Booster Spool Forward Flange Wear

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February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 1
Booster Spool Forward Flange Wear
February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 2
Background
• During shop visit, premature glazing/wear marks observed on the forward
flange of the booster spool at each fan B=blade position
 Glazing/wear marks caused by contact with fan blade shank aft surface
during wind milling and engine start sequence
Booster Spool Forward Flange Wear
FWD Flange
mating surface
February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 3
Field Exposure - Sampling Program
B20 1
B20/2 15
B22 1
B24 2
B26/2 4
B20 0,000
B20/2 0,053
B22 0,081
B24 0,086
B26/2 0,018
23
0,049
Engine Qty
Wear per 10,000 EFC (millimeters)
Total Engine Qty
Total Wear per 10,000 EFC (millimeters)
Booster Spool Forward Flange Wear
February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 4
Field Exposure - Sampling Program
0
0,05
0,1
0,15
0,2
0,25
0,3
0 5000 10000 15000 20000 25000 30000
OPERATING TIME (Cycles Since New)
WEAR DEPTH (mm)
Fleet average
Projected wear at part life limit
expiration: 0,005 in. (0,12 mm)
9365
Booster Spool Forward Flange Wear
February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 5
Windmilling test
• Objectives
 Reproduce wear seen in the field with
current design
 Define the best improvement :
– Seven new coatings tested:
 Baseline
 Two types of Teflon coating
 Cu-Ni-In
 Cu-Al
 Double Molydag varnish
 Baseline with periodic relube
 Molydag on # surface roughness
– Low speed (33 rpm) giving full rocking
of the fan blades
ESN 874986 - 2.8 mils wear depth
Booster Spool Forward Flange Wear
February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 6
Booster Spool Forward Flange Wear
February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 7
Windmilling Test
• Preliminary results (1 cycle = 1 rev) :
 1,686,000 cycles cumulated on 7 Jan 02
– Wear initiated with current design : 0.4
mils
 2,231,000 cycles cumulated on Jan 21, 02
– Wear increased with current design :
1.2 mils
 Wear with new configurations not measured
yet
• Plan
 Continue current test
 Wear phenomenon is not linear
 Wear threshold with current definition now
achieved, therefore final results expected by
end of Feb 2002
Booster Spool Forward Flange Wear
February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 8
Interim Control Program
• CESM No. 005 being revised to recommend lubrication in this area
 Benefit confirmed through engine test
– Booster spool condition not directly affected by the introduction of
elastomer axial buttons on Fan Retaining Flange (SB 72-318 or
72-325)
• Booster Spool front flange wear serviceability being extended
 Part installed : serviceable if not more than 0.008 in. (0,20 mm) deep
 Part removed : serviceable if not more than 0.003 in. (0,08 mm) deep
• Repair procedure being developed to restore part condition at piece-part-level
• New analysis in process to increase the 0,2 mm limit
• Continue to gather data in the fleet to better appreciate the wear propagation
rate
Booster Spool Forward Flange Wear
February 2002 WTT face to face CFMI / Boeing Proprietary Information - Unauthorized Disclosure, Use, or Export are Prohibited 9
Long Term Action
• Design improvement being reviewed to prevent occurrence of unserviceable
condition
 Application of thermal sprayed coating (Al-Cu or Cu-Ni-In) on fan blade
shank AFT surface decision based on Windmilling test results
Booster Spool Forward Flange Wear

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Booster Spool Forward Flange Wear