TASK 72-50-32-300-045 LPT Stage 4 Blade - Weld Build Up Repair Of Outer Shroud Hardfacing, Repair-045 (VRS4287)

DMC:V2500-A0-72-50-3204-03A-627A-C|Issue No:003.00|Issue Date:2019-11-01

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 72-50-32-300-045 LPT Stage 4 Blade - Weld Build Up Repair Of Outer Shroud Hardfacing, Repair-045 (VRS4287)

Effectivity

FIG/ITEM

PART NO.

01-150

3A1804

01-150

3A2374

Material of component

DESCRIPTION

IAE SYMBOL

MATERIAL

Stage 4 turbine blade

Inconel 100

General

Price and availability - none

The practices and processes referred to in the 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 70-23-08-230-501, SPM TASK 70-31-08-310-501, SPM TASK 70-37-10-370-501 and SPM TASK 70-38-13-380-501.
Equivalent materials may be used.

NOTE

To identify the consumable materials refer to the PCI.

NOTE

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

NOTE

  1. If repair of pre-twist is also required, then do VRS4305 TASK 72-50-32-300-046 (REPAIR-046) first, before start of this repair.

  2. Touch-up of aluminide coating in repaired areas is not required.

  3. Before repair, write down turbine blade part number and serial number.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Rockwell hardness testerLOCALRockwell hardness tester
10X Illuminated magnifierLOCAL10X Illuminated magnifier
Hand held grinderLOCALHand held grinder
IAE 2M14189 Inspection gage0AM53IAE 2M141891
IAE 3M14398 Welding mounting block0AM53IAE 3M143981
IAE 3M14402 Grinding fixture (convex/concave side)0AM53IAE 3M144021
IAE 3M14498 Welding fixture0AM53IAE 3M144981

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-283 COATING ALLOY0CZB2CoMat 03-283
CoMat 05-029 CAST STEEL SHOT, S110LOCALCoMat 05-029
CoMat 05-030 CAST STEEL SHOT DELETED0AM53CoMat 05-030
CoMat 05-031 CAST STEEL SHOT DELETED0AM53CoMat 05-031
CoMat 05-075 WATERPROOF SILICON CARBIDEIE241CoMat 05-075
CoMat 05-138 SHOT, CAST STEEL, S11011851CoMat 05-138
CoMat 05-177 CUT WIRE SHOT,CW-14LOCALCoMat 05-177

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-50-32-326-002 Remove the Coating Locally

      1. Remove the aluminide coating, locally.

    2. SUBTASK 72-50-32-110-120 Clean the Stage 4 Turbine Blade

      1. Aqueous cleaning

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

    3. SUBTASK 72-50-32-310-070 Weld Build-Up Repair the Worn Surfaces

    1. Refer to Figure.

      2. Gas tungsten arc weld surfaces

      1. Refer to the SPM TASK 70-31-08-310-501.

        Make sure that there is sufficient material to do last machining.

        Decrease temperature of the turbine blade to reduce heat affected zone to a minimum.

        In area A4 electrical contact is permitted.

        No burning, pitting or selective attack is permitted.

    4. SUBTASK 72-50-32-220-310 Examine the Welded Areas

      1. Examine the hardness of weld nugget.

      1. Rockwell 40 HRC minimum or equivalent required.

      2. Examine visually.

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

    5. SUBTASK 72-50-32-320-085 Machine the Welded Areas

    1. Refer to Figure, Figure, and Figure.

      2. Grind the welded areas.

      3. CAUTION

        DO NOT OVERHEAT THE AREAS TO BE DRESSED.

        Dress the welds.

      1. Welded areas must be equal to the original contours and must be flush with the adjacent surfaces. Remove burrs and sharp edges.

    6. SUBTASK 72-50-32-220-311 Examine the Machined Outer Shroud Hardfacing

    1. Refer to Figure and Figure.

      2. Examine the hardfacing visually.

      1. The extension of linear discontinuites to any edge is not permitted.

      3. Examine the machined areas dimensionally.

    7. SUBTASK 72-50-32-370-084 Heat Treatment after Machining

      NOTE

      Do the stress-relief after all weld and coating operations.
      This SUBTASK is optional if aluminide coating will be completely removed and re-applied per VRS4296, TASK 72-50-32-300-043 (REPAIR-043) after weld repair.

