TASK 72-50-24-300-009 LPT Inner Diffuser Duct Segment - Replace The Honeycomb Seal Segment, Repair-009 (VRS4115)

DMC:V2500-A0-72-50-2401-01A-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 72-50-24-300-009 LPT Inner Diffuser Duct Segment - Replace The Honeycomb Seal Segment, Repair-009 (VRS4115)

Effectivity

FIG/ITEM

PART NO.

01-010

3A0771

Material of component

RR

DESCRIPTION

SYMBOL

MATERIAL

Inner duct segment

Inconel 713

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 70-09-00-400-501, 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 PCI.

NOTE

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

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Grinding machineLOCALGrinding machine
Spot welding machineLOCALSpot welding machine
Turning latheLOCALTurning lathe
Belt grinderLOCALBelt grinder
IAE 3M14210 Grinding/turning fixture0AM53IAE 3M142101
IAE 3M14211 Spot welding fixture0AM53IAE 3M142111
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 02-144 BONDING AGENTC7208CoMat 02-144
CoMat 03-148 BRAZING FILLER POWDERLOCALCoMat 03-148
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 03-249 BRAZING FILLER MATERIAL,Ni-BASELOCALCoMat 03-249

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Honeycomb seal segment3A15851

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-50-24-325-051 Remove the Damaged Honeycomb Seal Segment

    1. Refer to Figure and Figure.

      2. Machine off the worn honeycomb seal segment.

      1. Use IAE 3M14210 Grinding/turning fixture 1 off and turning lathe or grinding machine.

        Keep material removal to a minimum.

        Remove the damaged honeycomb seal segment fully. Remaining braze thickness not more than 0.005 in. (0.13 mm) is permitted.

    2. SUBTASK 72-50-24-110-068 Clean the Inner Duct Segment

      1. Aqueous cleaning.

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

    3. SUBTASK 72-50-24-230-056 Examine the Inner Duct Segment for Cracks

      1. Do the test for cracks.

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

        No cracks are permitted.

    4. SUBTASK 72-50-24-310-054 Prepare the Honeycomb Seal Segment for Brazing

      1. Cut the new honeycomb seal segment to length.

      1. Replacement honeycomb is supplied longer than necessary.

        Use belt grinder.

    5. SUBTASK 72-50-24-110-069 Clean the Inner Duct Segment and the New Honeycomb 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 72-50-24-310-051 Braze in the New Honeycomb Seal Segment

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

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

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

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

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

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

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

      7. Attach the inner duct segment on to the spot welding fixture.

      1. Make sure that the inner duct 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 tape to the inner duct segment mating side of the honeycomb seal segment.

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

      9. Position the honeycomb seal segment on to the inner duct segment.

      1. Align the honeycomb seal segment.

      10. 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.

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

      1. Make sure that the brazing filling 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 inner duct segment.

    7. SUBTASK 72-50-24-110-170 Clean the Inner Duct Segment

      1. Aqueous cleaning.

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

    8. SUBTASK 72-50-24-210-051 Examine the Brazed Honeycomb Seal Segment

      1. Do the gravity leak test.

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

      2. Acceptance limits.

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

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

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

        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 72-50-24-325-052 Machine the Honeycomb Seal Segment

    1. Refer to Figure and Figure.

      2. Grind the honeycomb seal segment.

      1. Use IAE 3M14210 Grinding/turning fixture grinding/turning fixture 1 off and grinding machine.

      3. Deburr the honeycomb seal segment.

      1. Refer to the SPM TASK 70-31-07-310-501 or use wire brush.

    10. SUBTASK 72-50-24-110-071 Clean the Inner Duct Segment

      1. Aqueous cleaning.

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

    11. SUBTASK 72-50-24-220-225 Do the Post Repair Inspection

    1. Refer to Figure and Figure.

    2. Examine dimensionally.

      3. Examine visually.

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

    12. SUBTASK 72-50-24-350-062 Make a Mark to Identify the Repair

      1. Electrolytically etch or vibropeen VRS4115 adjacent to the part number.

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

    13. Figure: Repair Details and Dimensions

    Sheet 1

    Legend
    Repair Details and Dimensions

    Sheet 1

    Close

    Figure: Repair Details and Dimensions

    Sheet 2

    Legend
    Repair Details and Dimensions

    Sheet 2

    Close

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Editorial correction due to conversion

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: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: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: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 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
Link not Found
Manufacturer Code:0AM53
Tool Number:IAE 3M14210
Tool Name:IAE 3M14210 Grinding/turning fixture
Manufacturer Code:0AM53
Tool Number:IAE 3M14211
Tool Name:IAE 3M14211 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