TASK 72-50-32-300-023 LPT Stage 4 Blade - Weld Build Up Repair Of Outer Shroud Hardfacing, Repair-023 (VRS4201)

DMC:V2500-A0-72-50-3204-00A-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 72-50-32-300-023 LPT Stage 4 Blade - Weld Build Up Repair Of Outer Shroud Hardfacing, Repair-023 (VRS4201)

Effectivity

FIG/ITEM

PART NO.

01-150

3A0884

Material of component

PART IDENT

SYMBOL

MATERIAL

Stage 4 turbine blade

MTS1084D

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 70-11-01-300-503, SPM TASK 70-23-03-230-501, SPM TASK 70-23-08-230-501, SPM TASK 70-31-08-310-501, SPM TASK 70-37-00-370-501, SPM TASK 70-37-10-370-501 and SPM TASK 70-38-04-300-503.
Equivalent materials and 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.

NOTE

If repair of pre-twist per VRS4200 TASK 72-50-32-300-022 (REPAIR-022) is also required, then do VRS4200 TASK 72-50-32-300-022 (REPAIR-022) first, before the start of this repair.
Before start of repair, record the stage 4 turbine blade manufacturing code part number, heat code, blade life figure and serial number, if marked on blade.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Cleaning facilityLOCALCleaning facility
Welding facilityLOCALWelding facility
Inspection facilityLOCALInspection facility
Machining facilityLOCALMachining facility
Heat treatment facilityLOCALHeat treatment facility
Crack inspection equipmentLOCALCrack inspection equipment
Blasting facilityLOCALBlasting facility
Marking facilityLOCALMarking facility
IAE 2M14167 Inspection gage0AM53IAE 2M141671
IAE 3M14398 Welding mounting block0AM53IAE 3M143981
IAE 3M14498 Welding fixture0AM53IAE 3M144981
IAE 3M14509 Grinding fixture0AM53IAE 3M145091

(convex/concave side)

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-283 COATING ALLOY0CZB2CoMat 03-283
CoMat 05-030 CAST STEEL SHOT DELETED0AM53CoMat 05-030
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-50-32-110-103 Clean the Stage 4 Turbine Blade

      1. Vapor degrease.

      1. Refer to the SPM TASK 70-11-01-300-503.

    2. SUBTASK 72-50-32-310-061 Weld Build-Up Repair the Worn Surfaces

      1. Tungsten inert gas weld build-up surfaces.

      1. Refer to Fig. 72-50-32-990-141 and the SPM TASK 70-31-08-310-501.

        Build up sufficient material to do last machining.

        In area A4 electrical contact is permitted.

        No burning, pitting or selective attack is permitted.

    3. SUBTASK 72-50-32-220-217 Examine the Welded Areas

      1. Examine the hardness of weld nugget.

      1. Use Rockwell hardness tester.

        Rockwell 40 HRC minimum or equivalent required.

      2. Visually examine.

      1. Use 10x magnifying glass.

        Refer to the SPM TASK 70-31-08-310-501 for weld acceptance limits.

    4. SUBTASK 72-50-32-320-068 Machine the Welded Areas

      1. Grind the welded areas.

      1. Refer to Figure and Fig. 72-50-32-142-002 for dimensions.

      2. Remove weld to original contours on inner and outer surfaces.

      1. Use hand held rotating polishing wheel.

        Refer to Figure for dimensions.

        Use radius gage set.

      3. Remove burrs and sharp edges.

      1. Use pneumatic hand held grinder.

        Refer to Figure for dimensions.

    5. SUBTASK 72-50-32-220-218 Examine Repaired Outer Shroud Hardfacing

      1. Visually examine the hardfacing.

      1. Use 10x magnifying glass.

        The extension of linear discontinuities to any edge is not permitted.

