TASK 72-50-53-300-077 Turbine Exhaust Case (TEC) - Plasma Spray Repair The Rear Inner Flange Face, Repair-077 (VRS3654)

DMC:V2500-A0-72-50-5301-03A-609A-C|Issue No:001.00|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 72-50-53-300-077 Turbine Exhaust Case (TEC) - Plasma Spray Repair The Rear Inner Flange Face, Repair-077 (VRS3654)

Effectivity

FIG/ITEM

PART NO.

03-001

4A8014

03-001

4A8025

21-300

2A1209-01

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

IAE

SYMBOL

MATERIAL

Turbine exhaust case

AMS 5616 Stainless steel

General

Price and availability - refer to IAE

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

NOTE

To identify the consumable materials, refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NONE

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)LOCALCoMat 06-064
CoMat 07-123 WIRE0AM53CoMat 07-123
CoMat 03-096 PLASMA SPRAY POWDERLOCALCoMat 03-096

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 72-50-53-320-130 Machine the Rear Inner Flange Face

    1. Refer to: Figure

      2. Machine rear face of inner rear flange.

      1. Machine rear face to remove wear of damage.

        Keep removal of material to minimum that is necessary to remove damage.

        Make sure dimension is 10.017 to 10.026 in. (254.43 to 254.66 mm) in relation to surface Z.

    2. SUBTASK 72-50-53-230-117 Examine the Rear Inner Flange before Coating

      1. Do a fluorescent penetrant inspection of rear inner flange face for cracks.

      1. No cracks are permitted.

        NOTE

        This step is required if the method of machining used in Step (4) was grinding. For all other methods, this step is optional.

    3. SUBTASK 72-50-53-350-169 Prepare the Rear Inner Flange Face for Coating

      1. Prepare surface for plasma or other thermal spray.

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

      2. Apply a mask to areas of turbine exhaust case not to be plasma sprayed.

      1. No coating is permitted in the holes.

    4. SUBTASK 72-50-53-110-133 Clean the Turbine Exhaust Case

      1. Clean case after abrasive blast.

      1. Clean case with a blast of dry air.

        Use clean, lint-free gloves to handle case after you clean it.

    5. SUBTASK 72-50-53-340-053 Apply Plasma Spray to the Rear Face of the Rear Inner Flange

      CAUTION

      APPLY METAL PLASMA SPRAY TO THE REAR FACE AS SOON AS POSSIBLE IN LESS THAN TWO HOURS AFTER YOU ABRASIVE BLAST. DO THE ABRASIVE BLAST AGAIN IF YOU EXCEEDED THIS TIME LIMIT.

      1. Apply plasma spray to rear face of rear inner flange.

      1. Apply plasma spray to a sufficient thickness to permit finish machining to the dimensions given in the figure.

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

        Use CoMat 03-096 PLASMA SPRAY POWDER if the final coating thickness is less than 0.015 in. (0.38 mm).

        Use CoMat 07-123 WIRE, if a final coating thickness of more than 0.015 in. (0.38 mm) is necessary.

        No overspray is permitted.

    2. Remove mask and clean remaining masking adhesive.

    6. SUBTASK 72-50-53-320-131 Finish Machine the Rear Face of the Rear Inner Flange

      1. Machine rear face of rear inner flange.

      1. Rear face must be 10.029 in. to 10.049 in. (254.74 to 255.24 mm) in relation to Surface Z.

        Minimum coating thickness must be 0.003 in. (0.076 mm).

    7. SUBTASK 72-50-53-220-217 Examine the Repair

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

    8. SUBTASK 72-50-53-350-170 Identify the Repair

      1. Vibration peen VRS3654 adjacent to part number.

      1. Refer to the 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

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 03-096
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:X222X
Supply Number:CoMat 06-064
Type:sp01
Supply Short Name:CoMat 06-064FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Supply Name:CoMat 06-064 FLUORESCENT PENETRANT (WATER WASHABLE MEDIUM SENSITIVITY)
Specification Groups:
Doc NumberType
It is not permitted to mix the selected CoMat 06‐064 letter suffix material with other CoMat 06‐064 letter suffix materials.Where CoMat 06‐064 is specified with no suffix, use one of the CoMat 06‐064 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
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