TASK 72-50-24-300-061 LPT Stage 3 Inner Air Seal Ring - Replace The Honeycomb Seal Segments, Repair-061 (VRS4564)

DMC:V2500-A0-72-50-2404-01A-920A-C|Issue No:003.00|Issue Date:2018-08-01

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 72-50-24-300-061 LPT Stage 3 Inner Air Seal Ring - Replace The Honeycomb Seal Segments, Repair-061 (VRS4564)

Effectivity

FIG/ITEM

PART NO.

01-250

3A3108

01-250

3A3109

Material of Component

PART IDENT

SYMBOL

MATERIAL

Stage 3 air seal ring

-

C263

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.

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
IAE 3M14208 Grinding/turning fixture0AM53IAE 3M14208

1 off

IAE 3M14209 Spot welding fixture0AM53IAE 3M14209

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

IAE 3M14363 Spot welding fixture (rear)0AM53IAE 3M14363

1 off

Turning latheLOCALTurning lathe
Grinding machine0AM53Grinding machine
Belt grinderLOCALBelt grinder
Spot welding machineLOCALSpot welding machine

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
SEAL SEGMENT - HONEYCOMB0AM533A31101

FIG/ITEM 01-296

SEAL - HONEYCOMB0AM533A31111

FIG/ITEM 01-306

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-50-24-320-001 Machine the Damaged Honeycomb Seal Segments

    1. Refer to Figure.

      2. Machine off the worn honeycomb seal segments.

      2. Keep material removal to a minimum.

      3. Remove the damaged honeycomb seal segments fully.

      4. Remaining braze thickness not more than 0.005 in. (0.13 mm) is permitted.

    2. SUBTASK 72-50-24-110-001 Clean the Air Seal Ring

      1. Aqueous cleaning.

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

    3. SUBTASK 72-50-24-230-001 Examine the Air Seal Ring for Cracks

      1. Do the test for cracks.

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

      2. No cracks are permitted.

    4. SUBTASK 72-50-24-310-001 Prepare the Honeycomb Seal Segments for Brazing

      1. Cut the honeycomb seal segments to length.

      1. Replacement honeycombs are supplied longer than necessary.

    5. SUBTASK 72-50-24-110-002 Clean the Air Seal Ring and the New Honeycomb Seal Segments

      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 72-50-24-310-002 Braze in the New Honeycomb Seal Segments

    1. Refer to Figure and Figure.

      NOTE

      If CoMat 03-234 BRAZING FILLER TAPE or CoMat 03-249 BRAZING FILLER MATERIAL,Ni-BASE is used, do not perform Step and Step.
      If CoMat 03-151 HIGH TEMP. BRAZING FILLERPOWDER or CoMat 03-148 BRAZING FILLER POWDER is used, do not perform Step.

      NOTE

      If you replace the rear honeycomb segment do not perform Step.

      NOTE

      If you replace the front honeycomb segment do not perform Step.

      2. Make sure that the electrode insert with the mark "INNER" and "OUTER" (parts of the electrode swivel) are installed.

      8. Attach the air seal ring onto the spot welding fixture.

      1. Make sure that the air seal ring is installed correctly against the spacer gages (parts of the spot welding fixture).

      9. Prepare the new honeycomb seal segments.

      2. Apply brazing filler tape to the air seal ring mating side of the honeycomb seal segment.

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

      10. Put the honeycomb seal segments onto the air seal ring.

      1. Align the honeycomb seal segments.

      11. Resistance weld the honeycomb seal segments.

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

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

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

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

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

      14. Apply white stop off around the edges of the air seal ring.

    7. SUBTASK 72-50-24-110-003 Clean the Air Seal Ring

      1. Aqueous cleaning

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

    8. SUBTASK 72-50-24-210-001 Examine the Brazed Honeycomb Seal Segments

      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 except the following limits:

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

        2. The minimum space between the unbonded areas of more than 0.063 sq in. (40.650 sq mm) should be 1.000 in. (25.400 mm).

        3. The honeycomb wall thickness must not be increased by more than 0.001 in. (0.030 mm) in the area above the braze fillet.

    9. SUBTASK 72-50-24-370-001 Precipitation Heat Treatment of the Air Seal Ring

      1. Precipitation heat treat the air seal ring.

      1. Refer to SPM TASK 70-37-00-370-501.

      2. Put the part in an oven for eight hours at 1450 to 1500 °F (788 to 816 °C).

      3. Use argon or vacuum.

      4. Cooling rate equivalent to air cooling.

    10. SUBTASK 72-50-24-320-002 Machine the Honeycomb Seal Segments

    1. Refer to Figure and Figure.

      2. Grind the honeycomb seal segments.

      3. Deburr the honeycomb seal segments.

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

    11. SUBTASK 72-50-24-110-004 Clean the Air Seal Ring

      1. Aqueous cleaning

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

    12. SUBTASK 72-50-24-220-001 Do the Post Repair Inspection

    1. Refer to Figure and Figure.

    2. Examine dimensionally.

      3. Examine visually.

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

    13. SUBTASK 72-50-24-350-001 Make a Mark to Identify the Repair

      1. Electrolytically etch or vibro-peen VRS4564 adjacent to the part number.

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

    14. SUBTASK 72-50-24-280-001 Examine the Air Seal Ring for Hardness

      1. Examine the air seal ring for hardness.

      1. Hardness to be 22 HRC minimum or equivalent.

        NOTE

        If hardness is less than the minimum specified, do a subsequent heat treat as given in Step.

    15. SUBTASK 72-50-24-370-002 Heat Treat the Air Seal Ring

      1. Precipitation heat treat the air seal ring.

      1. Refer to SPM TASK 70-37-00-370-501.

      2. Put the part in an oven for eight hours at 1450 to 1500 °F (788 to 816 °C).

      3. Use argon or vacuum.

      4. Cooling rate equivalent to air cooling.

        NOTE

        Heat treatment is only required if hardness is less than the minimum specified. Refer to Step.

      2. Do a check of the air seal ring hardness.

      1. Refer to Step.

      2. If minimum hardness is not obtained, repeat procedure in Step.

    16. Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added Support Equipment

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:3A3110
Part Name:SEAL SEGMENT - HONEYCOMB
Manufacturer Code:0AM53
Part Number:3A3111
Part Name:SEAL - 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: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 3M14208
Tool Name:IAE 3M14208 Grinding/turning fixture
Manufacturer Code:0AM53
Tool Number:IAE 3M14209
Tool Name:IAE 3M14209 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 3M14363
Tool Name:IAE 3M14363 Spot welding fixture (rear)
Manufacturer Code:LOCAL
Tool Number:Spot welding machine
Tool Name:Spot welding machine
Manufacturer Code:LOCAL
Tool Number:Turning lathe
Tool Name:Turning lathe