TASK 72-50-53-300-053 Turbine Exhaust Case (TEC) - Plasma Spray The Front Flange And The Front Mating Diameter, Repair-053 (VRS3062)

DMC:V2500-A0-72-50-5301-01A-609A-C|Issue No:003.00|Issue Date:2021-08-01

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 72-50-53-300-053 Turbine Exhaust Case (TEC) - Plasma Spray The Front Flange And The Front Mating Diameter, Repair-053 (VRS3062)

Effectivity

FIG/ITEM PART NO.

21-300

2A2620-01

21-300

2A3111-01

21-300

2A3183-01

21-300

2A3455-01

21-300

2A3183-101

21-300

2A4258-01

21-300

2A4263-01

Material of component

PART IDENT

SYMBOL

MATERIAL

Turbine Exhaust Case

-

AMS 5616 Stainless Steel

General

Price and availability - refer to IAE

The practices and processes referred to in the procedure by the TASK numbers are in SPM.

NOTE

To identify the consumable materials refer to the PCI.

NOTE

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

Preliminary Requirements

Pre-Conditions

Action/ConditionData Module/Technical Publication
Make sure that all cleaning and inspection procedures are performed before this repair.

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
IAE 3P16432 Machining fixture0AM53IAE 3P164321

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 03-096 PLASMA SPRAY POWDERLOCALCoMat 03-096
CoMat 07-123 WIRE0AM53CoMat 07-123

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-50-53-320-100 Machine the Front Flange Face and/or the Front Mating Diameter

    1. Refer to Figure.

    2. Install the part in the IAE 3P16432 Machining fixture 1 off.

      3. Machine the front flange face to remove wear or surface damage or existing plasma coating.

      1. Flange thickness must be not less than 0.120 in. (3.05 mm) after you remove the damage or plasma coating.

      2. Keep material removal to a minimum so the coating will be 0.003 in. to 0.015 in. (0.08 mm to 0.38 mm) thick after finish machining.

      4. Machine the front mating diameter to remove wear or surface damage or existing plasma coating.

      1. The inner diameter must be between 38.665 in. to 38.752 in. (982.091 mm to 984.3 mm) after machining. Remove all damage, wear, or coating, but do not remove more than 0.025 in. (0.635 mm) of material.

        NOTE

        If the machined diameter is between 38.676 in. to 38.752 in. (982.370 mm to 984.3 mm), you must use CoMat 07-123 WIRE.

    2. SUBTASK 72-50-53-110-107 Clean the Turbine Exhaust Case

      1. Clean the case.

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

    3. SUBTASK 72-50-53-380-057 Prepare the Front Flange and/or the Front Mating Diameter

      1. Grit blast the front flange and/or the front mating diameter.

      1. Refer to SPM TASK 70-34-18-380-501.

    2. Grit blast out of repair area(s) is not permitted. Use masks or maskants.

    4. SUBTASK 72-50-53-340-051 Plasma Spray the Front Flange and/or the Front Mating Diameter

    1. Refer to Figure and Figure.

      2. Plasma spray the front flange and/or the front mating diameter.

        1. Refer to SPM TASK 70-34-03-340-501.

        2. Apply the plasma spray to a sufficient thickness so that the front flange will be 11.590 in. to 11.610 in. (294.39 mm to 294.89 mm) diameter after finish machining.

        3. Apply the plasma spray to a maximum thickness of 0.015 in. (0.381 mm).

        4. No overspray is permitted.

      3. Plasma spray the front mating diameter.

        1. Refer to SPM TASK 70-34-03-340-501.

        1. If the machined diameter is less than 38.676 in. (982.37 mm), you may use CoMat 03-096 PLASMA SPRAY POWDER. If the machined diameter is between 38.676 in. to 38.752 in. (982.37 mm to 984.30 mm), you must use CoMat 07-123 WIRE. The front mating diameter must be 38.652 in. to 38.658 in. (981.761 mm to 981.913 mm) after coating and final machining.

    5. SUBTASK 72-50-53-320-178 Machine the Front Flange and/or the Front Mating Diameter

      1. Set up the part in the IAE 3P16432 Machining fixture and machine the front flange and/or the front mating diameter.

      1. Machine the front flange to 11.590 in. to 11.610 in. (294.39 mm to 294.89 mm) diameter and/or the front mating diameter to 38.652 in. to 38.658 in. (981.761 mm to 981.913 mm).

      2. Machine the chamfer to 0.035 in. to 0.045 in. (0.89 mm to 1.14 mm) by 45 degrees.

      3. The minimum coating thickness is 0.003 in. (0.076 mm).

    6. SUBTASK 72-50-53-220-200 Examine the Repair

    1. Visually examine the coated area for chips, cracks, lifted material and coating that is not attached to the base metal. Surfaces that show heat cracks are not acceptable.

    7. SUBTASK 72-50-53-220-228 Examine the Bolt Holes and Pin Hole to Establish the Bolt Circle Diameter

    1. Refer to Figure.

      2. Measure the bolt circle diameter.

      1. If the bolt circle is 39.561 in. (1004.849 mm) as given in the figure, accept the part.

        2. If the bolt circle is not 39.561 in. (1004.849 mm) elongate the holes as follows:

          1. Radially elongate the 114 equally spaced holes and the locating pin hole to establish the bolt circle again as necessary.

            1. Elongate the boltholes radially inward to 0.344 in. (8.74 mm) maximum length.

            1. Bolthole ID must not intersect the fillet.

            2. Elongate the boltholes circumferentially to 0.305 in. (7.747 mm) maximum width.

            1. Minimum strap thickness to edge radius must be 0.165 in. (4.191 mm).

          3. Elongate the locating pin hole radially inward to 0.294 in. (7.47 mm) maximum length.

            NOTE

            Pin hole elongation in a circumferential direction is not permitted.

    8. SUBTASK 72-50-53-350-111 Identify the Repair

      1. Vibration peen VRS3062 adjacent to the part number.

      1. Refer to SPM TASK 70-09-00-400-501. Use the vibration peen method with 0.006 in. (0.15 mm) maximum depth.

    9. 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:

Corrected metric dimension. (CAS-105879-K0V3K3)

Change Type:

Editorial update to reinstate deleted data due to xml issue.

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 03-096
Type:sp01
Supply Short Name:CoMat 03-096 PLASMA SPRAY POWDER
Supply Name:CoMat 03-096 PLASMA SPRAY POWDER
Specification Groups:
Doc NumberType
AMPERIT 298.442 OR AMPERIT 299.442
Suppliers:
ManufacturerRemarks
LOCAL
IAE15
IE252
Manufacturer Code:0AM53
Supply Number:CoMat 07-123
Type:sp01
Supply Short Name:CoMat 07-123 WIRE
Supply Name:CoMat 07-123 WIRE
Specification Groups:
Doc NumberType
TRANSFERRED TO COMAT 03-481
Suppliers:
ManufacturerRemarks
0AM53
Manufacturer Code:0AM53
Tool Number:IAE 3P16432
Tool Name:IAE 3P16432 Machining fixture