TASK 72-41-22-300-026 HP Compressor Stator Vane Stages 6 To 11 - Weld Repair The Airfoil Tip - Repair-026 (VRS9535)

DMC:V2500-A5-72-41-2206-00A-970A-C|Issue No:005.00|Issue Date:2019-11-01

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 72-41-22-300-026 HP Compressor Stator Vane Stages 6 To 11 - Weld Repair The Airfoil Tip - Repair-026 (VRS9535)

Effectivity

FIG/ITEM

PART NO.

SERVICE BULLETIN

ASSEMBLY

01-350D

6A8767

72-0561

A

01-400D

6A8765

72-0561

A

01-448D

6A8765

72-0561

A

01-450D

6A8766

72-0561

A

02-350D

6A8770

72-0561

B

02-400F

6A8768

72-0561

B

02-448D

6A8768

72-0561

B

02-450D

6A8769

72-0561

B

03-200D

6A8774

72-0561

C

03-250D

6A8775

72-0561

C

03-350D

6A8776

72-0561

C

03-400E

6A8772

72-0561

C

03-448D

6A8772

72-0561

C

03-450D

6A8773

72-0561

C

04-200D

6A8780

72-0561

D

04-250D

6A8781

72-0561

D

04-350C

6A8782

72-0561

D

04-400C

6A8778

72-0561

D

04-448C

6A8778

72-0561

D

04-450C

6A8779

72-0561

D

05-350D

6A8786

72-0561

E

05-355D

6A8785

72-0561

E

05-400D

6A8783

72-0561

E

05-448D

6A8783

72-0561

E

05-450D

6A8784

72-0561

E

06-200C

6A8789

72-0561

F

06-250D

6A8790

72-0561

F

06-350D

6A8791

72-0561

F

06-400E

6A8787

72-0561

G

06-448D

6A8787

72-0561

G

06-450C

6A8788

72-0561

G

Material of Component

PART IDENT

MATERIAL

HP Compressor Stator Vanes Stages 6 to 11

Heat resisting alloy

General

This TASK gives the procedure to repair the HP Compressor Stator Vanes, Stages 6 to 11 tip length by welding.

This repair must only be done when the HP Compressor Stator Vane satisfies the minimum chord width requirements as given in the relevant inspection procedures (identified by the applicable part number) located in section 72-41-22.

This is a source demonstrated repair which can only be done by approved vendors.

To keep the HP Compressor efficiency, stator vanes are repaired as near to the new vane condition as possible.

Stator vanes must be repaired as soon as damage or wear is monitored, to get back HP Compressor efficiency and extend the stator vane life.

This repair can be done again to the welded HP Compressor Stator Vanes if the airfoil surface has been polished up to two times; refer to Repair, VRS6210 TASK 72-41-22-300-022 (REPAIR-022).

TASKS identified by SPM TASK are in the Standard Practices Manual (SPM).

Price and Availability.

Refer to International Aero Engines (IAE)

NOTE

It is possible that some materials in the consumable materials chart cannot be used for some or all of the necessary applications. Before you use the materials, make sure the types, quantities and applications of the materials necessary are legally permitted in your location. All persons must obey all applicable federal, state, local and provincial laws and regulations when it is necessary to work with these materials.

NOTE

To identify the consumable materials refer to the Overhaul Processes and Consumable Materials Index (PCI).

NOTE

Other necessary consumable materials are referred to in SPM TASKS in this TASK.

Preliminary Requirements

Pre-Conditions

NONE

Support Equipment

NameManufacturerPart Number / IdentificationQuantityRemark
Abrasive Blast EquipmentLOCAL
Argonarc Welding EquipmentLOCALArgonarc Welding Equipment
Chemical cleaning equipmentLOCALChemical Cleaning Equipment
Grinding MachineLOCALGrinding Machine
Hardness TesterLOCALHardness Tester
Heat Treatment EquipmentLOCALHeat Treatment Equipment
Penetrant Crack Test EquipmentLOCAL
Radiographic EquipmentLOCALRadiographic Equipment
Standard workshop equipmentLOCAL
Vibro-engraving equipmentLOCAL
Workshop inspection equipmentLOCALWorkshop inspection equipment

Consumables, Materials and Expendables

NameManufacturerPart Number / IdentificationQuantityRemark
CoMat 02-001 ADHESIVE TAPE (MASKING)LOCALCoMat 02-001
CoMat 03-284 WELDING FILLER WIRE, NiBASELOCALCoMat 03-284
CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADELOCALCoMat 05-003
CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)LOCALCoMat 06-022

Spares

NONE

Safety Requirements

NONE

Procedure

    1. Repair Facilities

    1. The source demonstration requirements of this repair means that any facility not authorized to accomplish this repair either utilize the authorized repair vendors listed below or contact the IAE repair services group to determine if a qualification program can be initiated at their facility.

