CFM Stage 5 Booster Blade
**** Hidden Message ***** Stage 5 Booster<BR>Blade<BR>Over-Length<BR>Issue<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 3<BR>• End 1999, 5th stage clearance found under min. tolerance at<BR>engine assembly line<BR>- Blade tip profile discrepancy outside the two reference points<BR>• One blade failure event: ESN 779761, Aug 2000<BR>Over Length: Experience<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 4<BR>• Production stocks purged of discrepant blades<BR>• 100% blade verification before shipment by vendor:<BR>Dec 99<BR>- New tooling for full airfoil tip profile check: swivel gage<BR>- go - no go inspection<BR>• 100% booster rotor inspection at engine assembly line<BR>• Suspect population<BR>- Manufactured prior to Dec 1999<BR>- 6 batches suspected to contain discrepant blades<BR>Over Length: Corrective Actions<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 5<BR>• Engine population identified: 152 engines<BR>- Equipped with blades from the 6 suspect batches<BR>• SB 72-0391, cat 2, issued Oct 2001<BR>- On-wing one time BSI<BR>- Engine removal if wave pattern rub on stage 5 booster abradable<BR>- Repeat inspection in case of FOD, stall, or HPC damage<BR>- Blade measurement and replacement at shop visit<BR>Over Length: Field Plan<BR>Clearance Issue<BR>/ Blade Length<BR>Quality Escape<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 7<BR>Clearance Issue / Blade Length Quality Escape<BR>• Two booster blade failures: Sept 2001<BR>- Root cause: insufficient blade/shroud clearance margin<BR>• Three engines removed due to wave pattern and cracked<BR>blade findings: Sept 2001<BR>- S-5 blades measured in shop<BR>- 80% blades found out of max/min tolerances<BR>• Engines not included in SB 72-0391 “over-length”<BR>population<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 8<BR>• Investigation results: Nov 2001<BR>- No clear process deviation at blade manufacturer<BR>- Inspection tool (swivel gage)<BR>- Generates random errors<BR>- Delinquent calibration tractability: no records<BR>- Erroneous calibration<BR>- +/- 0.1 mm systematic error at trailing edge<BR>Clearance Issue / Blade Length Quality Escape<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 9<BR>• Blade length assessment after tooling calibration error<BR>correction<BR>- All blades delivered from Jan 2000 potentially affected<BR>- T.E. max. + 0.05mm min. - 0.22mm<BR>- L.E. max. + 0.12mm min. - 0.12mm<BR>- Sampling on 8000 blades revealed 2 blades at 0.1mm above max<BR>All Engines Potentially Affected<BR>No Population Segregation Possible<BR>Clearance Issue / Blade Length Quality Escape<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 10<BR>• Snecma quality containment plan<BR>- 100% S-5 blade incoming check: Jan 2002<BR>- At booster assembly line<BR>- Full airfoil profile<BR>- Modified and re-calibrated swivel gage<BR>- Independent inspection tooling for quarterly sampling<BR>- Targeted June 2002<BR>Snecma Quality Containment Maintained Until BTL<BR>Shipment at Zero Defect and Quality Is Insured<BR>Clearance Issue / Blade Length Quality Escape<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 11<BR>• Corrective action at production level<BR>- Increased clearance 0.4 mm (0.0157 in.)<BR>• Field plan<BR>- 0.4mm clearance opening compensates potential overlength<BR>for blades produced after Jan 2000<BR>- Based upon stator material<BR>- Steel has less clearance margin than titanium<BR>- Inspection program for all -5B engines not incorporating<BR>increased clearance<BR>- BSI every 300 cycles up to 1000 cycles for S-5<BR>abradable wave pattern<BR>Clearance Issue / Blade Length Quality Escape<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 12<BR>S-5 Booster Overall Field Plan<BR>• 152 engines affected by 6 suspect over-length blade<BR>batches<BR>- On-wing one time BSI<BR>- Engine removal if wave pattern rub on stage 5 booster<BR>abradable<BR>- Repeated inspection in case of FOD, stall, or HPC damage<BR>- In shop<BR>- Blade measurement and replacement at shop visit<BR>• SB 72-0391, cat 2, issued Oct 2001<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 13<BR>• All other CFM56-5B engines not incorporating increased<BR>clearance<BR>• On-wing recommendation<BR>- BSI, SB 72-0420, cat 2, rev 1 to be issued mid-April 2002<BR>- All -5B ratings, every 300 cycles up to 1000 cycles<BR>- Engine removal within 10 cycles / 25 hours if wave pattern rub<BR>on stage 5 booster abradable<BR>- Repeat inspection in case of FOD, stall, HPC damage up to<BR>2000 cycles<BR>S-5 Booster Overall Field Plan<BR>CFM56 Operators Conference – May 21 - 22, 2002 CFM Proprietary Data Unauthorized Disclosure Prohibited 14<BR>• In-shop recommendation<BR>- Abradable rework instructions per SB 72-0418, rev 1 to be<BR>issued mid-April 2002<BR>- Cat 3 for steel stator, Cat 4 for titanium stator<BR>- For engines equipped with titanium stator<BR>- S-5 abradable BSI, SB 72-0418 application if wear<BR>- SB 72-0418 application at part exposure<BR>- For engines equipped with steel stator<BR>- No BSI, straight SB 72-0418 application<BR>- SB 72-0423 to be revised mid-April 2002<BR>S-5 Booster Overall Field Plan :victory: :victory: CFM Stage 5 Booster Blade <h2>e Module IDG Acoustic Pane</h2>
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