Fan Module Program

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Fan Module
Program
Fan Module Program
• Fan Blade
- Pressure Face Coating Flaking Issue
• Fan Disk
- Pressure Face Wear
- Wear Versus Relube Interval
- Fan Disk Repair
• Fan Platform
• Booster Spool Counterweight
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 3
Fan Rotor Program Status
Fan Disk
Fan Blade
Fan Platform Booster Counterweight
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 4
Fan Blade Flaking
Background
• Premature dovetail pressure face coating (Cu-Ni-In)
flaking
- Convex side more affected
- No relation with engine thrust rating
- High variability within a set
- Extensive flaking leads to contact between fan
blades and fan disk parent materials
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 5
Fan Blade Flaking Background
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 6
Corrective Actions
• Fan blade root / fan disk slots lubrication
- Every 1500 to 3000 cycles
- CESM No. 005 issued in May, 2000
- Benefit confirmed through airline feedback
• Fan blade root undercut
- Fan blade flaking due to high local crush stress level
- New Fan Blades P/N 340-001-026/027-0 with smoother undercut
- SB 72-253 issued, incorporate P/N 340-001-022-0 rework
Fan Blade Flaking
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 7
Smoother undercut :
P/N 340-001-026/027-0
Initial undercut :
P/N 340-001-022-0
Fan Blade Root Undercut
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 8
Field Plan
• To complete first relube and Blade upgrade by December,31th/2002
Fleet Support
• Fan blade rotable pool increased to 100 sets since Sept.01
- Maximize Rotable flow
• Three substantiated rework sites (APS, Chem-tronics, SNS StQuentin)
- Expedite all Fan Blades shipments to Shop for rework
Retrofit Status
• As of March, 2002 undercut on 53% of affected fleet (798 sets)
• Steady implementation with current avg. rate ~ 60 sets/month
Fan Blade Upgrade Program
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 9
Experience
• Fan disk wear phenomenon due to early fan blade
flaking issue
• No relubrication implemented at E.I.S.
• Pressure face wear phenomenon occurred around
3,000 cycles / 6,000 Hours (average value)
Fan Disk Field Wear Experience
Premature Wear Identified on Fan Disk Due to Fan Blade
Early Design, and No Relube
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 10
Fan Disk Field Wear Experience
Pressure Face Wear
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 11
• Wear Identified during Fan Blade Retrofit program
• > 900 disks exposed
- 217 disks inspected with 856A4633G02 tooling
- 178 disks within serviceable limit
- 32 disks within service extension limits
- 7 disks beyond serviceable limit
Fan Disk Field Wear Experience
Premature Wear Phenomenon Found on Fan Disk With No
Relube, and High Flight Leg Operators
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 12
Fan disk without relube, and fan blade without undercut
Fan Disk Wear Versus Relube
Wear Rate Seems to be Conducted Per Flight Hours
CFM56-7 Fan Disk Wear Depth Rate Versus Flight-leg
0,000
0,005
0,010
0,015
0,020
0,025
0,030
0,035
0,00 0,50 1,00 1,50 2,00 2,50 3,00 3,50 4,00
Flight leg
Wear rate per 10000 cycles or hours
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 13
Fan Disk Wear Versus Relube
• CFM56-3 Main engine population with flight leg within
1.4 to 2 hrs per cycle
- Relube interval range from 2500 to 4500 Hrs
• CFM56-7B Main engine population with flight leg
within 1.8 to 3.4 hrs per cycle
- Relube interval range from 1700 to 9500 Hrs
Factor 5 in Time,
Can Be Reached With Current CESM Spec
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 14
Fan Disk Wear Versus Relube
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 15
Conclusion:
• Fan Disk wear rate driven by flight leg / flight hours
• Introduction of relube threshold in operating hours for high flight
leg customers (does not affect most of CFM56-7B operators)
• New Relube interval implemented in CESM005 in April,2002
Fan Disk Wear Versus Relube
Within 3,000 Cycles or 5,000 Flight Hours,
Whichever Comes First
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 16
Fan Disk Repair
Pressure Face Wear
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 17
Rework Description:
• Slot = 0.017 inch machined
• Addition of shims coated with Molydag Varnish
• New spacer geometry to fit the machined slot,
and new shim
Fan Disk Repair
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 18
Rework Overview
Before Reworked
New Shim
New Spacer
Fan Disk Repair
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 19
Rework Validation Plan
• Rework certified by the Authorities in Dec, 2001
• First rework site validation
- Machining process and toolings Complete
- 3D measurement tooling available Complete
- First disk machined and inspected Complete
- Shim and spacer parts available April 2002
Fan Disk Repair
First Rework Site Operational Early 2nd Quarter 2002
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 20
Fan Blade & Disk Program Summary
• New blade design with smoother undercut retrofit program
on track
• Fan disk / fan blades relubrication implemented
- In place since May, 2000 and interval modified (5,000 Hrs)
- CESM 005 published in April, 2002
• Disk repair approved since December, 2001
- First repair site operational early 2nd quarter 2002
