GENX-1B - CLEANING,INSPECTION,AND REPAIR MANUAL

	GENX-1B CLEANING,INSPECTION,AND REPAIR MANUAL	Dated: 04/30/2019
	CIR 72-00-01 , REPAIR 003
	FAN STATOR MODULE ASSEMBLY - REPAIR - ABRADABLE SHROUD AND TRENCHFILLER FACESHEET REPAIR

* * * FOR ALL

TASK 72-00-01-300-801

1 .

Abradable Shroud and Trenchfiller Facesheet Repair.

CAUTION:

INCORRECT REPAIR OF THE ABRADABLE SHROUD CAN CAUSE SEVERE ENGINE DAMAGE. DO THE REPAIR AS SPECIFIED IN THIS TASK.

This procedure gives instructions to repair the fan stator module assembly (forward fan case) abradable shroud by applying a two part paste adhesive and, if necessary, by applying adhesive and glass cloth to the damaged facesheet. Refer to Figure 901.

The following Maximum Repairable limits apply to this repair:

NOTE:

The information below gives maximum repairable limits for the applicable Inspection sections. The paragraphs are numbered the same as the manual Inspection sections.

(4)

Visual Inspection

(a)

Do an inspection forward fan case (83500) for:

Voids wear grooves, rubs, and areas not bonded on the abradable material:

Maximum repairable limit:

Any circumferential length x 8.0 inches (203.2 mm) axial width, if the fan case is not damaged.

Spalled, loose, or missing abradable material in the transition zones:

Maximum repairable limit:

Any circumferential length x 8.0 inches (203.2 mm) axial width, if the fan case is not damaged.

Holes and punctures on the trenchfiller facesheet:

Maximum repairable limit:

Any amount, not more than 150.00 sq in. (96774 sq mm), if the fan case is not damaged.

NOTE:

For 72-00-21, Inspection 001. Refer to TASK 72-00-21-200-801 (72-00-21, INSPECTION 001) .

(4)

Visual Inspection

(a)

Do an inspection of the containment case assembly (forward fan case) (83500). Refer to Figure 801 .

Voids wear grooves, rubs, and areas not bonded on the abradable material:

Maximum repairable limit:

Any circumferential length x 8.0 inches (203.2 mm) axial width, if the fan case is not damaged.

Cracks in the eight trench filler panel joints and eight abradable panel joints

Maximum repairable limit:

Any amount, if the panel is not disbonded from the fan case.

Spalled, loose, or missing abradable material in the transition zones

Maximum repairable limit:

Any circumferential length x 8.0 inches (203.2 mm) axial width, if the fan case is not damaged.

Holes and punctures in the trenchfiller facesheet

Maximum repairable limit:

Any amount, not more than 150.00 sq in. (96774 sq mm), if the fan case is not damaged.

NOTE:

For 72-21-01, Inspection 001. Refer to TASK 72-21-01-200-801 (72-00-21, INSPECTION 001) .

(4)

Visual Inspection

(g)

Do an inspection of the abradable shroud for:

Voids wear grooves, rubs, and areas not bonded on the abradable material:

Maximum repairable limit:

Any circumferential length x 8.0 inches (203.2 mm) axial width, if the fan case is not damaged.

Spalled, loose, or missing abradable material in the transition zones:

Maximum repairable limit:

Any circumferential length x 8.0 inches (203.2 mm) axial width, if the fan case is not damaged.

Holes and punctures on the trenchfiller facesheet:

Maximum repairable limit:

Any amount, not more than 150.00 sq in. (96774 sq mm), if the fan case is not damaged.

(h)

Do an inspection of the eight trench filler panel joints and eight abradable panel joints for:

Cracks:

Maximum repairable limit:

Any amount, if the panel is not disbonded from the fan case.

The subsequent table gives a list of the part numbers that are applicable to this repair. All part numbers are applicable to all paragraphs unless specified differently.

Part Number(s)

NOTE:

This repair can be done at engine assembly level, fan module assembly level, or at the component level.

Proprietary/Complex Process Statement.

(1)

None.

2 .

Tools, Equipment, and Materials.

NOTE:

You can use equivalent alternatives for tools, equipment, and consumable materials.

Tools and Equipment.

(1)

Special Tools. None.

(2)

Standard Tools and Equipment.

Description

Manufacturer

Belt Sander

McMaster-Carr

P.O. Box 4355

Chicago, IL 60680-4355

Telephone (630) 833-0300

Fax: (630) 834-9427

or local purchase

Drive Mixer Model 285 (drive mixer)

Courtaulds Aerospace Semco

Packaging and Application Systems

5454 San Fernando Road

Glendale, CA 91203

Grinder, Right Angle Drive, 45105A11 (small right angle drive grinder)

McMaster-Carr

P.O. Box 4355

Chicago, IL 60680-4355

Telephone (630) 833-0300

Fax: (630) 834-9427

or local purchase

Heat Lamp

Local Purchase

Hot Air Gun

Local Purchase

Router, Hand Held, 3677A32 (hand held router)

McMaster-Carr

P.O. Box 4355

Chicago, IL 60680-4355

Telephone (630) 833-0300

Fax: (630) 834-9427

or local purchase

Thermocouple

Local Purchase

Wooden roller

Local Purchase

(3)

Locally Manufactured Tools.

Description

Figure

Profile Template

902

Steel Rod

906

Teflon Spatula

907

Consumable Materials.

Code No.

Description

C01-147

Adhesive, Structural, Liquid (liquid adhesive)

C01-155

Adhesive, Paste, Two Part (paste adhesive)

C01-161

Abradable Seal Material (abradable material)

C04-035

Solvent, General (isopropyl alcohol)

C05-003

Marking Pens

C10-003

Fabric, Glass

C10-108

Brush, Disposable, Natural Bristle (brush)

C10-133

Film, Polymer FEP, Un-perforated, 0.001 in. (0.03 mm) thick (FEP film)

C10-136

Tape, Pressure Sensitive (tape)

C10-137

Film, Vacuum Bag (vacuum bag film)

C10-140

Gloves, Film Latex or Nylon/Polyethylene Disposable (gloves)

C10-141

Abrasive Paper

C10-142

Film, Polyester, (Mylar), 0.002-0.004 in. thick (polyester film)

C10-182

Cloth, Cleaning for Aircraft Structural (SAE-AMS 3819, BMS 15-5) (cleaning cloth)

Referenced Procedures.

ATA No.

