TASK 72-50-22-300-020 LPT Stage 4 Vane - Replace The Honeycomb Seal Segments On The Inner Buttress, Repair-020 (VRS4059)

DMC:V2500-A0-72-50-2204-00A-920A-C|Issue No:002.00|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 72-50-22-300-020 LPT Stage 4 Vane - Replace The Honeycomb Seal Segments On The Inner Buttress, Repair-020 (VRS4059)

Effectivity

FIG/ITEM

PART NO.

01-550

3A0637

Material of component

RR

DESCRIPTION

SYMBOL

MATERIAL

Stage 4 turbine vane

MAR-M 247

Honeycomb seal segment

Hastelloy X

General

Price and availability - none

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

NOTE

For more equipment and materials necessary to do this repair refer to the SPM TASK 70-11-01-300-503, SPM TASK 70-12-08-300-503, SPM TASK 70-09-00-400-501, SPM TASK 70-23-08-230-501 and SPM TASK 70-31-07-310-501.

NOTE

To identify the consumable materials refer to the PCI.

NOTE

Special tools are identified in the procedure by the tool primary number.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Illuminated comparator magnifierLOCALIlluminated comparator magnifier
Belt grinderLOCALBelt grinder
Fluid tankLOCALFluid tank
Point welding deviceLOCALPoint welding device
Grinding machineLOCALGrinding machine
Spot welding machineLOCALSpot welding machine
Vertical turning latheLOCALVertical turning lathe
Workshop inspection equipmentLOCALWorkshop inspection equipment
IAE 3M14204 Grinding/turning fixture0AM53IAE 3M142041
IAE 3M14207 Spot welding fixture0AM53IAE 3M142071
IAE 3M14220 Cross slide table0AM53IAE 3M142201
IAE 3M14221 Electrode guide0AM53IAE 3M142211
IAE 3M14222 Electrode holder0AM53IAE 3M142221
IAE 3M14223 Universal joint electrode0AM53IAE 3M142231

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-001 SOLVENT, DELETED0AM53CoMat 01-001
CoMat 01-183 WETTING AGENT FOR ACIDCLEANER1XY28CoMat 01-183
CoMat 02-142 WETTING AGENT08340CoMat 02-142
CoMat 02-143 DELETED0AM53CoMat 02-143
CoMat 02-144 BONDING AGENTC7208CoMat 02-144
CoMat 03-151 HIGH TEMP. BRAZING FILLERPOWDERLOCALCoMat 03-151
CoMat 03-227 WHITE STOP OFFD3309CoMat 03-227
CoMat 03-234 BRAZING FILLER TAPELOCALCoMat 03-234
CoMat 10-061 STODDARD SOLVENTLOCALCoMat 10-061

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Honeycomb seal segment3A15771

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-50-22-325-057 Machine the Damaged Honeycomb Seal Segment

      1. Machine off the worn honeycomb seal segment.

      1. Use vertical turning lathe and the IAE IAE 3M14204 Grinding/turning fixture 1 off.

        Remove the damaged honeycomb sel segment fully.

        Keep the material removal to the minimum to allow subsequent repairs.

        To get this it is permitted to let stay a braze thickness of 0.005in. (0.13 mm).

        Refer to Figure.

    2. SUBTASK 72-50-22-110-099 Clean the Stage 4 Turbine Vane

      1. Vapor degrease.

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

    3. SUBTASK 72-50-22-230-061 Examine the Stage 4 Turbine Vane for Cracks

      1. Do the test for cracks.

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

        No cracks are permitted.

    4. SUBTASK 72-50-22-120-054 Wet Abrasive Blast the Stage 4 Turbine Vane

      1. Wet abrasive blast the machined area.

      1. Refer to the SPM TASK 70-12-08-300-503.

    5. SUBTASK 72-50-22-310-066 Prepare the Honeycomb Seal Segment for Brazing

      1. Cut the new honeycomb seal sement to length.

      1. The new honeycomb seal segment is supplied longer than necessary.

        Use belt grinder.

    6. SUBTASK 72-50-22-110-100 Clean the Stage 4 Turbine Vane and the New Honeycomb Seal Segment

      1. Vapor degrease.

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

        Use clean gloves when you touch the clean parts.

