TASK 72-50-22-300-129 Replace The Honeycomb Seal Segment On The Inner Buttress Of The Stage 5 Turbine Vane, Repair-129 (VRS4580)

DMC:V2500-A0-72-50-2205-06A-920A-C|Issue No:001.00|Issue Date:2015-02-01

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 72-50-22-300-129 Replace The Honeycomb Seal Segment On The Inner Buttress Of The Stage 5 Turbine Vane, Repair-129 (VRS4580)

Effectivity

FIG/ITEM

PART NO.

01-350

3A3120

Material of component

PART IDENT

IAE

SYMBOL

MATERIAL

Stage 5 turbine vane

MAR-M247

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 SPM TASK 70-09-00-400-501, SPM TASK 70-11-03-300-503, SPM TASK 70-23-02-230-501 and SPM TASK 70-31-07-310-501.
Equivalent equipment may be used.

NOTE

To identify the consumable materials, refer to the OPCI.

NOTE

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

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Turning latheLOCALTurning lathe
Grinding MachineLOCALGrinding Machine
Belt grinderLOCALBelt grinder
Spot welding machineLOCALSpot welding machine
IAE 3M14203 Grinding/turningfixture0AM53IAE 3M14203
IAE 3M14206 Spot welding fixture0AM53IAE 3M14206

1 off

IAE 3M14220 Cross slide table0AM53IAE 3M14220

1 off

IAE 3M14221 Electrode guide0AM53IAE 3M14221

1 off

IAE 3M14222 Electrode holder0AM53IAE 3M14222

1 off

IAE 3M14223 Universal joint electrode0AM53IAE 3M14223

1 off

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-144 BONDING AGENTC7208CoMat 02-144
CoMat 03-148 BRAZING FILLER POWDERLOCALCoMat 03-148
CoMat 03-227 WHITE STOP OFFD3309CoMat 03-227
CoMat 03-249 BRAZING FILLER MATERIAL,Ni-BASELOCALCoMat 03-249

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
SEAL SEGMENT - HONEYCOMB0AM533A31241

FIG/ITEM 01-371

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-50-22-320-063 Machine the Damaged Honeycomb Seal Segment

    1. Refer to Figure.

      2. Machine off the worn honeycomb seal segment.

      2. Keep material removal to a minimum.

      3. Remove the damaged honeycomb seal segment fully.

      4. Remaining braze thickness not more than 0.005 in. (0.130 mm) is permitted.

    2. SUBTASK 72-50-22-110-284 Clean the Stage 5 Turbine Vane

      1. Aqueous cleaning

      1. Refer to SPM TASK 70-11-03-300-503.

    3. SUBTASK 72-50-22-230-201 Examine the Stage 5 Turbine Vane for Cracks

      1. Do the test for cracks.

      1. Refer to SPM TASK 70-23-02-230-501.

      2. Cracks are not permitted.

    4. SUBTASK 72-50-22-310-131 Prepare the Honeycomb Seal Segment for Brazing

      1. Cut the new honeycomb seal segment to length.

      1. Replacement honeycomb is supplied longer than necessary.

    5. SUBTASK 72-50-22-110-285 Clean the Stage 5 Turbine Vane and the New Honeycomb Seal Segment

      1. Aqueous cleaning

      1. Refer to SPM TASK 70-11-03-300-503.

      2. Use clean gloves when you touch the clean parts.

    6. SUBTASK 72-50-22-310-132 Braze in the New Honeycomb Seal Segment

    1. Refer to Figure and Figure.

      NOTE

      If CoMat 03-249 BRAZING FILLER MATERIAL,Ni-BASE is used, do not perform Step to Step.
      If CoMat 03-148 BRAZING FILLER POWDER is used, do not perform Step.

      2. Install the cross slide table onto the spot welding machine.

      3. Install the electrode holder onto the spot welding machine.

      4. Install the electrode swivel onto the electrode holder.

      2. Make sure that the electrode insert with the mark "INNER" (part of the electrode swivel) is installed.

      5. Install the electrode guide onto the cross slide table.

      6. Install the spot welding fixture onto the electrode guide.

      7. Attach the stage 5 turbine vane onto the spot welding fixture.

      1. Make sure that the stage 5 turbine vane is installed correctly against the stop plates (parts of the spot welding fixture).

