TASK 72-50-32-300-050 LPT Stage 3 Blade - Weld Build Up Repair The Knife Edge Seals, Repair-050 (VRS4297)

DMC:V2500-A0-72-50-3203-02A-627A-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 72-50-32-300-050 LPT Stage 3 Blade - Weld Build Up Repair The Knife Edge Seals, Repair-050 (VRS4297)

Effectivity

FIG/ITEM

PART NO.

01-200

3A2055

Material of component

PART IDENT

IAE

SYMBOL

MATERIAL

Stage 3 turbine blade

Inconel 100

General

Price and availability - none

The practices and processes referred to in this procedure by the TASK number 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 70-11-03-300-501, SPM TASK 70-23-04-230-501, SPM TASK 70-23-05-230-501, SPM TASK 70-31-13-310-501, SPM TASK 70-37-10-370-501, SPM TASK 70-38-04-300-503 and SPM TASK 70-38-10-380-501.
Equivalent materials or equipment can 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.

NOTE

If repair of pre-twist per TASK 72-50-32-300-052 (VRS4306 REPAIR 052) is also required, then do TASK 72-50-32-300-052 (VRS4306 REPAIR 052) first, before start of this repair.
Do not repair the turbine blades that have cracks extending into the outer shroud.
Before you do the repair, write down the turbine blade length dimension, part number, heat code, blade life figure and serial number.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Shot peening equipmentLOCALShot peening equipment
Dial caliperLOCALDial caliper
Gas furnaceLOCALGas furnace

2400 deg F box

External grinding machineLOCALExternal grinding machine
Radius gage setLOCALRadius gage set
Roughness microtesterLOCALRoughness microtester
Tridimensional measuring unitLOCALTridimensional measuring unit
IAE 2M14195 Inspection mounting block0AM53IAE 2M141951
IAE 3M14411 Welding fixture0AM53IAE 3M144111
IAE 3M14466 Welding mounting block0AM53IAE 3M144661
IAE 3M14467 Grinding fixture0AM53IAE 3M144671
IAE 3M14524 Grinding mounting block0AM53IAE 3M145241

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-287 WELDING FILLER WIRELOCALCoMat 03-287
CoMat 05-030 CAST STEEL SHOT DELETED0AM53CoMat 05-030
CoMat 05-075 WATERPROOF SILICON CARBIDEIE241CoMat 05-075

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-50-32-324-055 Machine the Knife Edge Seals

      1. Machine the knife edge seals.

      1. Use the IAE 3M14524 Grinding mounting block 1 off, IAE 3M14467 Grinding fixture 1 off and external grinding machine.

        Refer to Figure.

        Keep material removal to the minimum to allow subsequent repairs.

      2. Remove the local aluminide coating.

    2. SUBTASK 72-50-32-220-313 Examine the Machined Edge Seals

      1. Dimensionally examine.

      1. Use the IAE IAE 2M14195 Inspection mounting block 1 off and the tridimensional measuring unit.

        Refer to Figure.

    3. SUBTASK 72-50-32-230-138 Do the Test for Cracks

      1. Do the test for cracks.

      1. Refer to the SPM TASK 70-23-05-230-501.

        Cracks are not permitted.

    4. SUBTASK 72-50-32-110-122 Clean the Stage 3 Turbine Blade

      1. Degrease.

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

    5. SUBTASK 72-50-32-310-071 Weld-Up Repair the Knife Edge Seals

      1. Tungsten inert gas weld build-up seal fins.

      1. Refer to Figure and Figure.

        Weld build-up sufficient material to do the final machining.

        Refer to the SPM TASK 70-31-13-310-501.

        Machining or manual tungsten inert gas welding is permitted.

    6. SUBTASK 72-50-32-370-085 Heat Treat after Weld Repair

      1. Heat treat the blade.

      1. Stress relieve.

        Refer to the SPM TASK 70-37-10-370-501.

        Use a gas furnace 2400 deg F box.

    7. SUBTASK 72-50-32-230-139 Examine the Welded Areas for Cracks

      1. Do the test for cracks.

      1. Refer to the SPM TASK 70-23-04-230-501.

        Cracks in the knife edge welds can be repaired if they do not extend into the shroud.

    8. SUBTASK 72-50-32-324-056 Machine the Welded Areas

      1. Grind the seal tip radius, end faces, thickness and fillet radius.

      1. Use IAE 3M14524 Grinding mounting block 1 off, IAE 3M14467 Grinding fixture 1 off and external grinding fixture.

        Refer to Figure and Figure for finishing dimensions.

        Use IAE 2M14195 Inspection mounting block 1 off, tridimensional measuring unit, dial caliper, dial gage set and roughness microtester.