    7. SUBTASK 72-50-22-310-054 Braze in the New Honeycomb Seal Segment

      NOTE

      If CoMat 03-234 BRAZING FILLER TAPE is used perform steps G. to I., if CoMat 03-151 HIGH TEMP. BRAZING FILLERPOWDER is used perform steps L. to M.

      1. Install the cross slide table on to the spot welding machine.

      1. Use the IAE IAE 3M14220 Cross slide table 1 off and spot welding machine.

      2. Install the electrode holder on to the spot welding machine.

      1. Use the IAE IAE 3M14222 Electrode holder 1 off.

      3. Install the universal joint electrode on the electrode holder.

      1. Make sure that the electrode insert with the mark INNER (part of the universal joint electrode) is installed.

      4. Install the electrode guide on to the cross slide table.

      1. Use the IAE IAE 3M14221 Electrode guide 1 off.

      5. Install the spot welding fixture on to the electrode guide.

      6. Attach the stage 4 turbine vane on to the spot welding fixture.

      1. Make sure that the stage 4 turbine vane is installed correctly against the stop plates (parts of the spot welding fixture).

      7. Prepare the new honeycomb seal segment.

      1. Apply brazing filler tape to the turbine vane mating side of the honeycomb seal segment.

        Use a roller or equivalent, roll the tape in to honeycomb cells and remove backing.

      8. Position the honeycomb seal segment on to the stage 4 turbine vane.

      1. Align the honeycomb seal segment, refer to Figure.

      9. Resistance weld the honeycomb seal segment.

      1. Use a short time and low weld amperage to safety the honeycomb seal without damage.

        Start to weld in the middle and continue to the outer sides.

      10. Position the honeycomb seal segment on to the stage 4 turbine vane.

      1. Align the honeycomb seal segment, refer to Figure.

      11. Resistance weld the honeycomb seal segment.

      1. Use short time and low weld amperage to safety the honeycomb seal without damage. Start to weld in the middle and continue to the outer sides.

      12. Apply brazing filler powder to the honeycomb seal segment.

      1. Make sure that the powder is applied equally around the honeycomb seal segment.

      13. Safety the powder to the honeycomb cells.

      14. Apply white stop off around the edges of the stage 4 turbine vane.

      15. Braze.

      1. Refer to the SPM TASK 70-31-07-310-501 and the special procedures for brazing.

        Refer to Figure.

    8. SUBTASK 72-50-22-110-101 Clean the Stage 4 Turbine Vane

      1. Vapor degrease.

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

    9. SUBTASK 72-50-22-210-054 Examine the Brazed Honeycomb Seal

      1. Prepare fluid tank.

      1. Use 200:1 mixture of water and CoMat 02-142 WETTING AGENT or 1:1 mixture of CoMat 10-061 STODDARD SOLVENT and CoMat 02-143 DELETED or 2500:1 mixture of water and CoMat 01-183 WETTING AGENT FOR ACIDCLEANER for acid cleaner or 1:1 mixture of CoMat 01-001 SOLVENT, DELETED and CoMat 10-061 STODDARD SOLVENT.

      2. Fill the honeycomb cells with the fluid.

      1. Put the assembly of the stage 4 turbine vane for 30 seconds in to the fluid.

        Hit assembly lightly while it is in the fluid to remove caught air bubbles from the honeycomb cells.

      3. Remove the assembly of the stage 4 turbine vane from the fluid tank.

      1. Turn the stage 4 turbine vane and wait 3 to 5 minutes for the fluid to drain.

      4. Examine the honeycomb cells for lack of the fluid.

      1. Empty honeycomb cells show not completed braze bond.

      5. Acceptance limits.

      1. Refer to the SPM TASK 70-31-07-310-501 except for the following:

        No unbrazed honeycomb cells around the edges of the honeycomb seal segment are permitted.

        The minimum space between the unbonded areas of more than 0.063 sqin (40.65 sqmm) should be 1.00in. (25.4 mm).

        Use illuminated comparator magnifier.

        No braze filled cells are permitted.

        The honeycomb wall thickness must not be increased by more than 0.001in. (0.03 mm) in the area above the braze fillet.

