TASK 72-50-32-300-040 LPT Stage 4 Blade - Weld Build Up Repair, Repair-040 (VRS4293)

DMC:V2500-A0-72-50-3204-02A-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 72-50-32-300-040 LPT Stage 4 Blade - Weld Build Up Repair, Repair-040 (VRS4293)

Effectivity

FIG/ITEM

PART NO.

01-150

3A1804

Material of component

PART IDENT

IAE

SYMBOL

MATERIAL

Stage 4 turbine blade

MTS1001D/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 70-11-03-300-503, SPM TASK 70-23-04-230-501, SPM TASK 70-23-05-230-501, SPM TASK 70-31-13-310-501, 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

  1. Do not repair the turbine blades that have cracks extending into the outer shroud.

  2. 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
Dial caliperLOCALDial caliper
External grinding machineLOCALExternal grinding machine
Gas furnaceLOCALGas furnace

2400 deg F (1315 deg C)

Radius gage setLOCALRadius gage set
Roughness microtesterLOCALRoughness microtester
Tridimensional measuring unitLOCALTridimensional measuring unit
IAE 2M14193 Inspection mounting block0AM53IAE 2M141931
IAE 3M14412 Welding fixture0AM53IAE 3M144121
IAE 3M14466 Welding mounting block0AM53IAE 3M144661
IAE 3M14468 Grinding fixture0AM53IAE 3M144681
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 72-50-32-325-060 Machine the Knife Edge Seals

      1. Machine the knife edge seals.

      1. Use IAE 3M14468 Grinding fixture 1 off, external grinding machine and IAE 3M14524 Grinding mounting block 1 off.

        Refer to Figure.

        Keep material removal to the minimum to allow subsequent repairs.

      2. Remove locally aluminide coating.

      1. Remove coating from knife edge weld area for a minimum distance of 0.040 in. (1.0 mm) all around.

        Refer to the SPM TASK 70-38-10-380-501.

    2. SUBTASK 72-50-32-220-333 Examine the Machined Edge Seals

      1. Dimensionally examine.

      1. Use IAE 2M14193 Inspection mounting block 1 off and tridimensional measuring unit.

        Refer to Figure.

    3. SUBTASK 72-50-32-230-160 Do the Test for Cracks

      1. Do the test for cracks.

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

        Use high sensitivity level.

        Cracks are not permitted.

    4. SUBTASK 72-50-32-110-132 Clean the Turbine Blade

      1. Aqueous degrease.

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

    5. SUBTASK 72-50-32-310-079 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 final machining.

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

        Machine or manual tungsten inert gas welding is permitted.

    6. SUBTASK 72-50-32-370-093 Heat Treat after Weld Repair

      1. Heat treat the blade.

      1. Stress relief.

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

        Use gas furnace 2400 deg F (1315 deg C).

    7. SUBTASK 72-50-32-230-161 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 72-50-32-320-099 Machine the Welded Areas

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

      1. Use IAE 3M14468 Grinding fixture 1 off, external grinding machine and IAE 3M14524 Grinding mounting block 1 off.

        Refer to Figure and Figure for finishing dimensions.

        Use IAE 2M14193 Inspection mounting block 1 off, tridimensional measuring unit, dial caliper, dial gage and roughness microtester.

    9. SUBTASK 72-50-32-230-162 Examine the Blade for Cracks

      1. Do the test for cracks.

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

        Use high sensitivity level.

        Cracks in knife edge welds can be repaired.

        For limits refer to VRS4301 TASK 72-50-32-300-062 (REPAIR 062, PB 901).

    10. SUBTASK 72-50-32-350-126 Shot Peen the Surface A1 of the Turbine Blade

      1. Mask turbine blade.

      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.

    11. SUBTASK 72-50-32-340-060 Remove the Protection from the Masked Surfaces

      1. Remove all masking.

      1. No masking permitted.

    12. SUBTASK 72-50-32-220-334 Examine the Blade Markings

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

      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 marking of turbine blade life.

      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.

    13. SUBTASK 72-50-32-320-100 Mark the Blade after Repair

      1. Vibro-peen VRS4293 and the applicable beehive symbol adjacent to the part number.

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

    14. Figure: Weld build-up knife edge seals of stage 4 turbine blade

    Weld build-up knife edge seals of stage 4 turbine blade

    Figure: Weld build-up knife edge seals of stage 4 turbine blade

    Sheet 1

    Legend
    Weld build-up knife edge seals of stage 4 turbine blade

    Sheet 1

    Close

    Figure: Weld build-up knife edge seals of stage 4 turbine blade

    Sheet 2

    Legend
    Weld build-up knife edge seals of stage 4 turbine blade

    Sheet 2

    Close

    Figure: Weld build-up knife edge seals of stage 4 turbine blade

    Weld build-up knife edge seals of stage 4 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 2M14193
Tool Name:IAE 2M14193 Inspection mounting block
Manufacturer Code:0AM53
Tool Number:IAE 3M14412
Tool Name:IAE 3M14412 Welding fixture
Manufacturer Code:0AM53
Tool Number:IAE 3M14466
Tool Name:IAE 3M14466 Welding mounting block
Manufacturer Code:0AM53
Tool Number:IAE 3M14468
Tool Name:IAE 3M14468 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:Tridimensional measuring unit
Tool Name:Tridimensional measuring unit