CFM56-7 FAN & BOOSTER PROGRAM STATUS

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CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 1 CFM56-7 FAN & BOOSTER PROGRAM STATUS March 27, 2001 CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 2 • Fan Blade & Disk (item) page - Background 3 - Corrective Actions 6 1. Relube 7 2. Inspection Limits (& Disposition) 9 - Fan Blade dovetail (70) 10 - Fan Blade airfoil pitting 12 - Fan Blade airfoil trailing edge 13 - Fan Disk dovetail (220) 14 - Platform (40) 19 - Fan Retaining Flange (20) 24 - Fan Spacer (50) 28 3. Fan Blade Modification 33 - Ongoing Development 41 - Summary 42 • Booster Spool Lug - Background (850) 43 - Investigation 46 - Corrective Actions 48 - Summary 55 Fan & Booster Program Status Contents: 850 CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 3 • Fan Blades have exhibited flaking of the Cu-Ni-In coating on the dovetail pressure faces (between layers & from Titanium base metal) Fan Blade & Disk Background • Concerns: - Fan Blades and Fan Disk may be found unserviceable at exposure - Fan Blades and Fan Disk may become non-repairable CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 4 CSN Number of Engines Inspected Number of Blades (24 per engine) Number of Blades w/Flaking Rate (%) Number of blades w/flaking beyond AMM limits Rate (%) <1500 Cy 40 960 387 40% 126 13% 1500 >Cy >3000 48 1,152 591 51% 335 29% >3000 Cy 24 576 438 76% 404 70% Total 112 2,688 1,416 53% 865 32% Some Flaking Beyond BMM limits Fan Blade & Disk Background - Fan Blade, Dovetail Coating Flaking • Wide scatter reported between 800 - 3,000 CSN • Non-repairable blades found 4,500 - 5,500 CSN (limited experience, small %) • No Rational Sub-group (prod batch, thrust, etc) 0 5 10 15 20 25 0 1000 2000 3000 4000 5000 6000 7000 CSN Qty of flaked fan blade Qtyof flaking blade Qty out of BMM serviceable limits Nonrepairable Data: 112 Engines Relubed CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 5 Fan Blade & Disk Background - Fan Disk Wear • During Fan Relubrication, ~200 disks inspected per AMM 72-21-02. • Correlation of Wear vs. Cycles or Hours not established • Two steps for Disk dovetail pressure face inspection: 1 - Visual inspection with surface limits (Area W and Z) 2 - Wear depth measurement (only if surface limits were exceeded) • Experience reported thru March ‘ 01: - Fan Disks exposed = 200 - Fan Disks with wear within surface limits (area Z) = 51 (25.5 %) - Fan Disks with depth measured  0.006 = 22 (11.0 %) - Fan Disks with depth 0.006-0.008” = 1 ( 0.5 %) - Fan Disks with depth over 0.008” (not serviceable) = 1 ( 0.5 %) CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 6 Objective: Protect Fan Hardware from becoming Unserviceable/Non-repairable. 1. Fan Relube recommended 2. Inspection Limits re-evaluated & Part Disposition identified 3. Fan Blade Modification (Undercut rework) launched Intent is to minimize the number of engines that receive first relube beyond 3000 cycles, and to complete Relube + Undercut by December 31, 2002 Fan Blade & Disk Corrective Actions - Summary Details for each of these actions are provided in the following pages CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 7 1. Fan Relube recommended - CESM No. 005 issued May 2000 - On-going Periodic Maintenance action for ALL CFM56-7 engines - Interval: every 1500 to 3000 cycles - Same as CFM56-3 model (CESM019) - Removes residual lube and flaked material from dovetail interface - Provides fresh Lube to surfaces - Requires Inspection of Fan Hardware per BMM 72-21-02 - Protection benefit confirmed through first airline feedback - Also useful in resolving N1 vibration issues Fan Blade & Disk Corrective Actions - Fan Relube Titanium (Base Metal) CU-NI-IN (Plasma Thermal Spray, xx-yy thick): applied at: Original Mfg, ESM Repair002, Rework SB 72-253 Dry Film Lubricant Varnish (oven cure, Molydag 254, CP2229): applied at: Original Mfg, ESM Repair002, Rework SB 72-253 Molykote (air cure, Molybdenum lube, CP2104, CP2444, CP2569, CP5062) applied at: Original Mfg, Relube CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 8 Relube Process: ~3 to 5 hour duration with 2 person crew Average CFM56-7 engine operates: 4.2 cycles/day = ~1,500 cycles/year Relube interval (1,500 - 3,000 cycles) ~ 12 to 24 months High Cycle CFM56-7 engines operate 7 cycles/day = ~2,500 cycles/year Relube interval (1,500 - 3,000 cycles) ~ 7 to 14 months Fan Blade & Disk Corrective Actions - Fan Relube First Relube CESM005 Nov-00 CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 9 2. Inspection Limits: Boeing Maintenance Manual (BMM 72-21-02) Limits are being reviewed/revised based on Fleet experience Part Disposition: Repairs, Rework & Design Changes are being prepared to resolve issues: a. Fan Blade dovetail coating flaking: b. Fan Blade airfoil pitting (platform seal contact area) c. Fan Blade airfoil trailing edge contact mark d. Fan Disk dovetail wear e. Platform f. Fan Retaining Flange g. Fan Spacer Fan Blade & Disk Corrective Actions - Inspection Limits Objective: use fleet experience to provide serviceable limits that: • protect hardware from becoming non-functional or non-repairable. • minimize nuisance part replacement/repair CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 10 TR ___ will change BMM 72-21-02 Flaking limits to values boxed below: - greater area of flaking permitted vs. Oct 10, 2000 BMM - “no cycle limit” if flaking within these limits & follow CESM N° 005 (was “1500 Cycle limit in Oct 10, 2000 BMM) - Repeated continue in service is permitted A. Fan Blade Dovetail Flaking Limits (unlimited cycles) Fan Blade & Disk Corrective Actions - Inspection Limits CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 11 Fan Blade Dovetail Flaking Limits (1500 cycles) Fan Blade & Disk Corrective Actions - Inspection Limits TR ___ will change BMM 72-21-02 Flaking limits to values boxed below: - greater area of flaking permitted vs. Oct 10, 2000 BMM - “1500 cycle limit” if flaking within these limits & follow CESM N° 005 (was “500 Cycle limit in Oct 10, 2000 BMM) - Repeated continue in service is not permitted CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 12 BMM 72-21-02 Subtask 200-001-F00 dated June 10, 2000 Inspection of “Area H”: Nicks, dents and scratches on the airfoil is permitted with this limit: not more than 0.004 inch (0.1mm) in depth. • Induced by particles (sand and dust) entrapped between platform seal (elastomer material) and blade -Operators not equally affected Pitting Fan Blade & Disk Corrective Actions - Inspection Limits b. Fan Blade Pitting at platform seal area Inspection of “Critical Area J”: Nicks, dents and scratches on the leading edge is permitted with this limit: not more than 0.0016 inch (.04mm) in depth. CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 13 - Induced by platform (metal) contact with the blade. - A few cases reported with depth >0.004 inch (0.1mm) Trailing Edge Contact Mark Fan Blade & Disk Corrective Actions - Inspection Limits c. Fan Blade Airfoil Trailing Edge Contact Mark (Area H) CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 14 Fan Blade & Disk Corrective Actions - Inspection Limits d. Fan Disk 1500 Cycles service extension limit (TR planned, not in current BMM) Serviceable Limits (Oct 10, 2000 BMM) Note: “Concave” and “Convex” Refer to Disk Slot (not Fan Blade) CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 15 • If “worn or fretted surface” area is within permitted surface limits, then depth inspection is not required (pressure faces are serviceable). • If “worn or fretted surface” area is beyond permitted surface limits, then a pressure face wear depth inspection with CFMI tool 856A4633G01 must be performed within the next 200 cycles of operation. This tool measures the depth of wear along the mid-line of the pressure face. Every pressure face (48 total) on the affected Disk shall be measured with this tool, and the greatest value compared to the following limits. These limits apply to this tool and measuring technique, provided the Fan Blade and Disk receive relubrication per CESM N°005: -Worn or fretted surface less than or equal to 0.006" (0.15mm) depth is permitted without service restriction. -Worn or fretted surface greater than 0.006" (0.15mm) and less than or equal to 0.007” depth is permitted with a 1000 cycle reinspection interval (repeat extensions allowed) -Worn or fretted surface greater than 0.007” and less than or equal to 0.008” depth is permitted with a 50 cycle reinspection interval (repeat extensions allowed). -Worn or fretted surface greater than 0.008” (0.20mm) must be removed. No service extension is permitted. Fan Blade & Disk Corrective Actions - Inspection Limits d. Fan Disk (limits to be in next AMM revision June ‘01) CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 16 Fan Blade & Disk Corrective Actions - Inspection Limits Fan Disk Visual Inspection No Service Limit 1500 cycles Service Extension No Wear Depth measurement of all 48 pressure faces with CFM tool for mid-line variation. Use highest value for “D” D  0.008 inch D  0.006 inch 0.006  D  0.007 inch Wear only within Area W Wear only within Area W & Z Yes Yes No 1000 cycles service extension (Repeat allowed) Disk Not Serviceable 0.007  D  0.008 inch 50 cycles service extension CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 17 Fan Blade & Disk Corrective Actions - Inspection Limits Fan Disk - Surface Tool 856A4627G01 CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 18 Fan Blade & Disk Corrective Actions - Inspection Limits Fan Disk - Depth Tool 856A4633G01 CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 19 - At Relube, some platforms (PN 340-001-806-0) have been found unserviceable due to: -Bushing disengagement -Elastomer Seal Tears/Disbond -Elastomer Strip Weight loose/missing (not all platforms need Strip Weight) Fan Blade & Disk Corrective Actions - Inspection Limits e. Platform ELASTOMER STRIP WEIGHT ADJUSTMENT (AS NECESSARY) CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 20 - TR and next BMM 72-21-02 will state: -Bushings may be reengaged at exposure provided: -Reengagement performed with CFMI tooling or equivalent tooling permitting smooth, straight and progressive reengagement (tooling to be reviewed with CFMI) - Swaged bushing incorporated at shop visit but no later than 20,000 CSN - Bushing disengagement is No Longer a reason for unserviceability -Elastomer Seal and Balance Weight issues: -Current (only) solution is to send platform to SNS for “Full Repair” -Rework Capacity ~15 sets/month - Program Support 100% if individual platform found unserviceable during program period (until 12/31/02). Send repair order requesting “Full Repair of Unserviceable platform” along with Engine Serial Number, engine TSN/CSN to: SNECMA SERVICES Philippe Rotger Centre de Saint Quentin en Yvelines Phone: 33 1 30 96 28 63 1 Rue des Freres FARMAN Fax: 33 1 30 96 27 23 78791 Magny les Hameaux France Fan Blade & Disk Corrective Actions - Inspection Limits Platform CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 21 Original design PN 340-001-806-0 Swaged design PN 340-001-809-0 -New Platform Design with Swaged Bushing: PN 340-001-809-0 -Introduced by SB 72-0271 •Production Introduction (new engines) August 2000 •SAC engines ESN 87t628, 631, 632, 634, 636, 638 and up •DAC engines ESN 87t744 and up •“t” = “6” or “7” •Rework / Repair possible •3 bushings/platform Fan Blade & Disk Corrective Actions - Inspection Limits Platform CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 22 - Full repair (SB 72-0271): -Process includes: remove seals, weight, bushings and coating; resize the bushing holes, anodize, install swaged bushings, replace seals & balance weight -RD issued and available (TR 72-0038 to be ESM 72-21-20 repair 1) -Addresses all platform damages together -Seal replacement is a vendor’s proprietary process - Full Repair available through Snecma Services - Local repair - to install Swaged Bushings only. -Procedure validated: Repair Document (Snecma No. 15-93702) -No repair site yet due to environmental issue linked with process to perform anodization of the reworked lug holes Fan Blade & Disk Corrective Actions - Inspection Limits Platform CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 23 - On-going actions - Full Repair: -Development of seal bonding specification - To allow seal replacement without vendor proprietary process - Based on development experience will need qualification through engine testing or rig test -Local Repair: - Seeking US repair source to perform existing swaged bushing rework - Other processes (environmental friendly alternate to lug anodization) are under review - “Over service extension” in progress for platform material missing after FOD event -New platform manufacturing capacity increased -Spare part inventory currently at 10 sets; to be increased by 10-20 sets/mo Fan Blade & Disk Corrective Actions - Inspection Limits Platform CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 24 Typically wear resides in the slot corner around the circumference of flange Fan Blade & Disk Corrective Actions - Inspection Limits f. Fan