TASK 72-50-23-300-049 LPT Stage 4 Outer Shroud Seal Segment - Replace The Honeycomb Segments, Repair-049 (VRS4487)

DMC:V2500-A0-72-50-2304-01A-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 72-50-23-300-049 LPT Stage 4 Outer Shroud Seal Segment - Replace The Honeycomb Segments, Repair-049 (VRS4487)

Effectivity

FIG/ITEM

PART NO.

01-250

3A1918

Material of component

PART IDENT

SYMBOL

MATERIAL

Stage 4 shroud seal segment

MTS1096A or WL2.4665.1/

Hastelloy X

Honeycomb seal segment

WL2.4665.1/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 70-09-00-400-501, SPM TASK 70-11-03-300-503, SPM TASK 70-23-02-230-501 and SPM TASK 70-31-07-310-501.

NOTE

To identify the consumable materials refer to the PCI.

NOTE

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

NOTE

Approved vendors for the supply of honeycomb material AMS5536, refer to CoMat 03-469 HONEYCOMB, NICKEL ANDCOBALT ALLOYS. To locally manufacture supplied honeycomb seal segments, refer to Figure and Figure.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Grinding machineLOCALGrinding machine
Spot welding machineLOCALSpot welding machine
Illuminated comparator magnifierLOCALIlluminated comparator magnifier
Turning latheLOCALTurning lathe
Fluid tankLOCALFluid tank
Belt grinderLOCALBelt grinder
IAE 3M14422 Grinding/turning fixture0AM53IAE 3M144221
IAE 3M14215 Spot welding fixture0AM53IAE 3M142151
IAE 3M14220 Cross slide table0AM53IAE 3M142201
IAE 3M14221 Electrode guide0AM53IAE 3M142211
IAE 3M14222 Electrode holder0AM53IAE 3M142221
IAE 3M14223 Universal joint electrode0AM53IAE 3M142231
IAE 3M14265 Spot welding fixture0AM53IAE 3M142651

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
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 03-148 BRAZING FILLER POWDERLOCALCoMat 03-148
CoMat 03-227 WHITE STOP OFFD3309CoMat 03-227
CoMat 03-249 BRAZING FILLER MATERIAL,Ni-BASELOCALCoMat 03-249
CoMat 03-469 HONEYCOMB, NICKEL ANDCOBALT ALLOYSLOCALCoMat 03-469
CoMat 10-061 STODDARD SOLVENTLOCALCoMat 10-061

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Honeycomb seal segment3A15811
Honeycomb seal segment3A15821

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-50-23-325-065 Machine the Damaged Honeycomb Seal Segment

      1. Machine off the worn honeycomb seal segment.

      1. Use turning lathe and IAE 3M14422 Grinding/turning fixture 1 off.

        Remove the damaged honeycomb seal segment fully.

        Keep material removal to the minimum to allow subsequent repairs.

        To get this it is permitted to let stay up to 0.005 in. (0.13 mm).

        Refer to Figure.

      2. Bend the shroud seal segment back to the shape if required.

      1. Refer to Figure.

        Use cold work.

    2. SUBTASK 72-50-23-110-143 Clean the Shroud Seal Segment

      1. Aqueous cleaning.

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

    3. SUBTASK 72-50-23-230-103 Examine the Shroud Seal Segment for Cracks

      1. Do the test for cracks.

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

        Refer to TASK 72-50-23-200-003-B00 (INSPECTION/CHECK-003, CONFIG-002) for acceptable limits.

    4. SUBTASK 72-50-23-310-090 Prepare the Honeycomb Seal Segment for Brazing

      1. Cut the honeycomb seal segments to length.

      1. Replacement honeycombs are supplied longer than necessary.

        Use belt grinder.

    5. SUBTASK 72-50-23-110-144 Clean the New Honeycomb Seal Segment and the Shroud Seal Segment

      1. Aqueous cleaning.

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

        Use clean gloves when you touch the clean parts.

    6. SUBTASK 72-50-23-310-091 Braze in the New Honeycomb Seal Segment

      NOTE

      If CoMat 03-249 BRAZING FILLER MATERIAL,Ni-BASE is used perform steps H. to J., if CoMat 03-148 BRAZING FILLER POWDER is used perform steps I. to L.
      If you install the honeycomb seal segment LPT Stage 3, 4, 5, 7 Outer Shroud Seal Segments (72-50-23, 01-281 do not perform the step E., and if you install the honeycomb seal segment LPT Stage 3, 4, 5, 7 Outer Shroud Seal Segments (72-50-23, 01-271 do not perform step F. Refer to Figure and Figure.

