CFM56-7 FAN & BOOSTER PROGRAM STATUS

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CFM56-7 FAN & BOOSTER
PROGRAM STATUS
March 27, 2001
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• 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
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• 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
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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
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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 %)
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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
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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
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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
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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
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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
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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
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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.
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- 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)
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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)
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• 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)
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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
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Fan Blade & Disk
Corrective Actions - Inspection Limits
Fan Disk - Surface Tool 856A4627G01
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Fan Blade & Disk
Corrective Actions - Inspection Limits
Fan Disk - Depth Tool 856A4633G01
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- 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)
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- 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
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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
•roduction 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
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- 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
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- 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
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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
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• 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
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• 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
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• 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
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spacer
Fan Blade & Disk
Corrective Actions - Inspection Limits
g. Fan Blade Spacer
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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
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Polyurethane tear
Disbonded polyurethane
Fan Blade & Disk
Corrective Actions - Inspection Limits
Fan Blade Spacer - Background
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• 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
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• 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
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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
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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
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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
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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
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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
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• 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
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• 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
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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
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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:
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• 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
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Booster Spool Lugs
Forward Flange Lugs
Fan Blade Platform threaded pin
View of affected area
BOOSTER SPOOL LUGS
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• 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
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• 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
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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
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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
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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
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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

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CFM56-7 FAN & BOOSTER PROGRAM STATUS