Retaining Flange Photo view: Aft looking Forward CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 25 • Several cases reported of fan retaining flanges found with wear/contact marks in the slot corners @ 1500-3000 CSN -Wear range in slot corners is 0.005- 0.010 in. (0.12 - 0.25 mm) deep -Wear found during on-wing periodic maintenance action - No operational consequences reported, except engine assembly disruption -Based on field experience, at least 40 percent of population may exhibit wear beyond manual serviceable limits - All damage is permitted if not more than 0.002 in. (0,05 mm) deep after removal of high metal Fan Blade & Disk Corrective Actions - Inspection Limits Fan Retaining Flange - Background CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 26 • Engineering analysis - Completed -Fan retaining flange deterioration is caused by the fan blade spacer contact -Current manual limit for acceptability can not be extended -High dynamic stress levels of this area Fan Blade & Disk Corrective Actions - Inspection Limits Fan Retaining Flange - Investigation CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 27 • Interim control program -Hand blend repair procedure available to repair unserviceable Fan Retaining Flange -On wing: 0.002 inch (0.5 mm) at 45 degrees chamfering - In Shop: 0.002 inch (0.5 mm) x 0.078 inch (2 mm) chamfering -Shot peening required -Hand blend rework available to modify the Fan Blade Spacer -Prevent fan retaining flange from further wear/contact • Long term action -Current design of Fan Blade Spacer to be modified to avoid potential contact -Expected first half 2001 Service Bulletin to be issued Fan Blade & Disk Corrective Actions - Inspection Limits Fan Retaining Flange CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 28 spacer Fan Blade & Disk Corrective Actions - Inspection Limits g. Fan Blade Spacer CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 29 8 cases of polyurethane tear reported through Dec 99 -18 parts exhibit tear (1,279-5,237 TSN) -1 part part exhibit disbonding • Identified during visual inspection of fan blade relubrication • No operational impact Fan Blade & Disk Corrective Actions - Inspection Limits Fan Blade Spacer - Background CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 30 Polyurethane tear Disbonded polyurethane Fan Blade & Disk Corrective Actions - Inspection Limits Fan Blade Spacer - Background CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 31 • Tear -X-ray fluorescence examination -Several torn parts exhibit a high MBOCA rate (level of MBOCA component within the polyurethane) - Investigation: need to confirm influence of MBOCA by examination of rate on platforms from a same set (failed and not failed) -Customer input expected • Disbonding -Sand blasting in good condition -Quality Investigation in progress Fan Blade & Disk Corrective Actions - Inspection Limits Fan Blade Spacer - Investigation CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 32 • All tears fully serviceable provided the spacers can be reinstalled with the polyurethane (PU) • Spacers with PU missing at one location are fully serviceable • AMM to be updated accordingly Repair • Currently no repair available - development launched Fan Blade & Disk Corrective Actions - Inspection Limits Fan Blade Spacer - Control and Plans CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 33 3. Fan Blade modification introduced - SB 72-253 Rev 1 issued November 2000 - Production Introduction (New engines): - SAC engines: ESN 87t 682 and up - DAC engines; ESN 87t 746 and up - (“t” can be “6” or “7”) - Fleet Program launched to modify blades in service - ~1500 Engines Fan Blade & Disk Corrective Actions - Fan Blade Modification Individual Blade Blade-pair (<200 gcm range) Non-undercut (new) 340-001-022-0 340-161-302-0 Undercut (reworked) 340-001-027-0 340-161-303-0 Undercut (new) 340-001-026-0 340-161-303-0 Part Numbers Part Description CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 34 Fan Blade modification introduced Fan Blade & Disk Corrective Actions - Fan Blade Modification Fan Blade Dovetail Area Pressure Face (Convex) Section “AA” thru Fan Blade Dovetail Forward looking Aft AA View of Fan Blade Dovetail Area Looking into convex Pressure Face Edge Forward Aft SB 72-253 Modification removes small amount of material from the Forward and Aft region of the Concave and Convex Pressure Faces. The length of material removed is ~1.5 inch The depth of material removed is tapered 0.0 to ~0.005”. Before After Detail of Material removed during Modification (Typical 4 places per blade) ~0.005 inch ~1.5 inch Pressure Face (Concave) Fan Blade CL CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 35 1. Fan Blade Rotables - CFMI has dedicated a Rotable pool of 75 Fan Blade sets to this program - allocation to airline is a function of: fleet size, age distribution, utilization - Blade Sets are “loaned” from CFMI for specific period to accomplish program. 