Preliminary Requirements

Safety Requirements

CAUTION

USE THIS REPAIR FOR THE DAMAGED PARTS WHICH HAVE LESS THAN THEIR LIFE CYCLE LIMIT. THIS REPAIR WILL NOT EXTEND THE LIFE CYCLE. DO NOT REPAIR THE AIR SEAL THAT HAS A CRACK OR ANY INDICATION THAT IS NOT CLEARLY THE RESULT OF LOCAL DAMAGE SUCH AS DENTS, NICKS, SCRATCHES AND CORROSION PITS. IF CRACKS OR OTHER UNUSUAL CONDITIONS ARE FOUND BY THE PENETRANT TEST OR VISUAL INSPECTION, REJECT THE PART.

Procedure

1. Repair Facilities

   1. 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 IAE Manager Maintenance Operations 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. Authorized Repair Vendors for the shotpeen for Repair VRS3195 are listed below:

      Pratt and Whitney Global Service Partners

      East Hartford Repair Operations (GSP-EHRO)

      400 Main Street, Well No.14 - Mail Stop 117-62

      East Hartford, CT 06108

      USA

      Tel: (860) 557-2646

      Fax: (860) 557-2647

      Metal Improvements Company Inc (MIC)

      145 Addison Road

      P. O. Box 487

      Windsor, CT 06095

      USA

      Tel: (860) 688-6201

      Fax: (860) 285-8809

      IHI Corporation

      229 Tonogaya,

      Mizuho-Machi Nishitama-Gun

      Tokyo 190-1297

      Japan

      Tel: 81-42-568-7362

      Fax: 81-42-568-7566

      ATTN: Program Manager, V2500

      MTU MAINTENANCE HANNOVER GmbH

      Flughafen Hannover

      Muenchner Strasse 31

      D-30855 Langenhagen

      Germany

      Tel: 49 511 7806 0

      Fax: 49 511 7806 111

      ATTN: Program Manager, V2500

      Metal Improvement Company, Inc. (MIC)

      Ascot Drive

      Derby DE24 8ST

      England

      Tel: 44-1-332-756-076

      Fax: 44-1-332-754-392

   3. 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 standards 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.

2. SUBTASK 72-45-12-350-053-001 Blend the Air Seal (Rotary Method)

   1. Blend the surface damage such as dents, nicks, scratches and corrosion pits.

      1. Refer to Figure requirements.

         1. Use the rotary consumable materials given in the general section.

         2. Make the abrasive coat become soft on the CoMat 05-146 WHEEL, SILICON CARBIDE ABRASIVE COAT DELETED. Remove the rough and unwanted grit until the wheel surface is smooth before you do the blend repair.

         3. All blended areas must be smooth and continuous.

         4. The minimum blend length to depth ratio is 15 to 1.

         5. The minimum blend radius to depth ratio is 30 to 1.

         6. Break all blended area edges 0.003 to 0.015 in. (0.08 to 0.38 mm).

   2. Blend repair at Loaction 2 is not permitted.

      1. Damage up to 0.001 in. (0.025 mm) is permitted.

   3. Blend all the areas at Loactions 1 and 4 to remove the surface damage.

      1. The maximum blend depth is 0.005 in. (0.127 mm).

   4. Blend at Loaction 6 to remove the surface damage.

      1. The maximum blend depth is 0.018 in. (0.457 mm).

   5. Blend the area at Loactions 5 to remove scattered surface damage on the diameter.

      1. The maximum blend depth is 0.005 in. (0.127 mm).

         The maximum blend length is 0.500 in. (12.7 mm) in a circumferential direction with a minimum distance between the blends of 2.000 in. (50.8 mm).

   6. Blend the edges (corners) at Loaction 7 to remove the surface damage.

      1. The maximum break-edge (corners) radius of 0.015 in. (0.0381 mm) is allowed.

   7. Blend the area at Loactions 3 to remove surface damage.

      1. The maximum blend depth is 0.005 in. (0.127 mm).

         A maximum of three tabs can be blended with a minimum of five tabs that are not blended between each blended tab.

   8. Blend the knife-edges to remove surface damage.

      1. Refer to the requirements given in the figure.

         1. The maximum blend area for one blend on a knife-edge is 0.100 sq in. (65 sq mm).

         2. The maximum cumulative blend area for one knife-edge is 0.200sq in. (129 sq mm). The maximum cumulative blend area for all three knife-edges is 0.300 sq in. (194 sq mm).

