Fan Module Program

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Fan Module Program Fan Module Program • Fan Blade - Pressure Face Coating Flaking Issue • Fan Disk - Pressure Face Wear - Wear Versus Relube Interval - Fan Disk Repair • Fan Platform • Booster Spool Counterweight CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 3 Fan Rotor Program Status Fan Disk Fan Blade Fan Platform Booster Counterweight CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 4 Fan Blade Flaking Background • Premature dovetail pressure face coating (Cu-Ni-In) flaking - Convex side more affected - No relation with engine thrust rating - High variability within a set - Extensive flaking leads to contact between fan blades and fan disk parent materials CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 5 Fan Blade Flaking Background CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 6 Corrective Actions • Fan blade root / fan disk slots lubrication - Every 1500 to 3000 cycles - CESM No. 005 issued in May, 2000 - Benefit confirmed through airline feedback • Fan blade root undercut - Fan blade flaking due to high local crush stress level - New Fan Blades P/N 340-001-026/027-0 with smoother undercut - SB 72-253 issued, incorporate P/N 340-001-022-0 rework Fan Blade Flaking CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 7 Smoother undercut : P/N 340-001-026/027-0 Initial undercut : P/N 340-001-022-0 Fan Blade Root Undercut CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 8 Field Plan • To complete first relube and Blade upgrade by December,31th/2002 Fleet Support • Fan blade rotable pool increased to 100 sets since Sept.01 - Maximize Rotable flow • Three substantiated rework sites (APS, Chem-tronics, SNS StQuentin) - Expedite all Fan Blades shipments to Shop for rework Retrofit Status • As of March, 2002 undercut on 53% of affected fleet (798 sets) • Steady implementation with current avg. rate ~ 60 sets/month Fan Blade Upgrade Program CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 9 Experience • Fan disk wear phenomenon due to early fan blade flaking issue • No relubrication implemented at E.I.S. • Pressure face wear phenomenon occurred around 3,000 cycles / 6,000 Hours (average value) Fan Disk Field Wear Experience Premature Wear Identified on Fan Disk Due to Fan Blade Early Design, and No Relube CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 10 Fan Disk Field Wear Experience Pressure Face Wear CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 11 • Wear Identified during Fan Blade Retrofit program • > 900 disks exposed - 217 disks inspected with 856A4633G02 tooling - 178 disks within serviceable limit - 32 disks within service extension limits - 7 disks beyond serviceable limit Fan Disk Field Wear Experience Premature Wear Phenomenon Found on Fan Disk With No Relube, and High Flight Leg Operators CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 12 Fan disk without relube, and fan blade without undercut Fan Disk Wear Versus Relube Wear Rate Seems to be Conducted Per Flight Hours CFM56-7 Fan Disk Wear Depth Rate Versus Flight-leg 0,000 0,005 0,010 0,015 0,020 0,025 0,030 0,035 0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00 Flight leg Wear rate per 10000 cycles or hours CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 13 Fan Disk Wear Versus Relube • CFM56-3 Main engine population with flight leg within 1.4 to 2 hrs per cycle - Relube interval range from 2500 to 4500 Hrs • CFM56-7B Main engine population with flight leg within 1.8 to 3.4 hrs per cycle - Relube interval range from 1700 to 9500 Hrs Factor 5 in Time, Can Be Reached With Current CESM Spec CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 14 Fan Disk Wear Versus Relube CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 15 Conclusion: • Fan Disk wear rate driven by flight leg / flight hours • Introduction of relube threshold in operating hours for high flight leg customers (does not affect most of CFM56-7B operators) • New Relube interval implemented in CESM005 in April,2002 Fan Disk Wear Versus Relube Within 3,000 Cycles or 5,000 Flight Hours, Whichever Comes First CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 16 Fan Disk Repair Pressure Face Wear CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 17 Rework Description: • Slot = 0.017 inch machined • Addition of shims coated with Molydag Varnish • New spacer geometry to fit the machined slot, and new shim Fan Disk Repair CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 18 Rework Overview Before Reworked New Shim New Spacer Fan Disk Repair CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 19 Rework Validation Plan • Rework certified by the Authorities in Dec, 2001 • First rework site validation - Machining process and toolings Complete - 3D measurement tooling available Complete - First disk machined and inspected Complete - Shim and spacer parts available April 2002 Fan Disk Repair First Rework Site Operational Early 2nd Quarter 2002 CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 20 Fan Blade & Disk Program Summary • New blade design with smoother undercut retrofit program on track • Fan disk / fan blades relubrication implemented - In place since May, 2000 and interval modified (5,000 Hrs) - CESM 005 published in April, 2002 • Disk repair approved since December, 2001 - First repair site operational early 2nd quarter 2002 • Operators engagement is essential for program execution CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 21 Background • Initial configuration (340-001-805/806-0) • Swaged