2. Fan Blade Rework Sites (3) “Substantiated” to perform SB 72-253: - Global Capacity 75 sets/month with 2-4 week in-house Turn-Around-Time. - CFMI linking each Customer with one Site, to balance capacity & demand. - CFMI pays “Undercut + Recoat + minor airfoil Blending” charges directly to Rework Site, provided undercut is accomplished at or before next Engine shop visit and before Dec 31, 2002 3. Fan Blade and Disk Hardware Supply - Fan Blades: Protection orders on manufacturing for 30 additional sets in 2001 if needed to replace non-repairable Fan Blades - Disks: 17 parts in stock; 5 p/mo requested starting Jan 01 Fan Blade & Disk Corrective Actions - Fan Blade Modification Program Elements CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 36 4.a. Tooling Available to Order Today: One Mirror, one Template, and one BlaMap CD can be provided to Airline at no-charge, and additional copies can be ordered at the price listed. The limited BlaMap CD can be copied by the Airline if needed. Description Calibration (inches) Calibration (mm) Price 1. Mirror Tool (Fan Disk wear area) 856A4627G01 856A4627G02 $1701 2. Template (Fan Blade wear area) 856A4628G01 856A4628G02 $416 3. BlaMap (limited Blade Map software) 856A3770P01 (free of charge, one CD) na Contacts: IncZone Customers can order any of these tools from: Terry Plunkett, GE Support Services (Mt.Laurel, NJ) phone (856) 802-4692, fax (856) 802-4700. SaZone Customers can order these tools from: Sylvie PHILIPPE, Tooling Commercial Support phone: 33 16414 –8850 4.b.Tooling In Development: 1. Disk wear depth measurement tool • Prototype validated : CFMI tool 856A4633G01 • 4 additional units launched to permit fleet support through trained personnel • Additional effort in process to make tool more user friendly (Mar-01 validation) Fan Blade & Disk Corrective Actions - Fan Blade Modification Program Elements CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 37 Fan Blade & Disk Corrective Actions - Fan Blade Modification Program Elements - Tooling Mirror Tool for Fan Disk wear area PN 856A4627G01 (in) PN 856A4627G02 (mm) Template for Fan Blade flaking area PN 856A4628G01 (in) PN 856A4628G02 (mm) Blamap Software for Fan Blade Set Balancing PN 856A3770P01 CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 38 • CFMI recommends Operators to: - Plan Strategy with CFMI CSM/ATPM/Rep - Maximize Rotable flow - Check availability of a complete set of FB prior to performing a Relube - Perform Relubes at all opportunities per CESM intervals - 1) Aircraft scheduled check, for engines > 1500 CSN - 2) Overnight check, for “high to low” CSN engines - Expedite all FB shipments to Shop for rework - Report/close follow-up with help from CFMI Rep • Mixing “original” with “undercut” Fan Blades into one set is not recommended - Disk protection not fully achieved if one blade is original configuration - Logistics challenge to track (PN is only distinguishing feature) - However mixing is technically “allowed” (to resolve FOD event, etc) Fan Blade & Disk Corrective Actions - Fan Blade Modification Execution Guidelines CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 39 • Strategy may vary by operator due to fleet size, age distribution, utilization, observed fall-out rate, etc. - Mode1= may benefit airlines with fleet > 15 aircraft: - Execute Relube(s) & install Rotable(s) - Sort out unserviceable vs. serviceable Blades per AMM - Rebuild Rotable set(s) with serviceable Blades (->ready for more Relubes) - Ship unserviceable Blades to Shop for undercut rework. - Switch to Mode 2 once all engines have received 1st Relube - Mode2= Airlines with fleet < 15 aircraft: - Execute Relube(s) & install Rotable(s) - Ship complete set(s) of removed Blades to Shop for undercut rework • Recommend Airline + CFM CSM/ATPM/Rep jointly develop a