         3. Blend the knife-edge smooth and continuous into the original contour.

3. SUBTASK 72-45-12-350-053-002 Blend the Air Seal (Manual Method)

   1. Blend the surface damage such as dents, nicks, scratches and corrosion pits.

      1. Refer to Figure requirements.

         1. Use CoMat 05-143 STONE, BROWN INDIA (MEDIUM) and CoMat 05-148 STONE, WHITE ARKANSAS (HARD).

         2. All blended areas must be smooth and continuous.

         3. The minimum blend length to depth ratio is 15 to 1.

         4. The minimum blend radius to depth ratio is 30 to 1.

         5. Break all blended area edges 0.003 to 0.015 in. (0.08 to 0.38 mm).

   2. Blend repair at Loaction 2 is not permitted.

      1. Damage up to 0.001 in. (0.025 mm) is permitted.

   3. Blend all the areas at Loactions 1 and 4 to remove the surface damage.

      1. The maximum blend depth is 0.005 in. (0.127 mm).

   4. Blend at Loaction 6 to remove the surface damage.

      1. The maximum blend depth is 0.018 in. (0.457 mm).

   5. Blend the area at Loactions 5 to remove scattered surface damage on the diameter.

      1. The maximum blend depth is 0.005 in. (0.127 mm).

         1. The maximum blend length is 0.500 in. (12.7 mm) in a circumferential direction with a minimum distance between the blends of 2.000 in. (50.8 mm).

   6. Blend the edges (corners) at Loaction 7 to remove the surface damage.

      1. The maximum break-edge (corners) radius of 0.015 in. (0.0381 mm) is allowed.

   7. Blend the area at Loactions 3 to remove surface damage.

      1. The maximum blend depth is 0.005 in. (0.127 mm).

         A maximum of three tabs can be blended with a minimum of five tabs that are not blended between each blended tab.

   8. Blend the knife-edges to remove surface damage.

      1. Refer to the requirements given in the figure.

         1. The maximum blend area for one blend on a knife-edge is 0.100 sq in. (65 sq mm).

         2. The maximum cumulative blend area for one knife-edge is 0.200 sq in. (129 sq mm). The maximum cumulative blend area for all three knife-edges is 0.300 sq in. (194 sq mm).

         3. Blend the knife-edge smooth and continuous into the original contour.

4. SUBTASK 72-45-12-230-055 Fluorescent Penetrant the Repair Areas

   1. Fluorescent penetrant inspect all of the repaired surfaces for cracks.

      1. Refer to Figure.

         1. Do the procedure given in SPM TASK 70-23-04-230-501.

         2. No cracks permitted.

5. SUBTASK 72-45-12-380-051 Shotpeen the Air Seal Repaired Area (Local Application)

   
   CAUTION
   THE SOURCE DEMONSTRATION VENDOR IS REQUIRED AT LOCATIONS 3, 4, 5, AND 7 OR DAMAGE TO THE PART CAN OCCUR.

   1. Shotpeen all of the repaired surfaces at Loactions 1 and 6. The minimum intensity 6A or equivalent is not required. You must shotpeen the complete repaired area.

      1. Refer to Figure.

         1. Do the procedure given in SPM TASK 70-38-13-380-501. Use CoMat 05-032 CAST STEEL SHOT, S170 or CoMat 05-033 CAST STEEL SHOT DELETED.

         2. OR.

         3. As an alternative use CoMat 05-029 CAST STEEL SHOT, S110 or CoMat 05-030 CAST STEEL SHOT DELETED or CoMat 05-031 CAST STEEL SHOT DELETED.

6. SUBTASK 72-45-12-380-052 Shotpeen the Air Seal Repaired Areas (Source Demonstration)

   
   CAUTION
   THE SOURCE DEMONSTRATION VENDOR IS REQUIRED AT LOCATIONS 3, 4, 5, AND 7 OR DAMAGE TO THE PART CAN OCCUR.

   1. Shotpeen all of the repaired surfaces at Loactions 3, 4 and 7. Use a minimum intensity 6A or equivalent.

      1. Refer to Figure.

         1. Do the procedure given in SPM TASK 70-38-13-380-501. Use CoMat 05-032 CAST STEEL SHOT, S170 or CoMat 05-033 CAST STEEL SHOT DELETED.

   2. Shotpeen all of the repaired surfaces at Loactions 5. The minimum intensity 6A or equivalent is not required. You must shotpeen the complete repaired area.

      1. Refer to Figure.

         1. Do the procedure given in SPM TASK 70-38-13-380-501. Use CoMat 05-032 CAST STEEL SHOT, S170 or CoMat 05-033 CAST STEEL SHOT DELETED.

Figure: Repair Details and Dimensions

Repair Details and Dimensions



Figure: Repair Details and Dimensions

Repair Details and Dimensions