• Operators engagement is essential for program execution
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 21
Background
• Initial configuration (340-001-805/806-0)
• Swaged bushing (340-001-809/810-0)
- Implemented since Oct. 2000
- Rework since Nov. 2000
- SB 72-271 : recommend to implement swaged bushing at next
shop visit when engine > 10,000CSN
• Material: anodized 7075 aluminum
• Minor interferences with disk and blades
• Cases of seal disbond
Fan Platform
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 22
• P/N 340-001-805/806-0
- Concern with bushing migration
• Product Improvement
- -805 becomes -810
- -806 becomes -809
Fan Platform
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 23
Technical Status
Rig tests experience
• 4 middle lug ruptures encountered during engineering rig tests
- Parts representative of type designs : with and w/o swaged bushing
- Test representative of operating conditions
• Cracks found during same tests after around 40,000 cycles on
- Middle, Forward, and AFT lug holes
- Ribs
No Cracks Found In-service
Fan Platform
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 24
Technical Status
• Mechanical, and finite Element Model
analysis confirmed critical locations
- Predicted - 3S life for non-swaged platform
(805/806) life :
21,400 cycles
- Predicted - 3S life for swaged platform
(809/810) life :
26,500 cycles
Initiation site
Middle Lug
Fan Platform
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 25
Design Improvement
• New platform design (340-001-814-0) launched to
achieve durability goal
- More than 36,000 cycles at crack initiation
• New geometry with swaged bushings
• New material Aluminum 7449 instead of Aluminum 7075
• Shot-peening implemented
• Weight decreased
Fan Platform
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 26
Thickening
New hole
for mass
and static
balancing
optimizatio
n
Draft
removal
New
transition
radius
Constant
thickness
New
extrado
s edge
for seal
Thick
bushing
New intrados edge
to prevent
interference with
blade
New Platform: 340-001-814-0
Fan Platform
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 27
Implementation Plan
• On production engines by 2nd Quarter 2003
• On In-service engines
- Objective : Replace all platforms by new design
- Proposed retrofit plan no later than
- Sept,30th/ 2007 for -805/-806
- Sept,30th/ 2008 for -809/-810
- Service Bulletin Category 2 to be issued 2nd Quarter 2003
- Recommend replacement at shop visit
Fan Platform
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 28
• Development rig tests, and Finite Element model analysis
identified Fan Platform durability issue
• New design launched to reach the durability goal :
- 36,000 cycles at crack initiation
• New platform P/N 340-001-814-0 design frozen
- New geometry, new material, and shot-peening added
• New part on production engine by 2Q 2003
• Complete retrofit of the fleet to be done (at shop visit)
Fan Platform Program Summary
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 29
Forward Flange Lugs
Fan Blade Platform threaded pin
View of affected area
Booster Spool
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 30
Booster Spool Lug
Experience
• FWD flange lug separation encountered during rig test
(1Q2000)
- Part not representative of field configuration
• Development high time booster spool approx. 90,000
cycles
- FPI and ECI within the attachment holes revealed no crack
• P.C.A. engine (TSN/CSN : 7733 h / 6145 cycles)
- Light fretting surrounding each hole on mating surface
- FPI and ECI within the attachment holes revealed no crack
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 31
Separated forward flange lug
Booster Spool Lug
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 32
Investigation
• Failure mode root cause identified
- Centrifugal load from fan platform
- High bending stress leads to
- Crack initiation on forward flange lug
- Crack propagation on forward flange lug front mating surface and
inside the attachment hole up to lug separation
• Spool Lug separation consequence
- Forward flange lug separation leads to liberate fan platform
Booster Spool Lug
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 33
Forward Flange Lug Bending 3D model
Booster Spool Lug
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 34
Booster Spool Lug
Corrective actions
• Counter-weights on new aircraft since January, 2001
• New booster spool lug design (reinforced)
- Booster spool P/N 340-000-816-0 since June, 2001
In-service plan
• Service Bulletin 72-296 for counter weights installation
• Service Bulletin 72-295 for E.C.I. of lug attachment holes
- Category 2 issued February 2001
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 35
Introduction of counterweights
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 Lug
CFM56 Operators Conference – May 22 - 23, 2001 CFM Proprietary Data Unauthorized Disclosure Prohibited 36
Booster Spool Lugs Summary
• Development booster spool cracking root cause
understood
• Corrective action defined
- Interim fix by installing counter-weight
- New thickened lug design since june, 2001
• Fleet actions
- SB72-0295 & -0296 issued
- Recommended to implement during fan relubrication
- 1,300 kits have been delivered for 1,600 engines affected

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Fan Module Program