TASK 72-50-32-300-035 LPT Stage 5 Blade - Weld Build Up Repair, Repair-035 (VRS4291)

DMC:V2500-A0-72-50-3205-02A-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 72-50-32-300-035 LPT Stage 5 Blade - Weld Build Up Repair, Repair-035 (VRS4291)

Effectivity

FIG/ITEM PART NO.

01-100

3A1805

Material of component

PART IDENT

IAE

SYMBOL

MATERIAL

Stage 5 turbine blade

MTS1084A/INCO 713C

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 and SPM TASK 70-38-04-300-503.
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 furnace 2400 deg F (1315 deg C)LOCALGas furnace 2400 deg F (1315 deg C)
Radius gage setLOCALRadius gage set
Roughness microtesterLOCALRoughness microtester
Tridimensional measuring unitLOCALTridimensional measuring unit
IAE 2M14194 Inspection mounting block0AM53IAE 2M141941
IAE 3M14413 Welding fixture0AM53IAE 3M144131
IAE 3M14466 Welding mounting block0AM53IAE 3M144661
IAE 3M14470 Grinding fixture0AM53IAE 3M144701
IAE 3M14524 Grinding mounting block0AM53IAE 3M145241

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-245 WELDING FILLER WIRELOCALCoMat 03-245
CoMat 03-287 WELDING FILLER WIRELOCALCoMat 03-287
CoMat 05-030 CAST STEEL SHOT DELETED0AM53CoMat 05-030

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-50-32-325-058 Machine the Knife Edge Seals

      1. Machine the knife edge seals.

      1. Refer to Figure.

        Keep material removal to the minimum to allow subsequent repairs.

    2. SUBTASK 72-50-32-220-329 Examine the Machined Edge Seals

      1. Dimensionally examine.

      1. Use IAE 2M14194 Inspection mounting block 1 off and tridimensional measuring unit.

        Refer to Figure.

    3. SUBTASK 72-50-32-230-154 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 72-50-32-110-130 Clean the Turbine Blade

      1. Aqueous degrease.

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

    5. SUBTASK 72-50-32-310-077 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.

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

    6. SUBTASK 72-50-32-370-091 Heat Treat after Weld Repair

      1. Heat treat the blade.

      1. Stress relief at 1575 to 1625 deg F (857 to 885 deg C) for two hours.

        Heating and cooling rate 40 deg F (22 deg C) per minute.

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

    7. SUBTASK 72-50-32-230-155 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 72-50-32-320-095 Machine the Welded Areas

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

      1. Refer to Figure and Figure for finishing dimensions.

        Use IAE 2M14194 Inspection mounting block 1 off, tridimensional measuring unit, dial caliper, dial gage and roughness microtester.

    9. SUBTASK 72-50-32-230-156 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 Repair, VRS4192 TASK 72-50-32-300-014 (REPAIR-014).

    10. SUBTASK 72-50-32-350-124 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 72-50-32-340-058 Remove the Protection from the Masked Surfaces

      1. Remove all masking.

      1. No masking permitted.

    12. SUBTASK 72-50-32-220-330 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 72-50-32-320-096 Mark the Blade after Repair

      1. Vibro-peen VRS4291 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 5 turbine blade

    Weld build-up knife edge seals of stage 5 turbine blade

    Figure: Weld build-up knife edge seals of stage 5 turbine blade

    Sheet 1

    Legend
    Weld build-up knife edge seals of stage 5 turbine blade

    Sheet 1

    Close

    Figure: Weld build-up knife edge seals of stage 5 turbine blade

    Sheet 2

    Legend
    Weld build-up knife edge seals of stage 5 turbine blade

    Sheet 2

    Close

    Figure: Weld build-up knife edge seals of stage 5 turbine blade

    Weld build-up knife edge seals of stage 5 turbine blade

Requirements After Job Completion

Follow-On Conditions

NONE
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:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 03-245
Type:sp01
Supply Short Name:CoMat 03-245 WELDING FILLER WIRE
Supply Name:CoMat 03-245 WELDING FILLER WIRE
Specification Groups:
Doc NumberType
AMS 5679ALLOY FM62
Suppliers:
ManufacturerRemarks
LOCAL
2R602
39861
55596
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:LOCAL
Tool Number:Dial caliper
Tool Name:Dial caliper
Manufacturer Code:LOCAL
Tool Number:External grinding machine
Tool Name:External grinding machine
Link not Found
Manufacturer Code:0AM53
Tool Number:IAE 2M14194
Tool Name:IAE 2M14194 Inspection mounting block
Manufacturer Code:0AM53
Tool Number:IAE 3M14413
Tool Name:IAE 3M14413 Welding fixture
Manufacturer Code:0AM53
Tool Number:IAE 3M14466
Tool Name:IAE 3M14466 Welding mounting block
Manufacturer Code:0AM53
Tool Number:IAE 3M14470
Tool Name:IAE 3M14470 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