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

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

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

      3. Install the electrode swivel on to the electrode holder.

      1. Make sure that the electrode insert with the mark OUTER is installed.

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

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

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

      7. Attach the shroud seal segment on to the spot welding fixture.

      1. Make sure that the shroud seal segment is installed correctly against the stop plates (parts of the spot welding fixture).

      8. Prepare the new honeycomb seal segment.

      1. Apply brazing filler material to the shroud seal segment mating side of the honeycomb seal segment.

        Use a roller, roll material in to honeycomb cells and remove backing.

      9. Set the honeycomb seal segment on to the shroud seal segment.

      1. Align the honeycomb seal segment.

        Refer to Figure.

      10. Resistance weld the honeycomb seal segment.

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

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

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

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

      12. Safety the powder to the honeycomb cells.

      13. Apply white stop off around the edges of the shroud seal segment.

      14. Vacuum braze.

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

        Use process 2.

    7. SUBTASK 72-50-23-110-145 Clean the Shroud Seal Segment

      1. Aqueous cleaning.

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

    8. SUBTASK 72-50-23-210-059 Examine the Brazed Honeycomb Seal Segment

      1. Prepare the fluid tank.

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

      2. Fill the cells with the fluid.

      1. Put the shroud seal assembly in to the fluid for 30 seconds.

        Hit the assembly lightly while in the fluid to remove trapped air bubbles from the honeycomb cells.

      3. Remove the assembly from the fluid tank.

      1. Turn the part and wait 3 to 5 minutes for the fluid to drain.

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

      1. Empty cells indicate not completed brazed bond.

      5. Acceptance limits.

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

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

        Minimum distance between unbonded areas more than 0.063 sqin (40.65 sqmm) should be 1.00 in. (25.4 mm).

        Use illuminated comparator magnifier.

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

    9. SUBTASK 72-50-23-324-060 Do the Post Repair

      1. Finish machine the honeycomb seal segment.

      1. Grind to the dimensions.

        Refer to Figure.

        Use IAE 3M14422 Grinding/turning fixture 1 off and grinding machine.

      2. De-burr the honeycomb seal segments.

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

    10. SUBTASK 72-50-23-110-146 Clean the Honeycomb Seal

      1. Aqueous cleaning.

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

    11. SUBTASK 72-50-23-220-171 Do the Post Repair Inspection

      1. Examine dimensionally the shroud seal segment.

      1. Refer to Figure.

      2. Examine visually for damage.

      1. Use illuminated comparator magnifier.

      3. Electrolytically etch or vibro-peen VRS4487 adjacent to the part number.

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

    12. Figure: Replace the honeycomb seal segment of the shroud seal segment

    Replace the honeycomb seal segment of the shroud seal segment

    Figure: Replace the honeycomb seal segment of the shroud seal segment

    Replace the honeycomb seal segment of the shroud seal segment

    Figure: Local manufacture honeycomb seal segment of the shroud seal segment

    Local manufacture honeycomb seal segment of the shroud seal segment

    Figure: Local manufacture honeycomb seal segment of the shroud seal segment

    Local manufacture honeycomb seal segment of the shroud seal segment

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
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: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
Link not Found
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 03-148
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
Supply Number:CoMat 03-469
Type:sp01
Supply Short Name:CoMat 03-469 HONEYCOMB, NICKEL ANDCOBALT ALLOYS
Supply Name:CoMat 03-469 HONEYCOMB, NICKEL ANDCOBALT ALLOYS
Specification Groups:
Doc NumberType
(AMS 5536, AMS 5540) PWA 123HONEYCOMB, NICKEL AND COBALT ALLOYS
Suppliers:
ManufacturerRemarks
LOCAL
FA1X9
IE499
U0F75
0FGC3
0MRR3
0TML8
0ALH8
25632
49741
50554
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 3M14215
Tool Name:IAE 3M14215 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:0AM53
Tool Number:IAE 3M14265
Tool Name:IAE 3M14265 Spot welding fixture
Manufacturer Code:0AM53
Tool Number:IAE 3M14422
Tool Name:IAE 3M14422 Grinding/turning fixture
Manufacturer Code:LOCAL
Tool Number:Illuminated comparator magnifier
Tool Name:Illuminated comparator magnifier
Manufacturer Code:LOCAL
Tool Number:Spot welding machine
Tool Name:Spot welding machine
Manufacturer Code:LOCAL
Tool Number:Turning lathe
Tool Name:Turning lathe