Description

70-16-00

Marking Practices

70-16-02

Temporary Marking

70-46-01

Masking and Cleaning of Epoxy and Polyester Matrix Thermosetting Composite Materials

70-46-02

Drying of Thermosetting Composite Materials

70-46-03

Vacuum Bagging of Thermosetting Composite Repairs

72-00-01

Inspection 001

72-00-21

Inspection 001

72-21-01

Inspection 001

SAE ARP 5144 Heat Application for Thermosetting Resin Curing

Expendable Parts. None.

SPD Information. None.

Special Solutions. None.

Test Specimens. None.

3 .

Dimensional Information.

Subtask 72-00-01-220-093

Refer to Figure 901 for specified dimensions and locations.

NOTE:

The dimensional data identified within this repair procedure was designed using inches as the base unit of measurement for dimensional values. The conversion to millimeters is rounded to one less decimal digit than inches. For minimum dimensions converted values are rounded up. For maximum dimensions, converted values are rounded down. To avoid conversion errors, do not reconvert from millimeters to inches.

4 .

Setup Information.

None.

5 .

Procedure.

Subtask 72-00-01-350-001

If necessary, make a profile template. Refer to Figure 902.

Subtask 72-00-01-350-002

Apply masking around the forward fan case abradable shroud repair area. Refer to TASK 70-46-01-350-030 (MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS), and as follows:

(1)

Use Composite Masking Method No. 3.

Subtask 72-00-01-350-003

WARNING:

DO NOT BREATHE THE PARTICLES WHEN GRINDING OR SANDING. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.

Prepare the forward fan case abradable shroud for repair as follows:

(1)

Remove all loose material from the abradable shroud repair area. Refer to Figure 903.

CAUTION:

INCREASE THE ROUTER CUTTER DEPTH SLOWLY. STOP BEFORE THE CUTTER TOUCHES THE GLASS FIBER FACESHEET OR DAMAGE TO THE PART CAN OCCUR.

(2)

Use a hand held router or a small belt sander to remove the damaged forward fan case abradable material. Refer to Figure 904 and as follows:

(a)

Remove the remaining damaged abradable material but do not remove the material that is correctly bonded to the glass fiber facesheet.

(b)

Make sure that the edges of the remaining abradable material have straight sides or a small undercut. Refer to Figure 904 and Figure 905.

Subtask 72-00-01-160-007

(3)

Use a vacuum cleaner to remove all the unwanted material from the forward fan case abradable shroud repair area.

Subtask 72-00-01-220-106

(4)

Look for oil contamination in the forward fan case abradable shroud area that you will repair and do as follows:

Subtask 72-00-01-140-009

WARNING:

DO NOT BREATHE THE PARTICLES WHEN SANDING. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.

(a)

Sand the abradable shroud area to remove all the abradable material that has oil contamination as follows:

Use a hand held router or a small belt sander.

Subtask 72-00-01-220-094

WARNING:

USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.

(5)

Do an inspection of the abradable shroud repair area for areas moist with water and do as follows:

(a)

Dry the abradable shroud repair area to remove liquids. Refer to TASK 70-46-02-360-002 (DRYING OF THERMOSETTING COMPOSITE MATERIALS), and as follows:

Use Absorbed Moisture Removal - Method 2 (Radiant Heater) or Absorbed Moisture Removal - Method 3 (Hot Air Dryer).

Attach a thermocouple to the moist area.

Use a hot air gun or heat lamp to dry the areas. Increase the temperature of the area to a maximum of 180°F (82°C).

Keep the area at a temperature of 180°F (82°C) until you cannot see the water.

Continue to dry the repair area for a minimum of 30 minutes more after you cannot see the water.

Subtask 72-00-01-220-095

If you can see the glass fiber facesheet, do an inspection of the glass fiber facesheet as follows:

(1)

Look for damage to the facesheet and do as follows:

(a)

Put a mark around the facesheet damaged area. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-02-350-017 (TEMPORARY MARKING), and as follows:

Use a C05-003 marking pen.

Subtask 72-00-01-930-004

(2)

If necessary, make a steel rod. Refer to Figure 906.

Subtask 72-00-01-350-051

(3)

Tap the facesheet lightly with the steel rod. Listen to the sound and do as follows:

NOTE:

The different thickness of the facesheet and the backsheet will make a different sound. This difference in sound does not show a disbond.

(a)

If you hear a solid click, there is no disbond or delamination.

(b)

If you do not hear a solid click, there is a disbond or delamination.

(4)

Put a large mark around the facesheet areas that are disbonded, delaminated or damaged. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-02-350-017 (TEMPORARY MARKING), and as follows:

(a)

Use a C05-003 marking pen.

(b)

The mark must be a shape that is easy to cut out.

Subtask 72-00-01-350-004

If there is no damage or disbonds in the facesheet, go to Subtask 72-00-01-140-004 (paragraph 5.AA.). If the damaged area is less than 150.00 sq in. (96774 sq mm), go to Subtask 72-00-01-350-005 (paragraph 5.F.).

NOTE:

If the damaged area is larger than 150.00 sq in. (96774 sq mm) the forward fan case abradable shroud is not repairable by this repair procedure.

Subtask 72-00-01-350-005

WARNING:

DO NOT BREATHE THE PARTICLES FROM REPAIR OF COMPOSITE MATERIALS OR LET THE PARTICLES TOUCH YOU. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.

WARNING:

USE EYE PROTECTION WHEN YOU CUT MATERIAL OR PARTS. THE PARTICLES CAN CAUSE DAMAGE TO YOUR EYES.

Cut and remove the damaged and disbonded facesheet material as follows:

(1)

Drill a hole of a minimum of 0.5 inch (13 mm) in diameter through the facesheet at each corner of the area that you identified in Subtask 72-00-01-220-095 (paragraph 5.D.(4)) to cut out, and as follows:

(a)

Do not drill deeper than necessary to drill through the facesheet.

(2)

Cut along the mark around the area that you will remove and as follows:

(a)

Use a small, right-angle drive grinder with a small cut-off disk.

(b)

Do not cut deeper than necessary to cut through the facesheet.

(3)

Start at a corner and carefully pull the damaged facesheet from the honeycomb.

Subtask 72-00-01-350-006

Remove the loose or damaged honeycomb. Refer to Figure 904 and as follows:

(1)

Remove the loose or damaged honeycomb until the top of the honeycomb cells are open.

(2)

If necessary, remove all the temporary patch material in the honeycomb cells.

