TASK 75-24-48-300-001 HPT ACC Air Tubes - Weld Repair Cracks, Repair-001 (VRS1532)

DMC:V2500-A0-75-24-4802-00A-627A-C|Issue No:002.00|Issue Date:2020-08-01

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 75-24-48-300-001 HPT ACC Air Tubes - Weld Repair Cracks, Repair-001 (VRS1532)

Effectivity

FIG/ITEM

PART NO.

02-200

2A0220

02-210

2A0225

02-220

2A0229

02-230

2A0233

02-400

2A0223

02-410

2A0227

02-420

2A0231

02-430

2A0235

Material of component

DESCRIPTION

RR SYMBOL

MATERIAL

TCC tube assemblies

18Cr-10.5Ni-0.4Ti steel

General

Price and availability - none.

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

This Repair contains two type 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

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

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 01-031 ACETONE (CH3)2COLOCALCoMat 01-031
CoMat 02-099 LINT-FREE CLOTHX222XCoMat 02-099
CoMat 03-204 WELDING FILLER WIRELOCALCoMat 03-204

Spares

NONE

Safety Requirements

NONE

Procedure

    1. SUBTASK 75-24-48-230-054 Examine the TCC Tube Assemblies

      1. Fluorescent penetrant examine TCC tube assemblies for crack indications

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

    2. SUBTASK 75-24-48-350-054 Dress Out the Crack to Weld Without Patches

    1. Refer to Figure.

      2. Dress out the crack.

    3. Ensure that the crack is completely removed from the TCC tube assembly and/or turbine cooling manifold assembly.

    3. SUBTASK 75-24-48-110-057 Remove All the Soil from the Surface

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

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

    4. SUBTASK 75-24-48-310-051 Weld the Dressed Cracks on the TCC Tube Assembly

    1. Refer to Figure.

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

      1. Refer to SPM TASK 70-31-02-310-501.

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

    5. SUBTASK 75-24-48-350-055 Produce Airholes in the TCC Tube Assembly

      1. Produce airholes in repaired area of TCC tube assembly, (If applicable).

      1. Re-establish airhole pattern with same size and spacing of other holes, in same hole system, where welds affect holes.

    6. SUBTASK 72-24-48-210-058 Heat Treat the TCC Tube Assemblies

      1. Heat treat the TCC tube assemblies.

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

    7. SUBTASK 75-24-48-350-056 Examine the Repaired Area for Cracks

    1. Refer to Figure.

      2. Penetrant examine the repaired area.

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

      3. Visually examine the repaired area.

      1. Use a 8X magnifying glass.

      2. Refer to Inspection-000 TASK 75-24-48-200-100.

      4. Dimensionally check TCC tube assemblies for distortion (this does not include the patch welding repaired area).

      1. Refer to Figure.

    8. SUBTASK 75-24-48-350-057 Cut Out the Patch

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

      1. Use AMS5510, AMS5570 or AMS5576 patch material for tubes.

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

    9. SUBTASK 75-24-48-350-058 Cut Out the Damaged Area

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

    10. SUBTASK 75-24-48-110-058 Remove the All Soil from the Surfaces

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

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

    11. SUBTASK 75-24-48-350-059 Weld the Patch to the TCC Tube Assemblies

      1. Weld the patch.

      1. Refer to SPM TASK 70-31-02-310-501.

      2. NOTE

        Patch weld repair is not allowed tubes if total patch weld areas are greater than 20 per cent of surface.

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

      2. Avoid undercutting parent metal.

    12. SUBTASK 75-24-48-350-060 Make Airholes in the TCC Tube Assemblies

      1. Make airholes through the patch, (if applicable).

      1. Re-establish airhole pattern with same size and spacing of other holes, in same hole system, where welds or patches affect holes.

    13. SUBTASK 75-24-48-310-059 Heat Treat the TCC Tube Assemblies

      1. Heat treat the TCC tube assemblies.

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

    14. SUBTASK 75-24-48-350-061 Examine the Repaired Area for Cracks

    1. Refer to Figure.

      2. Penetrant examine the repaired area.

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

      3. Visually examine the edge of the patch.

      1. Use a 8X magnifying glass.

      2. Refer to Inspection-000 TASK 75-24-48-200-100.

      4. Dimensionally check TCC tube assemblies for distortion (Except the patch welding repaired area).

      1. Refer to Figure.

    15. Figure: Weld of the TCC Tubes

    Weld of the TCC Tubes

    Weld of the TCC Tubes

    Figure: Dimension of the TCC tubes

    Dimension of the TCC tubes

    Dimension of the TCC tubes

    Dimension of the TCC tubes

    Dimension of the TCC tubes

    Dimension of the TCC tubes

    Dimension of the TCC tubes

    Dimension of the TCC tubes

    Dimension of the TCC tubes

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised the procedural steps. (19VC242)

Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:X222X
Enterprise Name:N/A – REFER TO APPLICABLE COMAT SUFFIX
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 03-204
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
Manufacturer Code:LOCAL
Tool Number:Fluorescent penetrant inspection equipment
Tool Name:Fluorescent Penetrant Inspection Equipment
Manufacturer Code:LOCAL
Tool Number:Grinder, hand held pneumatic
Tool Name:Grinder, hand held pneumatic
Manufacturer Code:LOCAL
Tool Number:TIG welding equipment
Tool Name:TIG welding equipment