      2. Dimensionally examine the hardface areas.

    6. SUBTASK 72-50-32-370-075 Heat Treatment after Machining

      1. Heat treat the stage 4 turbine blade.

      1. Heating and cooling rate to be maximum 40 deg F (22 deg C) per minute.

    7. SUBTASK 72-50-32-230-117 Examine the Stage 4 Turbine Blade for Cracks after Heat Treatment

      1. Do the test for cracks.

      1. The maximum permitted length of discontinuities is 0.016 in. (0.4 mm) in the repaired areas.

    8. SUBTASK 72-50-32-110-104 Clean the Stage 4 Turbine Blade

      1. Vapor degrease.

      1. Refer to the SPM TASK 70-11-01-300-503.

    9. SUBTASK 72-50-32-380-073 Shot Peen the Surface A1 of the Stage 4 Turbine Blade

      1. Mask the turbine blade in area A3.

      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.

        Refer to Figure.

    3. Remove all masking.

    10. SUBTASK 72-50-32-220-219 Examine the Blade Markings

      1. Examine the markings of the stage 4 turbine blade manufacturing code, part number, heat code and serial number.

      1. If you cannot read any of these, make new marks.

        Use roll stamp method.

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

      2. Examine the marking of the stage 4 turbine blade life.

      1. If you cannot read this marking, make a new mark.

        Use vibropeen method.

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

    11. Figure: Weld build-up of outer shroud hardfacing

    Weld build-up of outer shroud hardfacing

    Figure: Weld build-up of outer shroud hardfacing

    Weld build-up of outer shroud hardfacing

    Figure: Weld build-up of outer shroud hardfacing

    Weld build-up of outer shroud hardfacing

    Figure: Weld build-up of outer shroud hardfacing

    Weld build-up of outer shroud hardfacing

    Figure: Weld build-up of outer shroud hardfacing

    Weld build-up of outer shroud hardfacing

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:0CZB2
Enterprise Name:DELETED. REFER TO VENDOR CODE 1YSY4.
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 02-001
Type:sp01
Supply Short Name:CoMat 02-001 ADHESIVE TAPE (MASKING)
Supply Name:CoMat 02-001 ADHESIVE TAPE (MASKING)
Specification Groups:
Doc NumberType
OMAT: 230 (RR REF)ZINC OXIDE AT142
JCR-197 (JAEC REF)ZINC OXIDE AT142
Suppliers:
ManufacturerRemarks
LOCAL
K6835
U0415
Manufacturer Code:0CZB2
Supply Number:CoMat 03-283
Type:sp01
Supply Short Name:CoMat 03-283 COATING ALLOY
Supply Name:CoMat 03-283 COATING ALLOY
Specification Groups:
Doc NumberType
POWDER PWA 694
Suppliers:
ManufacturerRemarks
0CZB2
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:LOCAL
Tool Number:Blasting facility
Tool Name:Blasting facility
Manufacturer Code:LOCAL
Tool Number:Cleaning facility
Tool Name:Cleaning facility
Manufacturer Code:LOCAL
Tool Number:Crack inspection equipment
Tool Name:Crack inspection equipment
Manufacturer Code:LOCAL
Tool Number:Heat treatment facility
Tool Name:Heat treatment facility
Manufacturer Code:0AM53
Tool Number:IAE 2M14167
Tool Name:IAE 2M14167 Inspection gage
Manufacturer Code:0AM53
Tool Number:IAE 3M14398
Tool Name:IAE 3M14398 Welding mounting block
Manufacturer Code:0AM53
Tool Number:IAE 3M14498
Tool Name:IAE 3M14498 Welding fixture
Manufacturer Code:0AM53
Tool Number:IAE 3M14509
Tool Name:IAE 3M14509 Grinding fixture
Manufacturer Code:LOCAL
Tool Number:Inspection facility
Tool Name:Inspection facility
Manufacturer Code:LOCAL
Tool Number:Machining facility
Tool Name:Machining facility
Manufacturer Code:LOCAL
Tool Number:Marking facility
Tool Name:Marking facility
Manufacturer Code:LOCAL
Tool Number:Welding facility
Tool Name:Welding facility