    10. SUBTASK 72-50-22-325-058 Do the Post Repair

      1. Finish machine the honeycomb seal segment.

      1. Grind to the dimensions.

        Refer to Figure.

        Use the IAE 3M14204 Grinding/turning fixture 1 off and grinding machine.

      2. De-burr the honeycomb seal segment.

      1. Refer to the SPM TASK 70-12-08-300-503 or use wire brush.

    11. SUBTASK 72-50-22-110-102 Clean the Honeycomb Seal Segment

      1. Vapor degrease.

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

    12. SUBTASK 72-50-22-220-131 Do the Post Repair Inspection

      1. Dimensionally examine the stage 4 turbine vane.

      1. Refer to Figure.

        Use workshop inspection equipment.

      2. Visually examine for damage.

      1. Use illuminated comparator magnifier.

    13. SUBTASK 72-50-22-350-069 Make a Mark to Indentify the Repair

      1. Electrolytically etch or vibro-peen VRS4059 adjacent to the part number.

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

    14. Figure: Replace the honeycomb seal segment on the inner buttress of the stage 4 turbine vane

    Replace the honeycomb seal segment on the inner buttress of the stage 4 turbine vane

    Figure: Replace the honeycomb seal segment on the inner buttress of the stage 4 turbine vane

    Replace the honeycomb seal segment on the inner buttress of the stage 4 turbine vane

    Figure: Special procedures for brazing the honeycomb seal segment on the inner buttress of the stage 4 turbine vane

    Special procedures for brazing the honeycomb seal segment on the inner buttress of the stage 4 turbine vane

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Editorial correction due to conversion