      IAE International Aero Engines AG

      400 Main Street

      Mail Stop 121-10

      East Hartford CT 06118

      Attn: Manager, Tech Services

    2. Authorized repair vendor for Repair VRS9535 is listed below:

      Turbine Overhaul Services Pte, Ltd. (TOS)

      5 Tuas Drive Two - Mail Stop 107-58

      Singapore 638639

      Tel: 65-6860-2260

      Fax: 65-6862-1068

    3. The designation by IAE of an authorized repair vendor indicates that the repair vendor has demonstrated the necessary capability to enable it to carry out the listed repair work. However, IAE makes no warranties or representations concerning the qualifications or quality standards of the repair vendors to carry out the repair work, and accepts no responsibility whatsoever for any work that may be carried out by a repair vendor other than when IAE is listed as the repair vendor. Authorized repair vendors do not act as agents or representatives of IAE.

    2. SUBTASK 72-41-22-220-001 Examine the HP Compressor Stator Vanes Stages 6 to 11

    1. For Assembly A, refer to Figure. For Assembly B, refer to Figure. For Assembly C, refer to Figure. For Assembly D, refer to Figure. For Assembly E, refer to Figure. For Assembly F and G, refer to Figure.

      2. Examine the vanes.

      1. Make sure the vanes can be repaired.

      2. Inspect the vanes if repair VRS6210, TASK 72-41-22-300-022 (REPAIR-022) is done.

      3. lf the vane is repaired by VRS6210, TASK 72-41-22-300-022 three times, reject the vane.

    3. SUBTASK 72-41-22-350-001 Remove the Damage from the HP Compressor Stator Vane Tip - Stages 6 to 11

      1. Remove damage from the vane tip.

      1. Refer to General Data, Repair Facilities for the approved vendor or use Standard workshop equipment.

      2. Remove the minimum quantity of material necessary to remove the damage.

      3. Continue to remove material until all the damage is removed.

      4. Make sure that all the damage is removed and the area is made smooth into the adjacent material.

    4. SUBTASK 72-41-22-220-002 Examine the HP Compressor Stator Vanes Stages 6 to 11

    1. For Assembly A, refer to Figure. For Assembly B, refer to Figure. For Assembly C, refer to Figure. For Assembly D, refer to Figure. For Assembly E, refer to Figure. For Assembly F, refer to Figure. For Assembly G, refer to Figure.

      2. Visually examine the vane.

      1. Make sure that the damage has been removed.

      3. Dimensionally examine the vane height.

      1. Make sure that length of the vane can be restored to its original height with maximum 0.060 in. (1.52 mm) weld build-up.

      2. If dimensions are within the limits, record the vane length before welding.

      3. If dimensions are not within the limits, reject the vane.

    5. SUBTASK 72-41-22-110-001 Do a Swab Etch

      1. Swab etch the repaired area.

      1. Refer to the SPM TASK 70-11-39-300-503, SUBTASK 70-11-39-300-001.

    6. SUBTASK 72-41-22-230-001 Do a Crack Test

    7. SUBTASK 72-41-22-120-001 Vapor Blast the HP Compressor Stator Vanes Stages 6 to 11

    1. For Assembly A, refer to Figure. For Assembly B, refer to Figure. For Assembly C, refer to Figure. For Assembly D, refer to Figure. For Assembly E, refer to Figure. For Assembly F, refer to Figure. For Assembly G, refer to Figure.

      2. Mask areas of the vane, not to be welded.

    4. Remove the masking tape.

    8. SUBTASK 72-41-22-110-002 Clean the HP Compressor Stator Vanes Stages 6 to 11

      1. Chemically clean the vanes.

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

      2. NOTE

        The vanes must be fully cleaned before you do Step.

    9. SUBTASK 72-41-22-310-001 Weld the HP Compressor Stator Vanes Stages 6 to 11 Tips

    1. For Assembly A, refer to Figure. For Assembly B, refer to Figure. For Assembly C, refer to Figure. For Assembly D, refer to Figure. For Assembly E, refer to Figure. For Assembly F, refer to Figure. For Assembly G, refer to Figure.