      1. Stress-relieve the turbine blade.

      1. Refer to the SPM TASK 70-37-10-370-501, Stress-Relief Cycle 5.

    8. SUBTASK 72-50-32-230-136-001 Examine the Machined Areas for Cracks

      1. Do the test for cracks.

      1. Refer to the SPM TASK 70-23-08-230-501.

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

    9. SUBTASK 72-50-32-110-121 Clean the Stage 4 Turbine Blade

      1. Aqueous cleaning

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

    10. SUBTASK 72-50-32-380-081 Shotpeen the Surface A1 of the Stage 4 Turbine Blade

    1. Refer to Figure.

      NOTE

      Do the shotpeening after all weld and coating operations.

    2. Mask the area A3.

      3. Shotpeen area A1.

      1. Refer to the SPM TASK 70-38-13-380-501.

        Shotpeen blade root flanks plus corner radii to end faces.

        Shotpeening is permitted in area A2.

      4. Remove the masking.

      1. Remove masking.

    11. SUBTASK 72-50-32-220-312 Examine the Stage 4 Turbine Blade Markings

      1. Examine the markings of part number and serial number.

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

        Use the roll stamp method.

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

    12. Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    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

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Added note. (92VM513/C)

Change Type:

Revised Support equipment nomenclature. Revised Consumable nomenclature. (Editorial)

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:11851
Enterprise Name:DANIELS MANUFACTURING CORP
BU Name:DANIELS MANUFACTURING CORP
Street:526 THORPE RD
City:ORLANDO
State:FL
Zip Code:32824
Country:USA
Phone Number:1-407-855-6161
Fax Number:1-407-855-6884
Internet:www.dmctools.com
Manufacturer Code:IE241
Enterprise Name:DELETED. Was ANGLO ABRASIVES.
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
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:55807
Supply Number:CoMat 05-029
Type:sp01
Supply Short Name:CoMat 05-029 CAST STEEL SHOT, S110
Supply Name:CoMat 05-029 CAST STEEL SHOT, S110
Specification Groups:
Doc NumberType
AMS 2431/1 ASR 110
Suppliers:
ManufacturerRemarks
55807
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:0AM53
Supply Number:CoMat 05-031
Type:sp01
Supply Short Name:CoMat 05-031 CAST STEEL SHOT DELETED
Supply Name:CoMat 05-031 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:55807
Supply Number:CoMat 05-138
Type:sp01
Supply Short Name:CoMat 05-138 SHOT, CAST STEEL, S110
Supply Name:CoMat 05-138 SHOT, CAST STEEL, S110
Specification Groups:
Doc NumberType
AMS 2431/1 ASR 110, HARDNESS 45-55 HRC
Suppliers:
ManufacturerRemarks
55807
Manufacturer Code:0FUN2
Supply Number:CoMat 05-177
Type:sp01
Supply Short Name:CoMat 05-177 CUT WIRE SHOT,CW-14
Supply Name:CoMat 05-177 CUT WIRE SHOT,CW-14
Specification Groups:
Doc NumberType
AMS 2431/3 AWCR 14 HARDNESS 45-55 HRC
Suppliers:
ManufacturerRemarks
0FUN2
29978
S5114
Link not Found
Manufacturer Code:LOCAL
Tool Number:Hand held grinder
Tool Name:Hand held grinder
Manufacturer Code:0AM53
Tool Number:IAE 2M14189
Tool Name:IAE 2M14189 Inspection gage
Manufacturer Code:0AM53
Tool Number:IAE 3M14398
Tool Name:IAE 3M14398 Welding mounting block
Manufacturer Code:0AM53
Tool Number:IAE 3M14402
Tool Name:IAE 3M14402 Grinding fixture (convex/concave side)
Manufacturer Code:0AM53
Tool Number:IAE 3M14498
Tool Name:IAE 3M14498 Welding fixture
Manufacturer Code:LOCAL
Tool Number:Rockwell hardness tester
Tool Name:Rockwell hardness tester