workable implementation plan Objective: Protect Fan Hardware from Becoming Unserviceable/Non-repairable. Fan Blade & Disk Corrective Actions - Fan Blade Modification Execution Guidelines CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 40 0 5 10 15 20 25 30 35 40 45 0,00 5,00 10,00 15,00 20,00 25,00 30,00 35,00 Months since sta rt Cumulative Engine Count Mode1Relub-Nb Mode1 Upgrade Nb Mode2Relub-Nb Mode2 Upgrade Nb Upg 19,0 Upg 37,0 Rew sets 20,0 Rew sets 40,0 Rew. Rotables 3,0 Rew. Rotables 3,0 Remaining upgrades 21,0 Remaining upg 3,0 Relubes Tot 40,0 Relubes Tot 40,0 Relube period (month) 18,0 Relube period (month) 26,0 Relube rate 1,7 Relube rate 1,2 Rework rate 0,6 Rework rate 1,1 Rem upg 5000cy Rem upg 5000cy Rem upg 3000cy 3,0 Rem upg 3000cy 3,0 Rem upg 1500cy 18,0 Rem upg 1500cy Completion period (month) 32,0 Completion period (month) 28,0 Mode 1 Mode 2 Status after 1st Relube Run Remaining Upgrades per cycle range for 2nd Relube 2700 Cycle Evolution until Relube/Upgrade 3900 1800 2350 3900 3900 360 360 0 0 0 0 1440 1853 2537 2145 0 500 1000 1500 2000 2500 3000 3500 4000 4500 Mode1 Max cycles Mode2 Max cycles Mode1.Aver.add.cycles Mode2.Aver.add.cycles Mode1Av.add.cy.Allpop Mode2Av.add.cy.Allpop Cycles RelubPop1500 RelubPop3000 RelubPop5000 After 1st Relube Run All pop. Until Upgrade completion All pop Cycles/mth <1500cycles 1500-2200 2200-3000 >3000 >5000 150 10 10 10 10 40 TAT 2 expected FallOut 40% 60% 100% 100% Add. TAT 0,25 RotableSets 3 A/LFleet Pop5000= engines>5000cycles Pop3000= engines 3000<<5000c Pop1500= engines 1500<<3000c Simulation Results - one airline Fan Blade & Disk Corrective Actions - Fan Blade Modification CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 41 1. Aluminum-Bronze coating may replace Cu-Ni-In on Fan Blades -Specimen tests (cyclic tensile stress) completed -Engine vibratory test performed: no impact on vib level -5000 ‘C’ Cycles completed: inspection shows some coating wear -Behavior and wear rate to be confirmed through 5000 additional ‘C’ cycles -Production introduction expected 1st half 2001 if development program conclusive 2. Disk repair/rework -Slot machining and shim addition -Configuration preliminary tested -Vibratory test to validate the repair planned Apr 2001 -Release expected mid 2001 Fan Blade & Disk Ongoing Development: CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 42 • Program Objective: Protect Fan hardware from becoming Unserviceable / Non-repairable • Program Support : 1. Relube CESM issued 2. BMM Inspection Limits re-evaluated (TR Mar’01) and Part Disposition identified 3. Fan Blade Modification Program being launched - FB Rotable pool dispatched - FB rework Shops operational • Operator engagement is essential for execution: - Plan Strategy w/CSM/ATPM/Rep (Customer Team) - Maximize Rotable flow - Perform Relubes at all opportunities per CESM intervals, and upgrade (“Mode1” or “Mode2” per CFMI recommendations) - Expedite all FB shipments to/from Rework site. - Report/close follow-up with help from CFMI Rep Fan Blade & Disk Program Summary CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 43 Booster Spool Lugs Forward Flange Lugs Fan Blade Platform threaded pin View of affected area BOOSTER SPOOL LUGS CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 44 • Forward flange lug separation encountered during rig test (1Q00) -Test conducted for platform modification substantiation -Lug failure after 18,374 cycles -Part not completely representative of field configuration -Forward flange lug attachment holes not shot peened • Development high time booster spool approx. 9,550 cycles -Spool used to run additional 90,000 cycles rig test -Visual inspection, FPI and ECI within the attachment holes revealed no crack Booster Spool Lugs Background CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 45 • P.C.A. engine (TSN/CSN : 7,733 hours/6,145 cycles) -Mark area with light fretting surrounding each hole on mating surface -Visual inspection, FPI and ECI within the attachment holes revealed no crack -3 forward flange lugs found with micro-crack on mating surface -1 crack of 0.5 mm (0.02 in.) found through detailed microscope inspection (not detectable by ECI) -2 cracks of 0.8 mm (0.03 in.) found through ECI -All cracks located in fretted area on the mating surface at about 3 o’clock • Engine 875297 (TSN/CSN : 4,642 hours/2,150 cycles) -No indication found