      2. Build-up the vane tip with weld to restore the length.

      1. Refer to the SPM TASK 70-31-02-310-501-001.

      4. Refer to General Data, Repair Facilities for the approved vendor or use Standard workshop equipment.

      3. Apply sufficient weld to get the necessary vane length.

      1. Identify a sample HP Compressor Stator Vane of the corresponding stage and repair along with each repair batch.

        NOTE

        An increase in vane length of up to a maximum of 0.060 in. (1.52 mm) is permitted by this repair.

    10. SUBTASK 72-41-22-370-001 Heat Treat the HP Compressor Stator Vanes Stages 6 to 11

      1. Heat treat the vane in a vacuum or controlled atmosphere.

      2. Heat the part to 1400 deg F (760 deg C) and hold for two hours in a vacuum or argon atmosphere. Furnace cool at a rate of 100 deg F (56 deg C) per hour to 1150 deg F (621 deg C) and hold for four hours.

      3. Cool to room temperature.

    11. SUBTASK 72-41-22-220-003 Do a Hardness Check

      1. Do a hardness check on a longitudinal cross section of a sample vane.

      1. Refer to General Data, Repair Facilities for the approved vendor or use Standard workshop equipment.

      2. Do a hardness check across the weld material, heat affected zone and base material.

      3. The minimum hardness value should be 361 HV.

      4. NOTE

        If the hardness value is below 361 HV minimum, then additional sample vanes should be selected for metallurgical examination.

    12. SUBTASK 72-41-22-350-002 Machine the Stages 6 to 11 HP Compressor Stator Vane Contour and Height

    1. For Assembly A, refer to Figure, Figure, Figure, Figure and Figure. For Assembly B, refer to Figure, Figure, Figure, Figure and Figure. For Assembly C, refer to Figure, Figure, Figure, Figure and Figure. For Assembly D, refer to Figure, Figure, Figure, Figure and Figure. For Assembly E, refer to Figure, Figure, Figure, Figure and Figure. For Assembly F, refer to Figure, Figure, Figure, Figure and Figure. For Assembly G, refer to Figure, Figure, Figure, Figure and Figure.

      2. Put the shape back on the vane contour.

      1. Refer to General Data, Repair Facilities for the approved vendor or use Standard workshop equipment.

      2. Hand methods are permitted to put the shape back on the vane contour.

      3. Grind the vane tip to the correct height.

      4. Dress the vane tip to remove burrs.

    13. SUBTASK 72-41-22-220-004 Examine the HP Compressor Stator Vanes Stages 6 to 11

    1. For Assembly A, refer to Figure, Figure, Figure, Figure and Figure. For Assembly B, refer to Figure, Figure, Figure, Figure and Figure. For Assembly C, refer to Figure, Figure, Figure, Figure and Figure. For Assembly D, refer to Figure, Figure, Figure, Figure and Figure. For Assembly E, refer to Figure, Figure, Figure, Figure and Figure. For Assembly F, refer to Figure, Figure, Figure, Figure and Figure. For Assembly G, refer to Figure, Figure, Figure, Figure and Figure.

      2. Visually examine the airfoil surface.

      1. Scratches or scores on the airfoil surface are not permitted.

      3. Visually examine the vane contour.

      1. Make sure the tip contour is contained within given limits.

      4. Dimensionally inspect the vane height.

      1. Compare before and after repair dimensions, refer to Step.

      2. Welded material must be contained within given limits.

      3. NOTE

        An increase in vane length of not more than a maximum of 0.060 in. (1 52 mm) is permitted by this repair.

    14. SUBTASK 72-41-22-350-003 Polish the Stages 6 to 11 HP Compressor Stator Vane Airfoil Surface and Contour

    1. Refer to Figure and Figure.

      2. Polish the vane airfoil surface and contour.

      1. Refer to General Data, Repair Facilities for the approved vendor or use Standard workshop equipment.

      2. Make sure that all scratches and scores are removed and the surface finish is as near as possible to the adjacent surface.

      3. Hand methods are permitted to polish the vane contour.

    15. SUBTASK 72-41-22-220-005 Do a Dimensional Inspection of the Stage 6 to 11 HP Compressor Stator Vanes

      1. Do a dimensional inspection of the vanes.

      1. Make sure that HP Compressor Stator Vanes satisfies the minimum chord width requirements as given in the relevant inspection procedures (identified by the applicable part number) located in section 72-41-22.