NOTE:

It is possible that a temporary repair has filled the honeycomb cells with RTV silicone rubber or other filler materials.

Subtask 72-00-01-220-096

Do an inspection of the honeycomb cells and the facesheet in the forward fan case repair area as follows:

Subtask 72-00-01-360-005

(1)

If necessary, dry the facesheet repair area to remove the liquids. Refer to TASK 70-46-02-360-002 (DRYING OF THERMOSETTING COMPOSITE MATERIALS), and as follows:

(a)

Use Visible Liquid Removal - Method 1 (water) or Visible Liquid Removal - Method 2 (liquid other than water).

(b)

After you remove the liquids, continue to dry the repair area as follows:

WARNING:

USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.

Use Absorbed Moisture Removal - Method 3 (Hot Air Dryer), and as follows:

Increase the temperature of the repair area to a maximum of 180°F (82°C).

Keep the repair area at 180°F (82°C) maximum until you cannot see the liquid.

Continue to dry the repair area for a minimum of 30 minutes more after you cannot see the liquid.

Subtask 72-00-01-350-052

(2)

If there is oil contamination in the honeycomb cells, do as follows:

(a)

Clean the honeycomb cells. Refer to TASK 70-46-01-350-030 (MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS), and as follows:

Use Honeycomb Cleaning Method 4.

WARNING:

ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.

Use C04-035 isopropyl alcohol.

(b)

Clean the honeycomb approximately 1.0 inch (25 mm) below the top of the cells.

(3)

If there is oil contamination on the facesheet repair area, do as follows:

Subtask 72-00-01-110-013

(a)

Clean the forward fan case facesheet repair area. Refer to TASK 70-46-01-350-030 (MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS), and as follows:

Use Composite Cleaning Method No. 4.

WARNING:

ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.

Use C04-035 isopropyl alcohol.

Subtask 72-00-01-140-001

WARNING:

Sand the forward fan case facesheet to make a taper in the glass fiber facesheet. Refer to Figure 904 and as follows:

(1)

Use a sanding disk of 1.0 inch (25 mm) in diameter in a small right angle drive grinder.

(2)

Make the taper 0.5 inch (13 mm) in width for each ply of the glass fiber cloth.

NOTE:

The facesheet has alternating layers of glass fiber cloth and film adhesive.

Subtask 72-00-01-140-002

WARNING:

CAUTION:

REMOVE ONLY A MINIMUM QUANTITY OF MATERIAL FROM THE FACESHEET. DAMAGE TO THE FACESHEET WILL MAKE THE REPAIR LARGER.

Prepare the surface of the remaining glass fiber facesheet as follows:

(1)

Sand manually the surface or use a belt sander until the surface has a constant matte finish.

NOTE:

A matte finish has a dull appearance with no brightness, luster or gloss.

(2)

Use C10-141 abrasive paper.

Subtask 72-00-01-110-014

Clean the forward fan case facesheet repair area. Refer to TASK 70-46-01-350-030 (MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS), and as follows:

(1)

Use Composite Cleaning Method No. 5.

WARNING:

ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.

(2)

Use C04-035 isopropyl alcohol.

Subtask 72-00-01-350-007

Apply masking to the forward fan case facesheet repair area. Refer to TASK 70-46-01-350-030 (MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS), and as follows:

(1)

Use Composite Masking Method No. 4.

(2)

Apply masking to the facesheet repair area until you apply the C01-161 abradable material.

Subtask 72-00-01-930-001

If necessary, make a Teflon spatula. Refer to Figure 907.

Subtask 72-00-01-350-008

WARNING:

THE ABRADABLE MATERIAL (C01-161) CONTAINS EPOXY RESIN. EPOXY RESIN AND CATALYST ARE TOXIC TO SKIN, EYES AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION ARE REQUIRED. USE IN A WELL VENTILATED AREA. WEAR CLEAN LATEX, NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN MIXING OR APPLYING ADHESIVE.

WARNING:

THIS ABRADABLE MATERIAL (C01-161) IS VERY REACTIVE. MIX ONLY THE KIT SIZES SUPPLIED. MIXED RESIN AND CATALYST GENERATE HEAT. THIS CAN DAMAGE THE MATERIAL AND CAUSE A FIRE HAZARD.

WARNING:

IF THE ABRADABLE MATERIAL (C01-161) STARTS TO MAKE TOO MUCH HEAT, PUT IT IN A STEEL OR ALUMINUM CONTAINER WITH A MINIMUM OF 10 GALLONS (38 LITERS) OF WATER. THE WATER WILL COOL THE ABRADABLE MATERIAL (C01-161) TO PREVENT BURNING AND DECOMPOSING. DO NOT USE ABRADABLE MATERIAL (C01-161) THAT HAS BEEN PUT IN WATER.

WARNING:

DO NOT MIX QUANTITIES GREATER THAN 650 GRAMS AS DANGEROUS HEAT BUILD UP CAN OCCUR CAUSING UNCONTROLLED DECOMPOSITION OF THE MIXED ADHESIVE. TOXIC FUMES CAN OCCUR RESULTING IN PERSONAL INJURY.

CAUTION:

IF THE ABRADABLE MATERIAL (C01-161) HAS BEEN STORED BELOW ROOM TEMPERATURE, MAKE SURE THAT THE ADHESIVE IS PERMITTED TO REACH ROOM TEMPERATURE BEFORE YOU OPEN THE CONTAINER.

Mix the C01-161 abradable material as follows:

Subtask 72-00-01-350-053

(1)

Alternative Procedure Available. Prepare the C01-161 abradable material packaged in the 1.5 lb (680 grams) [1 pint (473 milliliters)] kit as follows:

NOTE:

More than one mix can be used for larger repairs.

CAUTION:

USE ALL OF THE KIT. DO NOT WEIGH SMALLER MIXES FROM THE KIT. THE COMPONENTS CAN SEPARATE AND MAKE THE WEIGHED MIX INACCURATE.

(a)

Put the resin and hardener in a clean, grease- free metal plate. Keep the resin and hardener separate from each other.

(b)

Mix the resin and hardener separately with spatulas. Make sure that each part is fully mixed before you mix them together.

(c)

Mix the resin and hardener together until you see no streaks of the two components.

NOTE:

It is necessary to do this procedure for 4 or 5 minutes.

NOTE:

The pot life of the C01-161 abradable material is approximately 20 minutes at a temperature of 77°F (25°C). To increase the pot life of the C01-161 abradable material apply the mixed adhesive as a thin layer on the metal surface until it must be used.