through ECI within the attachment holes • Engine 874163 (TSN/CSN : 6,401 hours/6,164 cycles) -No indication found through ECI within the attachment holes • Engine 875241 (TSN/CSN : 6,112 hours/5,811 cycles) -No indication found through ECI within the attachment holes Booster Spool Lugs Background - Fleet Experience CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 46 Booster Spool Lugs Investigation • Root cause investigation - Engine tests and engineering analysis completed - Centrifugal load from fan blade platform results in forward flange lug bending - High bending stress leads to - Crack initiation on forward flange lug front mating surface - Crack propagation on forward flange lug front mating surface and inside the attachment hole led to lug separation. • Assess consequences of forward flange lug separation - Lug separation leads to liberate Fan Blade Platform - No containment concern in-service - Liberated hardware containment predicted by engineering analysis (trajectory and energy analysis) - Liberated hardware containment demonstrated by engine development tests through large bird ingestion fan blade out tests CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 47 Forward flange lug bending simulation Separated forward flange lug Booster Spool Lugs Investigation CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 48 Booster Spool Lugs Corrective Actions • Counter-Weights introduced for use on current configuration Booster Spools (P/N 340-000-814-0 & 340-000-815-0) - Balances the centrifugal load induced by Fan Blade Platform • Installation of 24 Counter-Weights P/N 340-251-201-0 • Installation of 24 threaded Pins P/N 649-782-300-0 · pin length increased to ease the Fan Blade Platform installation • Special care required during fan blade installation/removal to avoid interference between Counter-Weight sides and fan blade trailing edge • New Booster Spool design (thicker Lug) • Booster Spool P/N 340-000-816-0 in development • Scheduled for Production Introduction 2Q01 CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 49 Introduction of Counter-Weights 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 Lugs Corrective Actions CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 50 Booster Spool Lugs Corrective Actions - Production Engines • Counter-weight installation during engine assembly - Until new booster spool (with reinforced lugs) available - Change implemented on : - CFM56-7B (SAC) engines (with following ESNs, v=8 or 9): - 88v163 - 88v165 to 88v178 - 88v180 to 88v191 - 88v195 - 88v197 and up - CFM56-7B/2 (DAC) engines (with following ESNs, t=6 or 7) - 87t750 and up - New aircraft since January,2001???? - No on-wing or in shop action required • Introduction of new booster spool P/N 340-000-816-0 - SB 72-300 scheduled for 2Q01 CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 51 • Service Bulletin 72-0296 issued for Counter-Weight installation - Technical Compliance: Category 2, do at next Fan Blade removal opportunity - Kit PN 333-089-157-0 includes 24 CWs + 24 new pins (one engine set) - Program Support defined in SB - CW production 75 sets per month since Jan-’01 • Service Bulletin 72-0295 issued for Eddy Current Inspection of forward flange lug attachment holes - Technical Compliance: Category 2 - If Counter-weight installation before Spool reaches 7000 cycles since new, No Eddy Current Inspection required before counter-weight installation - If Counter-Weight installation after Spool reaches 7000 cycles since new - Counter-weight installation no later than July 31, 2001 - Eddy Current Inspection required before Counter-Weight installation - Spools with ECI indication are permitted a “continue in-service” extension of 1500 cycles before removal - All Spools which receive CW after zero CSN require a one-time Eddy Current Inspection between 15000 and 20000 CSN. Booster Spool Lugs Corrective Actions - Fleet CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 52 CFM56-7B engine currently being operated or stocked as spares is equipped with booster spool P/N 340-000-814-0 or P/N 340-000-815-0 No action required NO YES CFM56-7B engine currently being operated is equipped with the 24 counterweights P/N 340-251-201-0 and associated hardware since new YES Affected booster spool has cumulated more than 7000 flight cycle since new when S/B 72-296 is accomplished Perform an eddy current inspection