      2. If the part is less than the minimum chord width requirements, reject the part.

    16. SUBTASK 72-41-22-110-003 Do a Swab Etch

      1. Swab etch the repaired area.

      1. Refer to SPM TASK 70-11-39-300-503, SUBTASK 70-11-39-300-001.

    17. SUBTASK 72-41-22-230-002 Do a Crack Test

    18. SUBTASK 72-41-22-260-001 Radiographically Examine the HP Compressor Stator Vanes Stages 6 to 11

      1. Radiographically examine the welded vane tip.

      1. Cracks or unwanted material are not permitted. Pores larger than 0.006 in. (0.15 mm) diameter are not permitted. Pores with a distance of less than 0.200 in. (5.08 mm) between them are not permitted. Surfaces broken by pores are not permitted. Pores are not permitted less than 0.040 in. (1.01 mm) from the leading and trailing edges.

      3. Refer to General Data, Repair Facilities for the approved vendor or use Standard workshop equipment.

    19. SUBTASK 72-41-22-380-001 Restore the Airfoil Surface Finish

      1. Restore the airfoil surface finish.

      1. Refer to the Repair VRS6210, TASK 72-41-22-300-022 (REPAIR-022).

    20. SUBTASK 72-41-22-350-004 Identify the Repair

      CAUTION

      DO NOT VIBRO-ENGRAVE ON THE VANE AIRFOIL OR LOCATION FACES.

      NOTE

      If the HP Compressor Stator Vanes are already identified with the code symbol by vibro peen process from the previous repair application, further identification is not required.

    1. For Assembly A, refer to Figure. For Assembly B, refer to Figure. For Assembly C, refer to Figure. For Assembly D, refer to Figure. For Assembly E, refer to Figure. For Assembly F and G, refer to Figure.

      2. Vibro peen the code symbol adjacent to the assembly number.

      1. Refer to the SPM TASK 70-09-00-400-501, SUBTASK 70-09-00-400-001.

    21. Figure: HP Compressor Stage 6 Stator Vane (Assembly A) - Repair Details and Dimensions

    HP Compressor Stage 6 Stator Vane (Assembly A) - Repair Details and Dimensions

    Figure: HP Compressor Stage 6 Stator Vane (Assembly A) - Repair Details and Dimensions

    HP Compressor Stage 6 Stator Vane (Assembly A) - Repair Details and Dimensions

    Figure: HP Compressor Stage 6 Stator Vane (Assembly A) - Repair Details and Dimensions

    HP Compressor Stage 6 Stator Vane (Assembly A) - Repair Details and Dimensions

    Figure: HP Compressor Stage 7 Stator Vane (Assembly B) - Repair Details and Dimensions

    HP Compressor Stage 7 Stator Vane (Assembly B) - Repair Details and Dimensions

    Figure: HP Compressor Stage 7 Stator Vane (Assembly B) - Repair Details and Dimensions

    HP Compressor Stage 7 Stator Vane (Assembly B) - Repair Details and Dimensions

    Figure: HP Compressor Stage 7 Stator Vane (Assembly B) - Repair Details and Dimensions

    HP Compressor Stage 7 Stator Vane (Assembly B) - Repair Details and Dimensions

    Figure: HP Compressor Stage 8 Stator Vane (Assembly C) - Repair Details and Dimensions

    HP Compressor Stage 8 Stator Vane (Assembly C) - Repair Details and Dimensions

    Figure: HP Compressor Stage 8 Stator Vane (Assembly C) - Repair Details and Dimensions

    HP Compressor Stage 8 Stator Vane (Assembly C) - Repair Details and Dimensions

    Figure: HP Compressor Stage 8 Stator Vane (Assembly C) - Repair Details and Dimensions

    HP Compressor Stage 8 Stator Vane (Assembly C) - Repair Details and Dimensions

    Figure: HP Compressor Stage 9 Stator Vane (Assembly D) - Repair Details and Dimensions

    HP Compressor Stage 9 Stator Vane (Assembly D) - Repair Details and Dimensions

    Figure: HP Compressor Stage 9 Stator Vane (Assembly D) - Repair Details and Dimensions

    HP Compressor Stage 9 Stator Vane (Assembly D) - Repair Details and Dimensions

    Figure: HP Compressor Stage 9 Stator Vane (Assembly D) - Repair Details and Dimensions

    HP Compressor Stage 9 Stator Vane (Assembly D) - Repair Details and Dimensions

    Figure: HP Compressor Stage 10 Stator Vane (Assembly E) - Repair Details and Dimensions

    HP Compressor Stage 10 Stator Vane (Assembly E) - Repair Details and Dimensions

    Figure: HP Compressor Stage 10 Stator Vane (Assembly E) - Repair Details and Dimensions

    HP Compressor Stage 10 Stator Vane (Assembly E) - Repair Details and Dimensions

    Figure: HP Compressor Stage 10 Stator Vane (Assembly E) - Repair Details and Dimensions