Subtask 72-00-01-350-009

(1).A.

Alternative Procedure. Prepare the C01-161 abradable material packaged in the 6.0 oz (170 g) adhesive cartridge. Refer to Figure 908 and as follows:

(a)

Remove the cinch tape from the cartridge.

(b)

Pull the dasher rod up toward the threaded neck end of the cartridge.

NOTE:

This will pull the foil away from the mixing dasher.

(c)

Push the cartridge sides in the foil to cause damage to the foil barrier.

(d)

Push the dasher rod to the plunger end of the cartridge to take out the damaged foil barrier.

(e)

Put the dasher rod on the spindle of the drive mixer.

(f)

Turn the drive mixer on.

(g)

Hold the cartridge body and push and pull the cartridge body up and down for 4 minutes and do as follows:

Make sure that the dasher touches the two ends of the cartridge when it operates through its full movement.

Complete a minimum of 120 full movements during 4 minutes.

(h)

Stop the drive mixer.

(i)

Remove the bottom cap.

(j)

Push the dasher rod to the plunger end of the cartridge and hold the cartridge tightly at the plunger end.

(k)

Turn the dasher rod counterclockwise to disconnect it from the mixing dasher.

(l)

Remove the dasher rod from the cartridge.

(m)

Put the nozzle into the neck end of the cartridge.

(n)

Put the cartridge into a dispensing gun.

(o)

Make sure that you remove the material from the cartridge in 2 minutes or less after you mixed it.

NOTE:

It is possible to apply the C01-161 abradable material to the forward fan case or apply it on a clean, grease-free metal sheet. This procedure makes sure that the C01-161 abradable material does not get too hot.

Subtask 72-00-01-350-010

WARNING:

THIS ABRADABLE MATERIAL (C01-161) IS VERY REACTIVE. MIX ONLY THE KIT SIZES SUPPLIED. MIXED RESIN AND CATALYST GENERATE HEAT. THIS CAN DAMAGE THE MATERIAL AND CAUSE A FIRE HAZARD.

WARNING:

DO NOT MIX QUANTITIES GREATER THAN 650 GRAMS AS DANGEROUS HEAT BUILD UP CAN OCCUR CAUSING UNCONTROLLED DECOMPOSITION OF THE MIXED ADHESIVE. TOXIC FUMES CAN OCCUR RESULTING IN PERSONAL INJURY.

CAUTION:

IF THE ABRADABLE MATERIAL (C01-161) HAS BEEN STORED BELOW ROOM TEMPERATURE, MAKE SURE THAT THE ADHESIVE IS PERMITTED TO REACH ROOM TEMPERATURE BEFORE YOU OPEN THE CONTAINER.

Put the C01-161 abradable material in the honeycomb cells. Refer to Figure 909 and as follows:

(1)

Remove the masking from the repair area before the C01-161 abradable material is applied.

(2)

Use a C10-108 brush and the Teflon spatula to push the C01-161 abradable material to the top of all the honeycomb cells.

(3)

Fill the cells to approximately 0.4 inches (10 mm) in depth.

(4)

Use the Teflon spatula to make the C01-161 abradable material level with or a small amount above the top of the honeycomb cells.

Subtask 72-00-01-110-015

Remove the unwanted C01-161 abradable material from around the edge of the honeycomb as follows:

WARNING:

ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.

(1)

Use a C10-182 cleaning cloth moist with C04-035 isopropyl alcohol.

Subtask 72-00-01-220-097

Do an inspection of the C01-161 abradable material as follows:

(1)

If the C01-161 abradable material moves, use the Teflon spatula to smooth the C01-161 abradable material level with the top of the honeycomb cells.

Subtask 72-00-01-370-001

WARNING:

USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.

Alternative Procedure Available. Cure the C01-161 abradable material. Refer to SAE ARP 5144 Heat Application for Thermosetting Resin Curing, and as follows:

(1)

Cure the C01-161 abradable material for a minimum of 24 hours at a temperature range of 77 to 100°F (25 to 38°C).

(2)

If the ambient temperature is less than 77°F (25°C) you can use heat lamps or a thermal blanket to increase the temperature to 77°F (25°C) as follows:

(a)

Use a thermocouple to monitor the temperature.

(b)

Keep the temperature to a range of 77 to 100°F (25 to 38°C).

(3)

If the ambient temperature is above 77°F (25°C), do not increase the temperature.

NOTE:

It is possible to machine or sand the C01-161 abradable material after it has been at 77°F (25°C) for 3 hours. To find out when it is possible to machine or sand the C01-161 abradable material at other temperatures, measure the hardness of the C01-161 abradable material. It is possible to sand the C01-161 abradable material when the Shore D hardness of the C01-161 abradable material is more than 60 or when a fine dust is made when the C01-161 abradable material is sanded.

Subtask 72-00-01-370-002

WARNING:

THIS ABRADABLE MATERIAL (C01-161) IS HIGHLY REACTIVE. DO NOT APPLY EXTRA HEAT ABOVE 100°F (37°C) TO THE ABRADABLE MATERIAL (C01-161) DURING THE FIRST 3 HOURS OF THE CURE CYCLE. IT CAN MAKE THE MIXED RESIN AND CATALYST MAKE MORE HEAT. THIS CAN CAUSE DAMAGE TO THE ABRADABLE MATERIAL (C01-161) AND CAUSE A FIRE HAZARD.

WARNING:

USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.

R.A.

Alternative Procedure. Cure the C01-161 abradable material. Refer to SAE ARP 5144 Heat Application for Thermosetting Resin Curing, and as follows:

(1)

Cure the C01-161 abradable material for 3 hours at a temperature of 77°F (25°C) and do as follows:

(a)

If the ambient temperature is less than 77°F (25°C) you can use heat lamps or a thermal blanket to increase the temperature to 77°F (25°C), and as follows:

Use a thermocouple to monitor the temperature.

Keep the temperature at a range of 77 to 100°F (25 to 38°C).

(b)

If the ambient temperature is above 77°F (25°C), do not increase the temperature.

NOTE:

(2)

Increase the temperature of the C01-161 abradable material to a range of 100 to 120°F (38 to 49 °C) for a minimum of 2 hours and do as follows:

(a)

Use a heat lamp, thermal blanket or heat gun on the repair area to increase the temperature.

(b)

Use a minimum of 3 equally spaced thermocouples around the repair area.

Subtask 72-00-01-140-003

WARNING:

Sand the forward fan case C01-161 abradable material to make it smooth as follows:

(1)

Use C10-141 abrasive paper.

Subtask 72-00-01-160-003

WARNING:

USE EYE PROTECTION WHEN YOU USE COMPRESSED AIR TO CLEAN, COOL, OR DRY PARTS OR TOOLS. PARTICLES CAN CAUSE AN INJURY TO YOUR EYES. DO NOT USE MORE THAN 30 PSIG (200 KPA). DO NOT POINT COMPRESSED AIR AT YOURSELF OR OTHER PERSONS.

Clean the dust from the forward fan case repair area with clean, dry, compressed air that contains no oil.

Subtask 72-00-01-110-006

Clean the forward fan case damaged area. Refer to TASK 70-46-01-350-030 (MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS), and as follows:

(1)

Use Composite Cleaning Method No. 4 or Composite Cleaning Method No. 5.

WARNING:

ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.

(2)

Use C04-035 isopropyl alcohol.

Subtask 72-00-01-220-098

Do an inspection of the surface of the C01-161 abradable material as follows:

(1)

Make sure that the repair area has the same contour as the honeycomb cells.

(2)

If the shape of the repaired area of the C01-161 abradable material is below the contour of the edge of the taper, do Subtask 72-00-01-350-010 (paragraph 5.O.) thru Subtask 72-00-01-110-006 (paragraph 5.U.) again.

(3)

If the surface of the C01-161 abradable material has voids more than 0.125 inch (3.18 mm) in width, do as follows:

(a)

Fill the voids with the C01-161 abradable material. Refer to Subtask 72-00-01-350-010 (paragraph 5.O.) thru Subtask 72-00-01-110-006 (paragraph 5.U.).

Subtask 72-00-01-350-012

Apply masking to the forward fan case repair areas. Refer to TASK 70-46-01-350-030 (MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS), and as follows:

(1)

Use Composite Masking Method No. 4.

(2)

Apply the masking until you apply the adhesive.

Subtask 72-00-01-350-054

Alternative Procedure Available. Make an SPD facesheet as follows:

NOTE:

The alternative procedure must not be used if the repair must be done overhead. The alternative procedure must only be used for repairs between the 2-10 o'clock position, FLA.

Subtask 72-00-01-930-005

(1)

Make an aluminum tool to support the C10-003 glass fabric when you do the ply layup and curing procedure and as follows:

(a)

Make the tool to a contour that agrees with the repair area.

Subtask 72-00-01-350-055

(b)

Put a layer of C10-142 polyester film or C10-137 vacuum bag film on the tool.

WARNING:

USE EYE PROTECTION WHEN YOU CUT MATERIAL OR PARTS. THE PARTICLES CAN CAUSE DAMAGE TO YOUR EYES.

(2)

Make the SPD of sufficient size and with the same number of plies that you removed from the repair area. Refer to Figure 910 and as follows:

(a)

Make an SPD facesheet template larger than the prepared repair area.

NOTE:

The SPD facesheet can be cut from a serviceable section of facesheet material available on another forward fan case.

(b)

Make sure that the SPD facesheet agrees with the material, contour and ply thickness in the repair area.

(c)

Count the number of plies that you will need and do as follows:

Get sufficient C10-003 glass fabric for all the plies.

(d)

Put the C10-003 glass fabric on a new piece of C10-142 polyester film or C10-137 vacuum bag film.

WARNING:

EPOXY RESIN AND CATALYST ARE TOXIC TO SKIN, EYES AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION ARE REQUIRED. USE IN A WELL VENTILATED AREA. WEAR CLEAN LATEX, NYLON FILM OR POLYETHYLENE DISPOSABLE GLOVES (C10-140) WHEN MIXING OR APPLYING ADHESIVE.

WARNING:

DO NOT MIX QUANTITIES GREATER THAN 450 GRAMS AS DANGEROUS HEAT BUILD UP CAN OCCUR CAUSING UNCONTROLLED DECOMPOSITION OF THE MIXED ADHESIVE. TOXIC FUMES CAN OCCUR RESULTING IN PERSONAL INJURY.

CAUTION:

IF THE ADHESIVE WAS STORED BELOW ROOM TEMPERATURE, LET THE ADHESIVE TEMPERATURE INCREASE TO ROOM TEMPERATURE BEFORE YOU OPEN IT. CONDENSATION WILL DECREASE THE STRENGTH OF THE ADHESIVE.

(e)

Prepare the C01-147 liquid adhesive as follows:

Make an estimate of the quantity of C01-147 liquid adhesive that you will use.

Use a clean metal or paper container that has no wax.

Mix each component in the ratio that follows:

Part A (adhesive)- 100 parts by weight.

Part B (catalyst) - 30 parts by weight.

Mix the adhesive components until you cannot see streaks of the two components.

NOTE:

The pot life of the mixed adhesive is approximately 75 minutes.

(f)

Apply the C01-147 liquid adhesive on the C10-003 glass fabric with a new and clean C10-108 brush.

(g)

Put a second piece of new C10-142 polyester film or C10-137 vacuum bag film on top of the C10-003 glass fabric and C01-147 liquid adhesive.

(h)

Use the Teflon spatula to push the C01-147 liquid adhesive into the C10-003 glass fabric until the two sides are fully wet with C01-147 liquid adhesive.

(i)

Use the Teflon spatula to remove all the caught air and the unwanted liquid adhesive.

(j)

Put a mark on the forward fan case. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-02-350-017 (TEMPORARY MARKING), and as follows:

Put the SPD facesheet template on the C10-142 polyester film or C10-137 vacuum bag film and make a line around it.

Make the quantity of plies the same as the number of plies removed from the repair area.

Put the SPD facesheet template in a position that gives a 45 degree offset with alternating plies.

WARNING:

USE EYE PROTECTION WHEN YOU CUT MATERIAL OR PARTS. THE PARTICLES CAN CAUSE DAMAGE TO YOUR EYES.

(k)

Cut the plies along the lines that you made on the C10-142 polyester film or C10-137 vacuum bag film.

(l)

Remove one side of the polyester film or vacuum bag film from the first ply.

(m)

Put the C10-003 glass fabric ply with the side that you removed from the C10-142 polyester film or the C10-137 vacuum bag film on the support tool.

(n)

Remove the top piece of polyester film or vacuum bag film from the first C10-003 glass fabric ply.