Link not Found
Manufacturer Code:08340
Enterprise Name:MONSANTO CANADA LTD
BU Name:MONSANTO CANADA LTD
Street:425 ST PATRICK ST
P.O. Box:208
City:LASALLE QUE CAN
State:CANADA
Zip Code:H8N 2H3
Country:USA
Phone Number:1-314-694-1000
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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:1XY28
Enterprise Name:THE PROCTER AND GAMBLE CO.
BU Name:THE PROCTER AND GAMBLE CO.
Street:2 PROCTOR AND GAMBLE PLAZA
City:CINCINNATI
State:OH
Zip Code:45202
Country:USA
Phone Number:1-513-983-2757
Fax Number:1-513-983-9458
Internet:www.pg.com
Manufacturer Code:C7208
Enterprise Name:FONTARGEN GMBH
BU Name:FONTARGEN GMBH
Street:SIEMENSSTR. 4
City:67304 EISENBERG
Country:GERMANY
Phone Number:49-6351-4010
Fax Number:49-6451-40149
Manufacturer Code:D3309
Enterprise Name:MTU MOTOREN-UND-TURBINE UNION MUNCHEN GMBH
BU Name:MTU MOTOREN-UND-TURBINE UNION MUNCHEN GMBH
Street:DACHAUERSTRASSE 665
P.O. Box:80995
City:MUNCHEN 50
Country:GERMANY
Phone Number:49-89-14890
Fax Number:49-89-1502621
Internet:www.mtu.de
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Link not Found
Manufacturer Code:X111X
Supply Number:CoMat 01-001
Type:sp01
Supply Short Name:CoMat 01-001 SOLVENT, DELETED
Supply Name:CoMat 01-001 SOLVENT, DELETED
Specification Groups:
Doc NumberType
wiring harnesses. Where CoMat 01‐001 is specified to clean mechanical components, use one or more of the solvents that SPM TASK 70‐11‐26‐300‐503 specifies as applicable.DELETED. Where CoMat 01‐001 is specified to clean electrical contacts or wiring harnesses, use one or more of the solvents that SPM TASK 70‐11‐57‐110‐501 specifies to clean electrical contacts or
Suppliers:
ManufacturerRemarks
X111X
Manufacturer Code:1XY28
Supply Number:CoMat 01-183
Type:sp01
Supply Short Name:CoMat 01-183 WETTING AGENT FOR ACID CLEANER
Supply Name:CoMat 01-183 WETTING AGENT FOR ACIDCLEANER
Specification Groups:
Doc NumberType
OMAT:1/272ORVUS WA PASTE
PMC 1622ORVUS WA PASTE
Suppliers:
ManufacturerRemarks
1XY28
Manufacturer Code:08340
Supply Number:CoMat 02-142
Type:sp01
Supply Short Name:CoMat 02-142 WETTING AGENT
Supply Name:CoMat 02-142 WETTING AGENT
Specification Groups:
Doc NumberType
PMC 1629PHOTO FLO 200
Suppliers:
ManufacturerRemarks
08340
Manufacturer Code:0AM53
Supply Number:CoMat 02-143
Type:sp01
Supply Short Name:CoMat 02-143 DELETED
Supply Name:CoMat 02-143 DELETED
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
0AM53
Manufacturer Code:LOCAL
Supply Number:CoMat 02-144
Type:sp01
Supply Short Name:CoMat 02-144 BONDING AGENT
Supply Name:CoMat 02-144 BONDING AGENT
Specification Groups:
Doc NumberType
DELETED. USE COMAT 03-290.
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:LOCAL
Supply Number:CoMat 03-151
Type:sp01
Supply Short Name:CoMat 03-151 HIGH TEMP. BRAZING FILLER POWDER
Supply Name:CoMat 03-151 HIGH TEMP. BRAZING FILLERPOWDER
Specification Groups:
Doc NumberType
OMAT: 3/118NICROBRAZ 130 MSRR9500/114
Suppliers:
ManufacturerRemarks
LOCAL
K6835
63585
IE441
U0163
Manufacturer Code:D3309
Supply Number:CoMat 03-227
Type:sp01
Supply Short Name:CoMat 03-227 WHITE STOP OFF
Supply Name:CoMat 03-227 WHITE STOP OFF
Specification Groups:
Doc NumberType
MTH 316NICROBRAZE WHITE STOP OFF
Suppliers:
ManufacturerRemarks
D3309
Manufacturer Code:LOCAL
Supply Number:CoMat 03-234
Type:sp01
Supply Short Name:CoMat 03-234 BRAZING FILLER TAPE
Supply Name:CoMat 03-234 BRAZING FILLER TAPE
Specification Groups:
Doc NumberType
NICROBRAZ 130 BRAZING SHEET AMS 4778
Suppliers:
ManufacturerRemarks
LOCAL
K5086
K6835
U0163
Manufacturer Code:LOCAL
Supply Number:CoMat 10-061
Type:sp01
Supply Short Name:CoMat 10-061 STODDARD SOLVENT
Supply Name:CoMat 10-061 STODDARD SOLVENT
Specification Groups:
Doc NumberType
PMC 9001MIL-PRF-680, TYPE II
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:LOCAL
Tool Number:Belt grinder
Tool Name:Belt grinder
Manufacturer Code:LOCAL
Tool Number:Fluid tank
Tool Name:Fluid tank
Link not Found
Manufacturer Code:0AM53
Tool Number:IAE 3M14204
Tool Name:IAE 3M14204 Grinding/turning fixture
Manufacturer Code:0AM53
Tool Number:IAE 3M14207
Tool Name:IAE 3M14207 Spot welding fixture
Manufacturer Code:0AM53
Tool Number:IAE 3M14220
Tool Name:IAE 3M14220 Cross slide table
Manufacturer Code:0AM53
Tool Number:IAE 3M14221
Tool Name:IAE 3M14221 Electrode guide
Manufacturer Code:0AM53
Tool Number:IAE 3M14222
Tool Name:IAE 3M14222 Electrode holder
Manufacturer Code:0AM53
Tool Number:IAE 3M14223
Tool Name:IAE 3M14223 Universal joint electrode
Manufacturer Code:LOCAL
Tool Number:Illuminated comparator magnifier
Tool Name:Illuminated comparator magnifier
Manufacturer Code:LOCAL
Tool Number:Point welding device
Tool Name:Point welding device
Manufacturer Code:LOCAL
Tool Number:Spot welding machine
Tool Name:Spot welding machine
Manufacturer Code:LOCAL
Tool Number:Vertical turning lathe
Tool Name:Vertical turning lathe
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment