TASK 75-24-48-300-015 HPT ACC Air Manifold - Weld Repair Cracks, Repair-015 (VRS1546)

DMC:V2500-A0-75-24-4801-01A-627A-C|Issue No:002.00|Issue Date:2015-11-01

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 75-24-48-300-015 HPT ACC Air Manifold - Weld Repair Cracks, Repair-015 (VRS1546)

Effectivity

FIG/ITEM

PART NO.

02-500

2A1569

Material of component

DESCRIPTION

SYMBOL

MATERIAL

Turbine cooling manifold assembly

18Cr-10.5Ni-0.4Ti steel

Bracket

47.5Ni-22Cr-1.5C0-9.OMo- 0.6W-18.5Fe

General

Price and availability - none.

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

This repair scheme contains two types of repair, local crack welding repair (Step to Step) and flush patch welding repair (Step and Step to Step). Flush patch welding is for repair of large areas.

For the method to clean the parts, refer to Cleaning-000 TASK 75-24-48-100-100.

NOTE

Equivalent materials or equipment can be used.

NOTE

1. To identify the consumable materials refer to the PCI.
2. More equipment and materials necessary to do this repair are given in SPM TASK 70-23-02-230-501, SPM TASK 70-23-05-230-501 and SPM TASK 70-31-02-310-501.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
TIG welding equipmentLOCALTIG welding equipment
Grinder, Hand held pneumaticLOCALGrinder, Hand held pneumatic
Fluorescent Penetrant Inspection EquipmentLOCALFluorescent penetrant inspection equipment
Fluorescent Penetrant Inspection EquipmentLOCALFluorescent Penetrant Inspection Equipment
Magnifying glassLOCALMagnifying glass

8x

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-031 ACETONE (CH3)2COLOCALCoMat 01-031
CoMat 02-099 LINT-FREE CLOTHLOCALCoMat 02-099
CoMat 03-197 WELDING FILLER WIRELOCALCoMat 03-197
CoMat 03-204 WELDING FILLER WIRELOCALCoMat 03-204

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 75-24-48-230-061 Examine the Turbine Cooling Manifold Assembly

      1. Fluorescent penetrant examine the turbine cooling manifold assembly for crack indications.

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

    2. SUBTASK 75-24-48-350-109 Dress-Out the Crack to Weld without Patches

    1. Refer to Figure.

      2. Dress-out the Crack.

      1. Use a

    3. Make sure that the crack is completely removed from the turbine cooling manifold assembly.

    3. SUBTASK 75-24-48-110-068 Remove all the Dirt from the Surface

      1. Remove all the oxides, hydrocarbon, grit and scale by local cleaning from the surface to be welded and the adjacent area.

      1. Refer to Cleaning-000 TASK 75-24-48-100-100.

    4. SUBTASK 75-24-48-310-065 Weld the Dressed Cracks on the Turbine Cooling Manifold Assembly

    1. Refer to Figure.

      2. Weld the dressed cracks manually by tungsten inert gas (TIG) weld.

      3. Use CoMat 03-197 WELDING FILLER WIRE if the welding extends to, or on the bracket.

      3. Remove the excess weld and dress flush with the adjacent area.

    5. SUBTASK 75-24-48-350-110 Make Air-Holes in the Turbine Cooling Manifold Assembly

      1. Make air-holes in the repaired area of the turbine cooling manifold assembly, (if applicable).

      1. Make again the air-hole pattern to the same size and spacing as the other holes, in the same hole system, where welds affect the holes.

    6. SUBTASK 75-24-48-310-066 Heat Treat the Turbine Cooling Manifold Assembly

      1. Heat treat the turbine cooling manifold assembly.

      1. Stress relieve at 1200 deg F + 25 deg F (649 deg C + 14 deg C) for one hour.

    7. SUBTASK 75-24-48-350-111 Examine the Repaired Area for Cracks

      1. Penetrant examine the repaired area.

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

      2. Visually examine the repaired area.

      1. Use an 8x Magnifying glass.

      2. Refer to Inspection-000 TASK 75-23-48-200-100.

      3. Do a dimensional check of the turbine cooling manifold assembly for distortion (This does not include the patch welding repaired area).

      1. Refer to Figure.

    8. SUBTASK 74-24-48-350-112 Cut Out the Patch

      NOTE

      Patch weld repair is not allowed at the turbine cooling manifold assembly bracket.