(o)

Apply a layer of C01-147 liquid adhesive of approximate 0.010 inch (0.25 mm) in thickness on the first piece of C10-003 glass fabric as follows:

Use a new, clean C10-108 brush to apply the C01-147 liquid adhesive.

Use the Teflon spatula to remove all the caught air and make the C01-147 liquid adhesive smooth.

(p)

Put the next piece of C10-003 glass fabric on the previous ply as follows:

Remove the polyester film or the vacuum bag film from one side of the piece of C10-003 glass fabric.

Align the weave of the C10-003 glass fabric with the previous ply to a 45 degree offset.

Use the Teflon spatula to remove all the caught air and make the C01-147 liquid adhesive smooth.

Remove the polyester film or the vacuum bag film from the second side of the ply.

Subtask 72-00-01-370-016

(q)

Do Subtask 72-00-01-350-055 (paragraph 5.X.(2)(o)) thru Subtask 72-00-01-350-055 (paragraph 5.X.(2)(p)) again for the remaining plies.

Subtask 72-00-01-360-006

WARNING:

USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.

(r)

Make an envelope type vacuum bag to put around the SPD facesheet and support tool. Refer to TASK 70-46-03-360-003 (VACUUM BAGGING OF THERMOSETTING COMPOSITE REPAIRS), and as follows:

Use Method 1, Vertical Bleed Cure.

Subtask 72-00-01-370-017

(s)

Alternative Procedure Available. Let the mixed adhesive cure for 3-5 days at a minimum temperature of 65°F (18°C).

Subtask 72-00-01-370-003

WARNING:

USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.

(s).A.

Alternative Procedure. Let the mixed adhesive cure for 8 hours at a minimum temperature of 65°F (18°C) followed by a minimum of 1 hour at a temperature range of 180 to 200°F (82 to 93°C).

(t)

Remove the polyester film.

Subtask 72-00-01-350-056

(3)

Make the cured SPD facesheet to fit the repair area as follows:

(a)

Use the same taper angle that you made on the facesheet. Refer to Figure 910.

WARNING:

(b)

Sand the SPD facesheet to get a smooth matte finish as follows:

NOTE:

A matte finish has a dull appearance with no brightness, luster or gloss.

Use C10-141 abrasive paper.

Subtask 72-00-01-160-008

WARNING:

(c)

Remove the dust from the SPD facesheet with clean, dry, compressed air that contains no oil.

Subtask 72-00-01-350-057

WARNING:

DO NOT MIX QUANTITIES GREATER THAN 450 GRAMS AS DANGEROUS HEAT BUILD UP CAN OCCUR CAUSING UNCONTROLLED DECOMPOSITION OF THE MIXED ADHESIVE. TOXIC FUMES CAN OCCUR AND CAUSE PERSONAL INJURY.

CAUTION:

IF THE ADHESIVE HAS BEEN STORED BELOW ROOM TEMPERATURE, MAKE SURE THAT THE ADHESIVE REACHES ROOM TEMPERATURE BEFORE THE CONTAINER IS OPENED. CONDENSATION CAN DAMAGE THE ADHESIVE.

(4)

Prepare the C01-155 paste adhesive as follows:

(a)

Make an estimate of the quantity of the C01-155 paste adhesive that you will use.

(b)

Use a clean metal or paper container that has no wax.

(c)

Mix each component in the ratio that follows:

Part A (adhesive)- 100 parts by weight.

Part B (catalyst)- 17 parts by weight.

(d)

Mix the adhesive components until you cannot see streaks of the components.

NOTE:

The pot life of the mixed C01-155 paste adhesive is approximately 90 minutes. The mixed C01-155 paste adhesive can be used until 90 minutes after the mixing procedure.

Subtask 72-00-01-360-007

(5)

Bond the SPD facesheet to the forward fan case repair area as follows:

(a)

Remove all the masking from the repair area.

(b)

Apply sufficient masking to the surfaces adjacent to the forward fan case repair area to prevent unwanted adhesive on the external surfaces. Refer to TASK 70-46-01-350-030 (MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS) and do as follows:

Use Composite Masking Method No 3.

(c)

Apply the C01-155 paste adhesive on the bonding surfaces of the SPD facesheet and the repair area with a new and clean C10-108 brush.

(d)

Put the SPD facesheet in the repair area.

(e)

Apply a layer of C10-133 FEP film on the facesheet repair area.

(f)

Use the Teflon spatula to rub the C10-133 FEP film on the bond lines to make the repair area smooth.

(g)

Use a clean C10-182 cleaning cloth to remove the unwanted resin.

Subtask 72-00-01-350-058

(6)

Let the mixed C01-155 paste adhesive cure. Refer to Subtask 72-00-01-370-004 (paragraph 5.Y.) or Subtask 72-00-01-370-005 (paragraph 5.Y.A.).

(a)

Use C10-136 tape to keep the C10-133 FEP film and the SPD facesheet in place until you cure the C01-155 paste adhesive fully.

Subtask 72-00-01-140-010

WARNING:

(7)

Sand the cured SPD facesheet and facesheet to prepare the repair area for bonding a cover ply as follows:

(a)

Use C10-141 abrasive paper.

(b)

Use a belt sander or sand manually to get a smooth, matte finish.

NOTE:

A matte finish has a dull appearance with no brightness, luster or gloss.

(c)

Sand an area that is larger on all sides than the SPD facesheet repair area.

Subtask 72-00-01-110-016

(8)

Clean the repair area. Refer to TASK 70-46-01-350-030 (MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS), and as follows:

(a)

Use Composite Cleaning Method No. 5.

WARNING:

ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.

(b)

Use C04-035 isopropyl alcohol.

Subtask 72-00-01-350-059

(9)

Make a cover ply to bond on the repair area.

(a)

Make a cover ply template that is larger on all sides than the SPD repair area.

(b)

Get sufficient C10-003 glass fabric for this ply.

(c)

Put the C10-003 glass fabric on a new piece of C10-142 polyester film or C10-137 vacuum bag film.

WARNING:

DO NOT MIX QUANTITIES GREATER THAN 450 GRAMS AS DANGEROUS HEAT BUILD UP CAN OCCUR CAUSING UNCONTROLLED DECOMPOSITION OF THE MIXED ADHESIVE. TOXIC FUMES CAN OCCUR RESULTING IN PERSONAL INJURY.

