TASK 72-50-32-300-071 LPT Stage 4 Blade - Weld Build Up Repair The Knife Edge Seals, Repair-071 (VRS4538)

DMC:V2500-A0-72-50-3204-05A-627A-C|Issue No:003.00|Issue Date:2019-08-01

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 72-50-32-300-071 LPT Stage 4 Blade - Weld Build Up Repair The Knife Edge Seals, Repair-071 (VRS4538)

Effectivity

FIG/ITEM

PART NO.

01-150

3A2923

Material of component

PART IDENT

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.

A ** following any repair referenced in this inspection indicates that the repair is not yet published in the current revision of this manual and the part must be rejected.

Contact IAE for additional information concerning FAA approved data.

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 and SPM TASK 70-38-13-380-501.
Equivalent equipment may be used.

NOTE

To identify the consumable materials refer to the OPCI.

NOTE

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

NOTE

  1. If repair of pre-twist is also required, then do VRS4539 TASK 72-50-32-300-075 (REPAIR-075) first, before start of this repair.

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

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

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
External grinding machineLOCALExternal grinding machine
Tridimensional measuring unitLOCALTridimensional measuring unit
DELETED0AM53DELETED
IAE 3M14412 Welding fixture0AM53IAE 3M144121
IAE 3M14524 Grinding mounting block0AM53IAE 3M14524
IAE 3M14468 Grinding fixture0AM53IAE 3M14468
IAE 2M14193 Inspection mounting block0AM53IAE 2M14193
IAE 3M14466 Welding mounting block0AM53IAE 3M14466

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-287 WELDING FILLER WIRELOCALCoMat 03-287
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 05-138 SHOT, CAST STEEL, S11011851CoMat 05-138
CoMat 05-177 CUT WIRE SHOT,CW-14LOCALCoMat 05-177

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-50-32-324-061 Machine the Knife Edge Seals

    1. Refer to Figure.

      2. Grind the knife edge seals.

      1. Keep material removal to a minimum.

    2. SUBTASK 72-50-32-220-443 Examine the Machined Areas

    1. Refer to Figure.

    3. SUBTASK 72-50-32-230-190 Examine the Machined Areas for Cracks

      1. Do the test for cracks.

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

        Use high sensitivity level.

        No cracks are permitted.

    4. SUBTASK 72-50-32-110-143 Clean the Stage 4 Turbine Blade

      1. Aqueous cleaning.

      1. Refer to the SPM TASK 70-11-03-300-501.

    5. SUBTASK 72-50-32-310-086 Weld Build-Up Repair the Knife Edge Seals

    1. Refer to Figure and Figure.

      2. Gas tungsten arc weld build-up seal fins.

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

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

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

    6. SUBTASK 72-50-32-370-100 Heat Treatment after Weld Repair

      NOTE

      Do the stress-relief after all weld operations.

      1. Stress-relieve the turbine blade.

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

    7. SUBTASK 72-50-32-230-191 Examine the Welded Areas for Cracks

      1. Do the test for cracks.

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

        Repair cracks in knife edge welds if they do not extend into the outer shroud.

    8. SUBTASK 72-50-32-324-062 Machine the Welded Areas

    1. Refer to Figure and Fig 72-32-50-990-306-002.

    9. SUBTASK 72-50-32-230-192 Examine the Machined Areas for Cracks

      1. Do the test for cracks.

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

        Use high sensitivity level.

        Repair cracks in knife edge welds.

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

    10. SUBTASK 72-50-32-380-091 Shotpeen the Surface A1 of the Stage 4 Turbine Blade

    1. Refer to Figure.

      NOTE

      Do the shotpeening after all weld operations.

    2. Mask area A3.

      3. Shotpeen area A1.

      1. 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 72-50-32-220-444 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. SUBTASK 72-50-32-380-092 Make a Mark to Identify the Repair

      1. Vibropeen VRS4538 adjacent to the part number.

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

    13. Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    Figure: Repair Details and Dimensions

    Repair Details and Dimensions

    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:

Revised Support Equipment. Deleted Support Equipment. Revised Consumables. Revised Note. (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: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: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: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: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
Manufacturer Code:0AM53
Tool Number:DELETED
Tool Name:DELETED
Manufacturer Code:LOCAL
Tool Number:External grinding machine
Tool Name:External grinding machine
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:Tridimensional measuring unit
Tool Name:Tridimensional measuring unit