of the forward flange lug attachment holes Install the 24 counter-weights P/N 340-251-201-0 and associated hardware on the booster spool No action required NO NO YES Perform a one time on-wing or inshop eddy current an eddy current inspection of the forward flange lug attachment holes per S/B 72-295 instructions when booster spools have cumulated between 15000 and 20000 flight cycles since new Booster Spool Lugs Corrective Actions - Inspection Logic CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 53 Booster Spool - Age Distribution - Cycles Feb-01 0 50 100 150 200 250 300 350 400 450 500 0 50 100 150 200 250 300 350 400 450 500 1000 2000 3000 4000 5000 6000 7000 8000 9000 Number of Engines ECSN Distribution EC Inspection prior to CW Installation CW Installation with no EC Inspection Booster Spool Lugs Corrective Actions CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 54 High Cycle Spools ESN ECSN Aircraft Utilization(cy/mo) 31/01/01 28/02/01 31/03/01 30/04/01 31/05/01 30/06/01 31/07/01 874109 7848 737-700 200 8448 8648 8848 9048 9248 9448 9648 875134 7354 737-700 200 7954 8154 8354 8554 8754 8954 9154 874127 7352 737-700 200 7952 8152 8352 8552 8752 8952 9152 874133 7137 737-700 200 7737 7937 8137 8337 8537 8737 8937 874121 6664 737-700 200 7264 7464 7664 7864 8064 8264 8464 874174 6405 737-700 200 7005 7205 7405 7605 7805 8005 8205 874177 6405 737-700 200 7005 7205 7405 7605 7805 8005 8205 874128 6360 737-700 200 6960 7160 7360 7560 7760 7960 8160 874171 6313 737-700 200 6913 7113 7313 7513 7713 7913 8113 874187 6313 737-700 200 6913 7113 7313 7513 7713 7913 8113 875143 6296 737-700 200 6896 7096 7296 7496 7696 7896 8096 875360 6180 737-700 150 6630 6780 6930 7080 7230 7380 7530 875355 6180 737-700 150 6630 6780 6930 7080 7230 7380 7530 874120 6145 OFF-WING 0 6145 6145 6145 6145 6145 6145 6145 874163 6075 OFF-WING 0 6075 6075 6075 6075 6075 6075 6075 874289 6043 737-700 230 6733 6963 7193 7423 7653 7883 8113 874290 6043 737-700 230 6733 6963 7193 7423 7653 7883 8113 875229 5848 737-700 200 6448 6648 6848 7048 7248 7448 7648 875228 5848 737-700 200 6448 6648 6848 7048 7248 7448 7648 875233 5841 737-700 200 6441 6641 6841 7041 7241 7441 7641 875301 5841 737-700 200 6441 6641 6841 7041 7241 7441 7641 874353 5810 737-700 230 6500 6730 6960 7190 7420 7650 7880 874153 5776 737-700 200 6376 6576 6776 6976 7176 7376 7576 874151 5776 737-700 200 6376 6576 6776 6976 7176 7376 7576 874374 5726 737-800 150 6176 6326 6476 6626 6776 6926 7076 875241 5604 737-700 230 6294 6524 6754 6984 7214 7444 7674 875251 5599 737-700 200 6199 6399 6599 6799 6999 7199 7399 875252 5599 OFF-WING 0 5599 5599 5599 5599 5599 5599 5599 875264 5595 737-700 200 6195 6395 6595 6795 6995 7195 7395 874200 5435 737-700 200 6035 6235 6435 6635 6835 7035 7235 874162 5425 737-700 200 6025 6225 6425 6625 6825 7025 7225 875300 5423 737-700 200 6023 6223 6423 6623 6823 7023 7223 874272 5308 737-700 200 5908 6108 6308 6508 6708 6908 7108 874265 5308 737-700 200 5908 6108 6308 6508 6708 6908 7108 874149 5296 737-700 190 5866 6056 6246 6436 6626 6816 7006 874150 5296 737-700 190 5866 6056 6246 6436 6626 6816 7006 874112 5176 737-700 200 5776 5976 6176 6376 6576 6776 6976 Data extracted 09-Nov-00 for "all CFM56-7 engines" Approx. predicted ECSN as of: Booster Spool Lugs Corrective Actions CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 55 • Corrective Actions -Counter-Weight installation -Thickened lug (2Q01 intro.) • Fleet Actions -No specific action on engines equipped with CW from zero CSN -CW installation recommended at Fan Relube opportunity -Spools > 7000c require EC inspection at CW installation -EC inspection to be performed before 7/31/01, by SNS/GEES teams -All Spools which receive CWs after zero CSN must be EC inspected at 15-20K CSN Booster Spool Lugs Program - Summary

andyxds 发表于 2011-4-22 14:31:58

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979199501 发表于 2011-4-22 15:11:15

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CFMI Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited Page 1
CFM56-7 FAN & BOOSTER
PROGRAM STATUS
March 27, 2001

kinran 发表于 2011-6-4 23:09:46

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bocome 发表于 2011-7-31 05:01:28

CFM56-7 FAN & BOOSTER PROGRAM STATUS

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CFM56-7 FAN & BOOSTER PROGRAM STATUS

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