CAUTION:

IF THE ADHESIVE WAS STORED BELOW ROOM TEMPERATURE, LET THE ADHESIVE TEMPERATURE INCREASE TO ROOM TEMPERATURE BEFORE YOU OPEN IT. CONDENSATION WILL DECREASE THE STRENGTH OF THE ADHESIVE.

(d)

Prepare the C01-147 liquid adhesive as follows:

Make an estimate of the quantity of C01-147 liquid adhesive that you will use.

Use a clean metal or paper container that has no wax.

Mix each component in the ratio that follows:

Part A (adhesive)- 100 parts by weight.

Part B (catalyst) - 30 parts by weight.

Mix the adhesive components until you cannot see streaks of the two components.

NOTE:

The pot life of the mixed adhesive is approximately 75 minutes.

(e)

Apply C01-147 liquid adhesive on the C10-003 glass fabric with a new and clean C10-108 brush.

(f)

Put a second piece of new C10-142 polyester film or C10-137 vacuum bag film on top of the C10-003 glass fabric and the adhesive.

(g)

Use the Teflon spatula to push the C01-147 liquid adhesive into the C10-003 glass fabric until the two sides are fully wet with C01-147 liquid adhesive.

(h)

Use the Teflon spatula to remove all the caught air and the unwanted liquid adhesive.

(i)

Put a mark on the forward fan case. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-02-350-017 (TEMPORARY MARKING), and as follows:

Put the cover ply template on the C10-142 polyester film or C10-137 vacuum bag film and make a line around it.

Put the cover ply template in a position that gives a 45 degree offset with the facesheet fabric weave.

WARNING:

USE EYE PROTECTION WHEN YOU CUT MATERIAL OR PARTS. THE PARTICLES CAN CAUSE DAMAGE TO YOUR EYES.

(j)

Cut the ply along the lines that you made on the C10-142 polyester film.

Subtask 72-00-01-360-008

(10)

Bond the cover ply to the facesheet repair area as follows:

(a)

Apply a layer of C01-147 liquid adhesive of an approximate 0.010 inch (0.25 mm) in thickness on the facesheet repair area as follows:

Use a new, clean C10-108 brush to apply the C01-147 liquid adhesive.

Use the Teflon spatula to remove all the caught air and make the C01-147 liquid adhesive smooth.

(b)

Remove one side of the polyester film or vacuum bag film from the cover ply.

(c)

Put the cover ply on the facesheet repair area as follows:

Put the cover ply in position to make an overlap of the facesheet on all sides.

(d)

Apply a layer of C10-133 FEP film over the facesheet repair area.

(e)

Use the Teflon spatula to rub the C10-133 FEP film to make the repair area smooth and remove the caught air.

(f)

Use a C10-182 cleaning cloth to remove the unwanted resin.

Subtask 72-00-01-350-060

(11)

Let the mixed C01-147 liquid adhesive cure. Refer to Subtask 72-00-01-370-004 (paragraph 5.Y.) or Subtask 72-00-01-370-005 (paragraph 5.Y.A.) and as follows:

(a)

Use C10-136 tape to keep the C10-133 FEP film and the cover ply in place until you cure the C01-147 liquid adhesive fully.

Subtask 72-00-01-350-013

X.A.

Alternative Procedure. Make glass fiber plies and do a wet layup. Refer to Figure 910 and as follows:

(1)

Make ply templates for the glass fiber plies as follows:

(a)

Count the number of plies that you removed from the facesheet.

(b)

Measure the ply taper length that you cut in the glass fiber facesheet repair area.

(c)

Use C10-142 polyester film or C10-137 vacuum bag film to make the ply templates.

(d)

Make the number of ply templates the same as the number of plies removed.

WARNING:

USE EYE PROTECTION WHEN YOU CUT MATERIAL OR PARTS. THE PARTICLES CAN CAUSE DAMAGE TO YOUR EYES.

(e)

Cut the first ply template to the same size and shape as the filled area of the honeycomb and do as follows:

Put a mark on the ply template as a 0 degree or 90 degrees ply. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES) and TASK 70-16-02-350-017 (TEMPORARY MARKING).

(f)

Cut the subsequent ply template 0.5 inch (13 mm) larger around the previous ply template and do as follows:

Put a mark on the ply template as a plus 45/minus 45 degrees ply. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES) and TASK 70-16-02-350-017 (TEMPORARY MARKING).

(g)

Cut the subsequent ply template 0.5 inch (13 mm) larger around the previous ply template and do as follows:

Put a mark on the ply template as a 0 degree or 90 degrees ply. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES) and TASK 70-16-02-350-017 (TEMPORARY MARKING).

(h)

Do Subtask 72-00-01-350-013 (paragraph 5.X.A.(1)(e)) and Subtask 72-00-01-350-013 (paragraph 5.X.A.(1)(f)) again until you have sufficient ply templates to fill the taper.

NOTE:

The facesheet has a different thickness at different axial locations.

WARNING:

DO NOT MIX QUANTITIES GREATER THAN 450 GRAMS AS DANGEROUS HEAT BUILD UP CAN OCCUR CAUSING UNCONTROLLED DECOMPOSITION OF THE MIXED ADHESIVE. TOXIC FUMES CAN OCCUR AND CAUSE PERSONAL INJURY.

CAUTION:

IF THE ADHESIVE HAS BEEN STORED BELOW ROOM TEMPERATURE, MAKE SURE THAT THE ADHESIVE REACHES ROOM TEMPERATURE BEFORE THE CONTAINER IS OPENED. CONDENSATION CAN DAMAGE THE ADHESIVE.

CAUTION:

THE GLASS CLOTH LAYERS MUST BE APPLIED IN LESS THAN 90 MINUTES AFTER YOU MIX THE PASTE ADHESIVE (C01-155), IF NOT THE STRENGTH OF THE REPAIR WILL DECREASE.

(2)

Prepare and apply the C01-155 paste adhesive as follows:

(a)

Make an estimate of the quantity of adhesive that you will use.

(b)

Mix the C01-155 paste adhesive in a clean metal or in an uncoated paper container.

(c)

Mix each component in the ratio that follows:

Part A (resin, gray material) - 100 parts by weigh.

Part B (catalyst, liquid) - 17 parts by weight.

(d)

Mix the adhesive components until you cannot see streaks of the two components.

NOTE:

The pot life of the C01-155 paste adhesive will be approximately 90 minutes.

(e)

Rub the C01-155 paste adhesive on the prepared surface of the C01-161 abradable material and the facesheet tapered area with a C10-108 brush.