      8. Prepare the new honeycomb seal segment.

      2. Apply brazing filler tape to the stage 5 turbine vane mating side of the honeycomb seal segment.

      3. Use a roller or equivalent to roll the tape into the honeycomb cells and remove the backing.

      9. Put the honeycomb seal segment onto the stage 5 turbine vane.

      1. Align the honeycomb seal segment.

      10. Resistance weld the honeycomb seal segment.

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

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

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

      2. Make sure that the brazing filler powder is applied equally around the honeycomb seal segment.

      12. Safety the brazing filler powder to the honeycomb cells.

      13. Apply white stop off around the edges of the stage 5 turbine vane.

      14. Vacuum braze

      1. Refer to SPM TASK 70-31-07-310-501. Use process 2.

      2. Brazing time is 30 minutes maximum.

      3. Decrease temperature at a rate not less than 35 °F (19 °C) per minute to 1100 °F (593 °C).

      4. Further cooling rate is optional.

    7. SUBTASK 72-50-22-110-286 Clean the Stage 5 Turbine Vane

      1. Aqueous cleaning

      1. Refer to SPM TASK 70-11-03-300-503.

    8. SUBTASK 72-50-22-210-081 Examine the Brazed Honeycomb Seal Segment

      1. Do the gravity leak test.

      1. Refer to SPM TASK 70-31-07-310-501.

      2. Acceptance limits

        1. Refer to SPM TASK 70-31-07-310-501 other than the limits that follows:

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

        2. The minimum space between the unbonded areas of more than 0.063 sq in. (40.65 sq mm) should be 1.000 in. (25.40 mm).

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

    9. SUBTASK 72-50-22-320-064 Machine the Honeycomb Seal Segment

    1. Refer to Figure and Figure.

      2. Grind the honeycomb seal segment.

      3. Deburr the honeycomb seal segment.

      1. Refer to SPM TASK 70-31-07-310-501.

    10. SUBTASK 72-50-22-110-287 Clean the Stage 5 Turbine Vane

      1. Aqueous cleaning

      1. Refer to SPM TASK 70-11-03-300-503.

    11. SUBTASK 72-50-22-370-077 Precipitation Heat Treatment of the Stage 5 Turbine Vane

      1. Precipitation heat treat the stage 5 turbine vane.

      1. Refer to SPM TASK 70-37-27-370-501, allow PWA1447.

      2. Optional precipitation heat treatment of 1575° F to 1625° F (857° C to 885° C) for eight hours can be used.

    12. SUBTASK 72-50-22-220-374 Do the Post Repair Inspection

    1. Refer to Figure and Figure.

    2. Do a dimensional inspection.

      3. Do a visual inspection.

      1. Refer to SPM TASK 70-31-07-310-501.

    13. SUBTASK 72-50-22-350-123 Make a Mark to Identify the Repair

      1. Electrolytically etch or vibropeen VRS4580 adjacent to the part number.

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

    14. Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Repair Details and Dimensions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added new Repair-129. (12VM552)

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: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
Part Number:3A3124
Part Name:SEAL SEGMENT - HONEYCOMB
Manufacturer Code: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 03-148
Type:sp01
Supply Short Name:CoMat 03-148 BRAZING FILLER POWDER
Supply Name:CoMat 03-148 BRAZING FILLER POWDER
Specification Groups:
Doc NumberType
MSRR 9500/97NICROBRAZ LM NICROBRAZ LM (-150 MESH) AMS 4777 B.S.1845 HTN2
OMAT:3/181NICROBRAZ LM NICROBRAZ LM (-150 MESH) AMS 4777 B.S.1845 HTN2
JCR-214NICROBRAZ LM NICROBRAZ LM (-150 MESH) AMS 4777 B.S.1845 HTN2
Suppliers:
ManufacturerRemarks
LOCAL
63585
K6835
U0163
K5086
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 03-249
Type:sp01
Supply Short Name:CoMat 03-249 BRAZING FILLER MATERIAL, Ni-BASE
Supply Name:CoMat 03-249 BRAZING FILLER MATERIAL,Ni-BASE
Specification Groups:
Doc NumberType
AMS 4777
Suppliers:
ManufacturerRemarks
LOCAL
0UEE7
0Y7E4
01FK3
63585
Manufacturer Code:LOCAL
Tool Number:Belt grinder
Tool Name:Belt grinder
Manufacturer Code:LOCAL
Tool Number:Grinding Machine
Tool Name:Grinding Machine
Manufacturer Code:0AM53
Tool Number:IAE 3M14203
Tool Name:IAE 3M14203 Grinding/turningfixture
Manufacturer Code:0AM53
Tool Number:IAE 3M14206
Tool Name:IAE 3M14206 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:Spot welding machine
Tool Name:Spot welding machine
Manufacturer Code:LOCAL
Tool Number:Turning lathe
Tool Name:Turning lathe