bushing (340-001-809/810-0) - Implemented since Oct. 2000 - Rework since Nov. 2000 - SB 72-271 : recommend to implement swaged bushing at next shop visit when engine > 10,000CSN • Material: anodized 7075 aluminum • Minor interferences with disk and blades • Cases of seal disbond Fan Platform CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 22 • P/N 340-001-805/806-0 - Concern with bushing migration • Product Improvement - -805 becomes -810 - -806 becomes -809 Fan Platform CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 23 Technical Status Rig tests experience • 4 middle lug ruptures encountered during engineering rig tests - Parts representative of type designs : with and w/o swaged bushing - Test representative of operating conditions • Cracks found during same tests after around 40,000 cycles on - Middle, Forward, and AFT lug holes - Ribs No Cracks Found In-service Fan Platform CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 24 Technical Status • Mechanical, and finite Element Model analysis confirmed critical locations - Predicted - 3S life for non-swaged platform (805/806) life : 21,400 cycles - Predicted - 3S life for swaged platform (809/810) life : 26,500 cycles Initiation site Middle Lug Fan Platform CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 25 Design Improvement • New platform design (340-001-814-0) launched to achieve durability goal - More than 36,000 cycles at crack initiation • New geometry with swaged bushings • New material Aluminum 7449 instead of Aluminum 7075 • Shot-peening implemented • Weight decreased Fan Platform CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 26 Thickening New hole for mass and static balancing optimizatio n Draft removal New transition radius Constant thickness New extrado s edge for seal Thick bushing New intrados edge to prevent interference with blade New Platform: 340-001-814-0 Fan Platform CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 27 Implementation Plan • On production engines by 2nd Quarter 2003 • On In-service engines - Objective : Replace all platforms by new design - Proposed retrofit plan no later than - Sept,30th/ 2007 for -805/-806 - Sept,30th/ 2008 for -809/-810 - Service Bulletin Category 2 to be issued 2nd Quarter 2003 - Recommend replacement at shop visit Fan Platform CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 28 • Development rig tests, and Finite Element model analysis identified Fan Platform durability issue • New design launched to reach the durability goal : - 36,000 cycles at crack initiation • New platform P/N 340-001-814-0 design frozen - New geometry, new material, and shot-peening added • New part on production engine by 2Q 2003 • Complete retrofit of the fleet to be done (at shop visit) Fan Platform Program Summary CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 29 Forward Flange Lugs Fan Blade Platform threaded pin View of affected area Booster Spool CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 30 Booster Spool Lug Experience • FWD flange lug separation encountered during rig test (1Q2000) - Part not representative of field configuration • Development high time booster spool approx. 90,000 cycles - FPI and ECI within the attachment holes revealed no crack • P.C.A. engine (TSN/CSN : 7733 h / 6145 cycles) - Light fretting surrounding each hole on mating surface - FPI and ECI within the attachment holes revealed no crack CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 31 Separated forward flange lug Booster Spool Lug CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 32 Investigation • Failure mode root cause identified - Centrifugal load from fan platform - High bending stress leads to - Crack initiation on forward flange lug - Crack propagation on forward flange lug front mating surface and inside the attachment hole up to lug separation • Spool Lug separation consequence - Forward flange lug separation leads to liberate fan platform Booster Spool Lug CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 33 Forward Flange Lug Bending 3D model Booster Spool Lug CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 34 Booster Spool Lug Corrective actions • Counter-weights on new aircraft since January, 2001 • New booster spool lug design (reinforced) - Booster spool P/N 340-000-816-0 since June, 2001 In-service plan • Service Bulletin 72-296 for counter weights installation • Service Bulletin 72-295 for E.C.I. of lug attachment holes - Category 2 issued February 2001 CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 35 Introduction of counterweights and associated hardware Introduction of new booster spool P/N 340-000-816-0 with reinforced lugs New threaded pins P/N 649-782-300-0 Counter-weight P/N 340-251-201-0 Booster Spool P/N 340-000-814-0 or P/N 340-000-815-0 Booster Spool Lug CFM56 Operators Conference 每 May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 36 Booster Spool Lugs Summary • Development booster spool cracking root cause understood • Corrective action defined - Interim fix by installing counter-weight - New thickened lug design since june, 2001 • Fleet actions - SB72-0295 & -0296 issued - Recommended to implement during fan relubrication - 1,300 kits have been delivered for 1,600 engines affected

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CFM56-7B TRAINING MANUAL ENGINE FAN TRIM BALANCE

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Fan Module Program

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Fan Module Program

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