    HP Compressor Stage 10 Stator Vane (Assembly E) - Repair Details and Dimensions

    Figure: HP Compressor Stage 11 Stator Vane (Assembly F and G) - Repair Details and Dimensions

    HP Compressor Stage 11 Stator Vane (Assembly F and G) - Repair Details and Dimensions

    Figure: HP Compressor Stage 11 Stator Vane (Assembly F and G) - Repair Details and Dimensions

    HP Compressor Stage 11 Stator Vane (Assembly F and G) - Repair Details and Dimensions

    Figure: HP Compressor Stage 11 Stator Vane (Assembly F) - Repair Details and Dimensions

    HP Compressor Stage 11 Stator Vane (Assembly F) - Repair Details and Dimensions

    Figure: HP Compressor Stage 11 Stator Vane (Assembly G) - Repair Details and Dimensions

    HP Compressor Stage 11 Stator Vane (Assembly G) - Repair Details and Dimensions

    Figure: HP Compressor Stage 6 to 11 Stator Vane (All Assemblies) - Repair Details and Dimensions

    HP Compressor Stage 6 to 11 Stator Vane (All Assemblies) - Repair Details and Dimensions

    Figure: HP Compressor Stage 6 to 11 Stator Vane (All Assemblies) - Repair Details and Dimensions

    HP Compressor Stage 6 to 11 Stator Vane (All Assemblies) - Repair Details and Dimensions

Requirements After Job Completion

Follow-On Conditions

NONE
Change Type:

Revised Figures 4, 5 and 6. (19VG052)

Manufacturer Code:LOCAL
Enterprise Name:LOCALLY SUPPLIED
Manufacturer Code:LOCAL
Supply Number:CoMat 02-001
Type:sp01
Supply Short Name:CoMat 02-001 ADHESIVE TAPE (MASKING)
Supply Name:CoMat 02-001 ADHESIVE TAPE (MASKING)
Specification Groups:
Doc NumberType
OMAT: 230 (RR REF)ZINC OXIDE AT142
JCR-197 (JAEC REF)ZINC OXIDE AT142
Suppliers:
ManufacturerRemarks
LOCAL
K6835
U0415
Manufacturer Code:LOCAL
Supply Number:CoMat 03-284
Type:sp01
Supply Short Name:CoMat 03-284 WELDING FILLER WIRE, Ni BASE
Supply Name:CoMat 03-284 WELDING FILLER WIRE, NiBASE
Specification Groups:
Doc NumberType
INCONEL 718 AMS 5832 AWS 5.14 MSRR9500/220
INCONEL 718 AMS 5832 AWS 5.14CLASS ER NI FE Cr-2 OMAT:3/206
INCONEL 718 AMS 5832 AWS 5.14CLASS ER NI FE Cr-2
Suppliers:
ManufacturerRemarks
LOCAL
28553
IE137
08489
IE508
0ZDB5
2R602
55596
58401
80357
K6835
Manufacturer Code:X222X
Supply Number:CoMat 05-003
Type:sp01
Supply Short Name:CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE
Supply Name:CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE
Specification Groups:
Doc NumberType
Use one of the CoMat 05-003 letter suffix alternatives.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:X222X
Supply Number:CoMat 06-022
Type:sp01
Supply Short Name:CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)
Supply Name:CoMat 06-022 FLUORESCENT PENETRANT (POST-EMULSIFIED ULTRA HIGH SENSITIVITY)
Specification Groups:
Doc NumberType
ARDROX 985-P14 OMAT: 652 (CHEMETALL OAKITE 985-P14)It is not permitted to mix the selected CoMat 06‐022 letter suffix material with other CoMat 06‐022 letter suffix materials. Where CoMat 06‐022 is specified with no suffix, use one of the CoMat 06‐ 022 letter suffix materials.
Suppliers:
ManufacturerRemarks
X222X
Manufacturer Code:LOCAL
Tool Number:Argonarc Welding Equipment
Tool Name:Argonarc Welding Equipment
Link not Found
Manufacturer Code:LOCAL
Tool Number:Grinding Machine
Tool Name:Grinding Machine
Manufacturer Code:LOCAL
Tool Number:Hardness Tester
Tool Name:Hardness Tester
Manufacturer Code:LOCAL
Tool Number:Heat Treatment Equipment
Tool Name:Heat Treatment Equipment
Manufacturer Code:LOCAL
Tool Number:Radiographic Equipment
Tool Name:Radiographic Equipment
Manufacturer Code:LOCAL
Tool Number:Workshop inspection equipment
Tool Name:Workshop inspection equipment
Link not Found