEL, SILICON CARBIDE ABRASIVE COAT DELETED
Supply Name:CoMat 05-146 WHEEL, SILICON CARBIDE ABRASIVE COAT DELETED
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
0AM53
Manufacturer Code:LOCAL
Tool Number:Portable grinding equipment
Tool Name:Portablegrinding equipment
Manufacturer Code:LOCAL
Tool Number:Welding equipment
Tool Name:Welding equipment
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment