TASK 75-22-48-300-002 ACAC Exhaust Duct Housing - Weld Repair Or Replace The Flange, Repair-002 (VRS2209)

DMC:V2500-A0-75-22-4802-00A-627A-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 75-22-48-300-002 ACAC Exhaust Duct Housing - Weld Repair Or Replace The Flange, Repair-002 (VRS2209)

Effectivity

FIG/ITEM

PART NO.

01-040

740-1085-501

Material of component

DESCRIPTION

RR SYMBOL

MATERIAL

ACAC Duct Housing

Inconel 625

General

Price and availability - Refer to IAE.

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

This procedure provides two weld repairs for the ACAC duct housing. Step instructs a weld procedure to build-up the material in the worn areas of the flange. Step instructs replacement of the flange.

To do this procedure, welders must be certified. Refer to MIL-STD-1595 or equivalent.

Special tools - Locally manufactured.

NOTE

Equivalent materials or equipment can be used.

NOTE

To identify the consumable materials refer to the PCI.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Gas tungsten arc weld (GTAW) systemLOCALGas tungsten arc weld (GTAW) system
Hand Held Pneumatic GrinderLOCALHand Held Pneumatic Grinder
Hand held rotary grinderLOCALHand held rotary grinder
Fluorescent Penetrant Inspection EquipmentLOCALFluorescent Penetrant Inspection Equipment

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-076 METHYL ETHYL KETONELOCALCoMat 01-076
CoMat 02-099 LINT-FREE CLOTHLOCALCoMat 02-099
CoMat 03-287 WELDING FILLER WIRELOCALCoMat 03-287
CoMat 05-021 WATERPROOF SILICON CARBIDE44197CoMat 05-021
CoMat 06-131 MARKING PEN0AM53CoMat 06-131

Spares

NameManufacturerPart Number / IdentificationQuantityRemark
Flange51563740-1085-51

FIG/ITEM 01-055

Safety Requirements

NONE

Procedure

    1. SUBTASK 75-22-48-350-055 Weld Repair the Worn Areas on the ACAC Duct Housing Flange

      WARNING

      PUT ON PROTECTIVE GLOVES WHEN YOU USE THE DEGREASER.
      USE THE DEGREASER ONLY IN AREAS WITH GOOD AIRFLOW.
      THE DEGREASER IS VERY FLAMMABLE, KEEP IT AWAY FROM IGNITION SOURCES.

    1. Refer to Figure.

      2. Clean the repair area.

      1. Refer to Cleaning-001 TASK 75-22-48-100-101.

      3. Wipe the surface dry before the solvent evaporates.

        NOTE

        Position the copper back-up plate behind the flange during welding, so that it can absorb the heat and prevent the flange from buckling.

      3. Use the welding procedure to build-up the material in the worn area of the flange.

      4. Fluorescent penetrant inspect the repaired area for cracks.

      1. Refer to SPM TASK 70-23-02-230-501.

      3. No cracks are permitted.

      5. Remove the unwanted weld material and make the weld surface area smooth with the adjacent surface area.

      1. Use a Hand Held Pneumatic Grinder to grind the weld surface down to +0.005 in. (+0.127 mm) above the adjacent surface

      6. Fluorescent penetrant inspect the repaired area for cracks.

      1. Refer to SPM TASK 70-23-02-230-501.

      3. No cracks are permitted.

      7. Identify the repair.

      1. Put the mark, VRS2209, adjacent to the part number.

      2. Use a CoMat 06-131 MARKING PEN of a color that contrasts.

    2. SUBTASK 75-22-48-350-056 Replace the ACAC Duct Housing Flange

      WARNING

      PUT ON PROTECTIVE GLOVES WHEN YOU USE THE DEGREASER.
      USE THE DEGREASER ONLY IN AREAS WITH GOOD AIRFLOW.
      THE DEGREASER IS VERY FLAMMABLE, KEEP IT AWAY FROM IGNITION SOURCES.

    1. Refer to Figure.

      2. Remove the worn flange from the duct housing.

      1. Use a Hand held rotary grinder to carefully remove the worn flange.

      3. Remove the unwanted material.

      1. Use a Hand Held Pneumatic Grinder to grind the surface down to +0.005 in. (+0.127 mm) above the adjacent surface.

      4. Fluorescent penetrant inspect the repair area for cracks.

      1. Refer to SPM TASK 70-23-02-230-501.

      3. No cracks are permitted.

      5. Clean the repair area.

      1. Refer to Cleaning-001 TASK 75-22-48-100-101.

      3. Wipe the surface dry before the solvent evaporates.

      6. Position the tool and the copper back-up plate in the duct housing.

      1. The distance between the 740-1085-5 (flange) 1 off and the lower edge of the duct housing should be 0.78 in. (19.812 mm).

      7. Use the welding procedure to weld the spare flange into the duct housing.

      8. Identify the repair.

      1. Put the mark, VRS2209, adjacent to the assembly number.

      2. Use a CoMat 06-131 MARKING PEN of a color that contrasts.

    3. Figure: ACAC Exhaust Duct Housing Flange Worn Area Repair

    ACAC Exhaust Duct Housing Flange Worn Area Repair

    Figure: ACAC Exhaust Duct Housing Flange Replacement Repair

    ACAC Exhaust Duct Housing Flange Replacement Repair

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:44197
Enterprise Name:SAINT-GOBAIN INDUSTRIAL CERAMICS INC.
BU Name:SAINT-GOBAIN ABRASIVES, INC
Street:ONE NEW BOND STREET
P.O. Box:PO BOX 15008
City:WORCESTER
State:MA
Zip Code:01615-0008
Country:USA
Phone Number:1-508-795-5000
Fax Number:1-508-795-2828
Internet:www.saint-gobain-northamerica.com
Manufacturer Code:51563
Enterprise Name:ROHR INC, A COLLINS AEROSPACE COMPANY
BU Name:ROHR INC, A COLLINS AEROSPACE COMPANY
Street:850 LAGOON DRIVE
City:CHULA VISTA
State:CA
Zip Code:91910-2098
Country:USA
Phone Number:1-619-691-2089
Fax Number:1-619-691-6195
Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Link not Found
Manufacturer Code:LOCAL
Supply Number:CoMat 01-076
Type:sp01
Supply Short Name:CoMat 01-076 METHYL ETHYL KETONE
Supply Name:CoMat 01-076 METHYL ETHYL KETONE
Specification Groups:
Doc NumberType
METHYL ETHYL KETONE, TECHNICAL GRADE, CERTIFIED TO BSI BS 1940 OR ASTM D740, OR TT-M-261
Suppliers:
ManufacturerRemarks
LOCAL
Manufacturer Code:X222X
Supply Number:CoMat 02-099
Type:sp01
Supply Short Name:CoMat 02-099 LINT-FREE CLOTH
Supply Name:CoMat 02-099 LINT-FREE CLOTH
Specification Groups:
Doc NumberType
WHERE COMAT 02-099 IS SPECIFIED WITH NO SUFFIX, USE COMAT 02-099A OR COMAT 02-099B.
Suppliers:
ManufacturerRemarks
X222X
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:1E1X8
Supply Number:CoMat 05-021
Type:sp01
Supply Short Name:CoMat 05-021 WATERPROOF SILICON CARBIDE
Supply Name:CoMat 05-021 WATERPROOF SILICON CARBIDE
Specification Groups:
Doc NumberType
OMAT: 5/35 (RR REF)WATERPROOF SILICON CARBIDE ABRASIVE PAPER, CAMI GRIT DESIGNATION 240 (ANSI B74.18 )
JCR-188 (JAEC REF)
Suppliers:
ManufacturerRemarks
1E1X8
K6835
LOCAL
Manufacturer Code:0AM53
Supply Number:CoMat 06-131
Type:sp01
Supply Short Name:CoMat 06-131 MARKING PEN
Supply Name:CoMat 06-131 MARKING PEN
Suppliers:
ManufacturerRemarks
0AM53
Link not Found
Manufacturer Code:LOCAL
Tool Number:Gas tungsten arc weld (GTAW) system
Tool Name:Gas tungsten arc weld (GTAW) system
Link not Found
Manufacturer Code:LOCAL
Tool Number:Hand held rotary grinder
Tool Name:Hand held rotary grinder