TASK 72-50-53-300-014 Turbine Exhaust Case (TEC) - Plasma Coat The Inner Diameter Of The Front Flange, Repair-014 (VRS5398)

DMC:V2500-A1-72-50-5301-01A-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

V2500-A1

Common Information

TASK 72-50-53-300-014 Turbine Exhaust Case (TEC) - Plasma Coat The Inner Diameter Of The Front Flange, Repair-014 (VRS5398)

Effectivity

FIG/ITEM PART NO.

01-001

4A8014

01-001A

4A8025

Material of component

DESCRIPTION SYMBOL MATERIAL

Turbine exhaust case

Corrosion and heat resistant

iron base alloy

General

Price and availability - none

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

NOTE

  1. To identify the consumable materials refer to the PCI.

  2. Consumable materials are given in the SPM.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NONE

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 72-50-53-320-071 Machine the Inner Diameter of the Front Flange

    1. Refer to: Figure

      2. Machine the inner diameter of the front flange.

      1. The inner diameter must be between 38.665 to 38.752 in. (982.09 to 984.30 mm) after the removal of the damage.

        Remove all damage and wear.

        Keep the removal of material to the minimum necessary to remove the damage and not to exceed 0.025 in. (0.635 mm).

        NOTE

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

    2. SUBTASK 72-50-53-230-068 Examine the Inner Diameter

      1. Do the fluorescent penetrant inspection for cracks.

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

        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 72-50-53-110-059 Clean the Turbine Exhaust Case

      1. Degrease by aqueous cleaning.

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

    4. SUBTASK 72-50-53-120-052 Prepare the Inner Diameter of the Front Flange

    1. Refer to Figure.

      2. Prepare surface of part for plasma and other thermal spray coating.

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

    3. Use proper maskants.

      4. Clean the turbine exhaust case.

      1. Clean with dry air blast.

    5. SUBTASK 72-50-53-370-064 Metal Plasma Spray the Inner Diameter of the Front Flange

      CAUTION

      METAL PLASMA SPRAY THE FRONT FACE AS SOON AS POSSIBLE IN LESS THAN TWO HOURS AFTER THE ABRASIVE BLASTING.
      DO AGAIN THE ABRASIVE BLASTING IF YOU EXCEED THE ABOVE TIME LIMIT.

    1. Refer to Figure.

    2. Mask the areas of the turbine exhaust case not to be sprayed.

      3. Preheat the surface to be sprayed.

      1. Preheat temperature: 194 to 248 deg F (90 to 120 deg C).

      4. Metal plasma spray the inner diameter of the front flange.

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

        If machined diameter is less than 38.676 in. (982.37 mm) use CoMat 03-096 PLASMA SPRAY POWDER.

        Otherwise use CoMat 07-123 WIRE.

        Spraying distance

        5.510 in. (140 mm)

        Spraying angle

        90 degrees

        Component rotation speed

        16 RPM

        Gun traverse speed

        3.149 in./min (80 mm/min)

        Maximum working temperature

        392 deg F (200 deg C)

    5. Remove the mask.

      6. Clean the turbine exhaust case.

      1. Clean with dry air blast.

    6. SUBTASK 72-50-53-220-129 Examine the Turbine Exhaust Case

      1. Do the visual inspection of the coating for good adhesion.

      1. No cracks or separation from the parent material are permitted.

        Do again the process if cracks are evident.

    7. SUBTASK 72-50-53-320-072 Machine the Inner Diameter of the Front Flange

    1. Refer to: Figure

      2. Machine the inner diameter of the front flange.

      1. The last dimension must be between 38.6523 to 38.6587 in. (981.77 to 981.93 mm).

        Chamfer where necessary.

    8. SUBTASK 72-50-53-220-130 Examine the Coated Area

    1. Refer to Figure.

      2. Do the visual inspection.

      1. No cracks or separation from the parent material are permitted.

        Do again the process if cracks are evident.

    9. SUBTASK 72-50-53-220-227 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. (1004.85 mm) as given in the figure, accept the part.

        2. If the bolt circle is not 39.561 in. (1004.85 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 bolt holes radially inward to 0.330 in. (8.382 mm) maximum length.

            Elongate the locating pin hole radially inward to 0.294 in. (7.468 mm) maximum length.

            NOTE

            Elongation in a circumferential direction is not permitted.

    10. SUBTASK 72-50-53-350-064 Record the Repair

      1. Vibration peen VRS5398 adjacent to the 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.

    11. 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
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