      1. Cut out a patch that will sufficiently cover the damaged area.

      1. Use AMS5510, AMS5570 or AMS5576 patch material for the manifold.

      2. Use AMS5536 patch material for the bracket.

      3. Use 0.022 to 0.024 in. (0.559 to 0.609 mm) thickness.

    9. SUBTASK 75-24-48-350-113 Cut Out the Damaged Area

      1. Use a patch as a template to cut out the damaged area. Bevel the repair edges.

    10. SUBTASK 75-24-48-110-069 Remove all the Dirt from the Surface

      1. Remove all the oxides, hydrocarbon, grit and scale by local cleaning from the surface to be welded and the adjacent area.

      1. Refer to Cleaning-000 TASK 75-24-48-100-100.

    11. SUBTASK 75-24-48-350-114 Weld the Patch to the Turbine Cooling Manifold Assembly

      NOTE

      Patch weld repair is not allowed at the manifold if the total patch weld areas are greater than 20 percent of the surface.

      1. Weld the Patch.

      1. Refer to Task 70-31-02-310-501.

      2. In the contact area, remove the excess weld and dress flush with the adjacent area.

      1. Use a .

      2. Avoid undercutting the parent metal.

    12. SUBTASK 75-24-48-350-115 Make Air-Holes in the Turbine Cooling Manifold Assembly

      1. Make air-holes through the patch, (if applicable).

      1. Make again the air-hole pattern to the same size and spacing as the other holes, in same hole system, where the welds or patches affect the holes.

    13. SUBTASK 75-24-48-310-067 Heat Treat the Turbine Cooling Manifold Assembly

      1. Heat treat the turbine cooling manifold assembly.

      1. Stress relieve at 1200 deg F + 25 deg F (649 deg C + 14 deg C) for one hour.

    14. SUBTASK 75-24-48-350-116 Examine the Repaired Area for Cracks

      1. Penetrant examine the repaired area.

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

      2. Visually examine the edge of the patch.

      1. Use an 8x Magnifying glass.

      2. Refer to Inspection-000 TASK 75-23-48-200-100.

      3. Do a dimensional check of the turbine cooling manifold assembly for distortion Except the patch welding repaired area).

      1. Refer to Figure.

    15. Figure: Weld of the Turbine Cooling Manifold Assembly

    Weld of the Turbine Cooling Manifold Assembly

    Figure: Dimension of the Turbine Cooling Manifold Assembly

    Dimension of the Turbine Cooling Manifold Assembly

    Dimension of the Turbine Cooling Manifold Assembly

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised part number (typographical error). Added link to SPM task reference. (editorial)

Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 01-031
Type:sp01
Supply Short Name:CoMat 01-031 ACETONE (CH3)2CO
Supply Name:CoMat 01-031 ACETONE (CH3)2CO
Specification Groups:
Doc NumberType
OMAT: 150 (RR REF)COMMERCIAL GRADE O-A-51
PMC 9008 (PW REF)COMMERCIAL GRADE O-A-51
JCR-041 (JAEC REF)COMMERCIAL GRADE O-A-51
MTH 169 (98%) (MTU REF)COMMERCIAL GRADE O-A-51
Suppliers:
ManufacturerRemarks
LOCAL
K6835
81348
K3504
U1185
24853
70657
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 03-197
Type:sp01
Supply Short Name:CoMat 03-197 WELDING FILLER WIRE
Supply Name:CoMat 03-197 WELDING FILLER WIRE
Specification Groups:
Doc NumberType
MSRR9500/215HASTELLOY X
OMAT:3/165AMS 5798
OMAT:3/165
Suppliers:
ManufacturerRemarks
LOCAL
07098
IE508
0B491
2R602
36346
55596
57965
58401
80357
IE306
K6835
1GD26
Manufacturer Code:LOCAL
Supply Number:CoMat 03-204
Type:sp01
Supply Short Name:CoMat 03-204 WELDING FILLER WIRE
Supply Name:CoMat 03-204 WELDING FILLER WIRE
Specification Groups:
Doc NumberType
OMAT:306MSRR9500/2 B.S.2901:1970 347 S96/FORM. BSS2901 A8Nb
Suppliers:
ManufacturerRemarks
LOCAL
22994
IE306
Link not Found
Manufacturer Code:LOCAL
Tool Number:Fluorescent penetrant inspection equipment
Tool Name:Fluorescent Penetrant Inspection Equipment
Link not Found
Link not Found
Manufacturer Code:LOCAL
Tool Number:TIG welding equipment
Tool Name:TIG welding equipment