CFM Stage 5 Booster Blade

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CFM Stage 5 Booster Blade

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