CFM56 3D Aero HPT Blade Shank Separation

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Slide 1 CFMI PROPRIETARY INFORMATION
Investigation
• Initial metallurgical results
– Fatigue initiation origin from inside mid cooling cavity,
convex side, .420 inches from shank base
– 14 additional blades in set have internal cracks at same
location (found by borescope, confirmed by destructive
evaluation)
• Investigation task team formed
– Review manufacturing records
– Dimensionally inspect disk and blades
– Inspect other blade sets (BS and destructive evaluation)
– Review/refine analysis models
– Crack propagation analysis
– Material program on coating effects
CFM56 3D Aero HPT Blade Shank Separation
• CFM56-5B/2P engine experienced HPT blade failure
– Fully contained IFSD
– TSN/CSN 9027 / 8745
– Primary blade released in shank below platform
– One additional blade failed in shank in tensile overload,
remainder of blades failed at the airfoil root in tensile overload
• Failed blade was a 2002M52P04
– ~29 P04 blade sets shipped in 5B/P fleet
– No P04 blades in CFM56-7 fleet
– Shank geometry common to all HPT aero 3D aero blades (P04,
P05, P09, P11)
Background
Action Plan
• Initial metallurgical results Complete
• Review of manufacturing records Complete
• Disk/blade geometry inspections Complete
• 3D blade/disk analysis update Complete
• Blade inspection cutups Ongoing
• Crack propagation analysis* Feb 2001
• Define root cause March 2001
• Material testing program complete June 2001
• Define improvement June 2001
* Additional studies ongoing
Radial cross section of shank
Crack
Location
Fatigue
Origin of
Prime Blade
Secondary
damage
(tensile
overload)
Primary Blade Failure
CFM56 3D aero HPT blade has
experienced a new failure mode in-service

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CFM56 3D Aero HPT Blade Shank Separation