    9. SUBTASK 72-50-32-230-140 Examine the Stage 3 Turbine Blade for Cracks

      1. Do the test for cracks.

      1. Refer to the SPM TASK 70-23-05-230-501.

        Cracks in the knife edge welds can be repaired.

        For limits, refer to Repair VRS4204, TASK 72-50-32-300-026 (REPAIR-026).

    10. SUBTASK 72-50-32-350-116 Shot-Peen the Surface A1 of the Stage 3 Turbine Blade

      1. Mask the stage 3 turbine blade surfaces.

      1. Mask area A3 as shown in Figure.

      2. Shot peen area A1.

      1. Refer to the SPM TASK 70-38-04-300-503.

        Use CoMat 05-030 CAST STEEL SHOT DELETED to an intensity of 6A.

        Shot-peening is permitted in area A2 but must not be complete.

      3. Remove all masking from the stage 3 turbine blade surfaces.

      1. Remove masking.

    11. SUBTASK 72-50-32-220-314 Examine the Stage 3 Turbine Blade Markings

      1. Examine the blade length, part number, heat code and serial number markings.

      1. If any of these are unreadable, then make new marks.

        Use the roll stamp method.

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

      2. Examine the blade marking.

      1. If this marking is unreadable, then make a new mark.

        Use the vibro-peen method.

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

    12. SUBTASK 72-50-32-320-086 Mark the Stage 3 Turbine Blade after Repair

      1. Vibro-peen VRS4297 and the applicable beehive symbol adjacent to part number.

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

    13. Figure: Pre-machining the knife edge seals of the turbine blade

    Pre-machining the knife edge seals of the turbine blade

    Figure: Weld build-up and machining the knife edge seals of the turbine blade

    Sheet 1

    Legend
    Weld build-up and machining the knife edge seals of the turbine blade

    Sheet 1

    Close

    Figure: Weld build-up and machining the knife edge seals of the turbine blade

    Sheet 2

    Legend
    Weld build-up and machining the knife edge seals of the turbine blade

    Sheet 2

    Close

    Figure: Shot peening the blade root after weld build-up and machining the knife edge seals of the turbine blade

    Shot peening the blade root after weld build-up and machining the knife edge seals of the turbine blade

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Editorial correction due to conversion

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:IE241
Enterprise Name:DELETED. Was ANGLO ABRASIVES.
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 03-287
Type:sp01
Supply Short Name:CoMat 03-287 WELDING FILLER WIRE
Supply Name:CoMat 03-287 WELDING FILLER WIRE
Specification Groups:
Doc NumberType
INCONEL 625 AMS 5837 AMS 5837
Suppliers:
ManufacturerRemarks
LOCAL
2R602
55596
58401
Manufacturer Code:0AM53
Supply Number:CoMat 05-030
Type:sp01
Supply Short Name:CoMat 05-030 CAST STEEL SHOT DELETED
Supply Name:CoMat 05-030 CAST STEEL SHOT DELETED
Specification Groups:
Doc NumberType
DELETED
Suppliers:
ManufacturerRemarks
0AM53
Manufacturer Code:1E1X8
Supply Number:CoMat 05-075
Type:sp01
Supply Short Name:CoMat 05-075 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-075 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/28 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 800
JCR-181 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
K1905
K6835
LOCAL
Manufacturer Code:LOCAL
Tool Number:Dial caliper
Tool Name:Dial caliper
Manufacturer Code:LOCAL
Tool Number:External grinding machine
Tool Name:External grinding machine
Manufacturer Code:LOCAL
Tool Number:Gas furnace
Tool Name:Gas furnace
Manufacturer Code:0AM53
Tool Number:IAE 2M14195
Tool Name:IAE 2M14195 Inspection mounting block
Manufacturer Code:0AM53
Tool Number:IAE 3M14411
Tool Name:IAE 3M14411 Welding fixture
Manufacturer Code:0AM53
Tool Number:IAE 3M14466
Tool Name:IAE 3M14466 Welding mounting block
Manufacturer Code:0AM53
Tool Number:IAE 3M14467
Tool Name:IAE 3M14467 Grinding fixture
Manufacturer Code:0AM53
Tool Number:IAE 3M14524
Tool Name:IAE 3M14524 Grinding mounting block
Manufacturer Code:LOCAL
Tool Number:Radius gage set
Tool Name:Radius gage set
Manufacturer Code:LOCAL
Tool Number:Roughness microtester
Tool Name:Roughness microtester
Manufacturer Code:LOCAL
Tool Number:Shot peening equipment
Tool Name:Shot peening equipment
Manufacturer Code:LOCAL
Tool Number:Tridimensional measuring unit
Tool Name:Tridimensional measuring unit