(f)

Remove all the masking from the repair area.

(g)

Use Composite Masking Method No. 3.

(h)

Apply a layer of C01-155 paste adhesive of approximately 0.010 inch (0.25 mm) in thickness with a small spatula.

(i)

Remove the unwanted adhesive from around the repair area with a C10-182 cleaning cloth.

WARNING:

DO NOT MIX QUANTITIES GREATER THAN 450 GRAMS AS DANGEROUS HEAT BUILD UP CAN OCCUR CAUSING UNCONTROLLED DECOMPOSITION OF THE MIXED ADHESIVE. TOXIC FUMES CAN OCCUR RESULTING IN PERSONAL INJURY.

CAUTION:

IF THE ADHESIVE WAS STORED BELOW ROOM TEMPERATURE, LET THE ADHESIVE TEMPERATURE INCREASE TO ROOM TEMPERATURE BEFORE YOU OPEN IT. CONDENSATION WILL DECREASE THE STRENGTH OF THE ADHESIVE.

(3)

Make the glass fiber and the adhesive plies as follows:

(a)

Prepare the C01-147 liquid adhesive and do as follows:

Make an estimate of the quantity of C01-147 liquid adhesive that you will use.

Use a clean metal or paper container that has no wax.

Mix each component in the ratio that follows:

Part A (adhesive)- 100 parts by weight.

Part B (catalyst) - 30 parts by weight.

Mix the adhesive components until you cannot see streaks of the two components.

NOTE:

The pot life of the mixed adhesive is approximately 75 minutes.

(b)

Apply C01-147 liquid adhesive to the C10-003 glass fabric as follows:

Get sufficient C10-003 glass fabric for all the profile templates to have a correct fit and orientation without overlap.

Put the C10-003 glass fabric on a new piece of C10-142 polyester film or C10-137 vacuum bag film.

Apply the C01-147 liquid adhesive on the C10-003 glass fabric with a new and clean C10-108 brush.

Put a new piece of C10-142 polyester film or C10-137 vacuum bag film on top of the C10-003 glass fabric and C01-147 liquid adhesive.

Use the Teflon spatula to push the C01-147 liquid adhesive into the C10-003 glass fabric to fully wet both sides.

Remove all the air bubbles and the unwanted liquid adhesive.

(c)

Put the ply templates on the film covered C10-003 glass fabric. Make sure that the ply template is at the orientation written on the ply template.

WARNING:

USE EYE PROTECTION WHEN YOU CUT MATERIAL OR PARTS. THE PARTICLES CAN CAUSE DAMAGE TO YOUR EYES.

(d)

Put a mark on the forward fan case. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES) and TASK 70-16-02-350-017 (TEMPORARY MARKING), and as follows:

Make a line around the profile templates and cut out the ply shapes.

WARNING:

(4)

Put the plies on the repair area as follows:

(a)

Pull the C10-142 polyester film or C10-137 vacuum bag film from one side of the first piece of C10-003 glass fabric. Put the C10-003 glass fabric on the C01-155 paste adhesive and do as follows:

Use the Teflon spatula to remove all the wrinkles and the caught air before you remove the film from the second side of the ply.

(b)

Apply a layer of C01-147 liquid adhesive of 0.010 inch (0.25 mm) in thickness on the first piece of C10-003 glass fabric as follows:

Use a new, clean, C10-108 brush to apply the C01-147 liquid adhesive.

Use the Teflon spatula to remove all the caught air and make the C01-147 liquid adhesive smooth.

(c)

Put the second piece of C10-003 glass fabric on the first piece as follows:

Pull the C10-142 polyester film or C10-137 vacuum bag film from one side of the adjacent piece of C10-003 glass fabric.

Align the weave of the second piece of C10-003 glass fabric at 45 degrees to the first piece.

Use the Teflon spatula to remove all the wrinkles and the caught air.

Remove the film from the second side of the ply.

(d)

Do Subtask 72-00-01-350-013 (paragraph 5.X.A.(4)(b)) and Subtask 72-00-01-350-013 (paragraph 5.X.A.(4)(c)) and until you apply all the plies.

(e)

Apply a layer of C10-133 FEP film on the repair area.

(f)

Rub the C10-133 FEP film with the Teflon spatula from the center of the repair to the edge to remove the unwanted resin as follows:

Use a C10-182 cleaning cloth to remove the unwanted resin.

(g)

Keep the plies in place until the C01-147 liquid adhesive has fully cured.

Subtask 72-00-01-360-009

WARNING:

USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.

(5)

Make a vacuum bag to put around the repair area. Refer to TASK 70-46-03-360-003 (VACUUM BAGGING OF THERMOSETTING COMPOSITE REPAIRS), and as follows:

(a)

Use Bagging Method 1, Vertical Bleed Cure.

(b)

If necessary, make a support to keep the vacuum bag away from the edge of the facesheet.

Subtask 72-00-01-370-004

WARNING:

USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.

Alternative Procedure Available. Let the mixed adhesive cure for 3-5 days at a minimum temperature of 65°F (18°C). Refer to SAE ARP 5144, Heat Application for Thermosetting Resin Curing.

Subtask 72-00-01-370-005

WARNING:

USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.

Y.A.

Alternative Procedure. Let the mixed adhesive cure. Refer to SAE ARP 5144, Heat Application for Thermosetting Resin Curing and as follows:

(1)

Let the mixed adhesive cure for a minimum of 8 hours at a minimum temperature of 65°F (18°C)

(2)

Increase the temperature of the repair area to a temperature range of 180 to 200°F (82 to 93°C) for a minimum of 1 hour.

Subtask 72-00-01-370-006

Remove the FEP film.

Subtask 72-00-01-140-004

WARNING:

AA.

Sand the forward fan case facesheet repair area to get a smooth matte finish as follows:

NOTE:

A matte finish has a dull appearance with no brightness, luster or gloss.

(1)

Use C10-141 abrasive paper to make the repair area agree with the adjacent contour.

Subtask 72-00-01-160-004

WARNING:

AB.

Remove the dust from the forward fan case area with clean, dry, compressed air that contains no oil.

Subtask 72-00-01-160-005

AC.

Clean the forward fan case damaged area. Refer to TASK 70-46-01-350-030 (MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS), and as follows:

(1)

Use Composite Cleaning Method No. 4 or Composite Cleaning Method No. 5.

Subtask 72-00-01-350-014

AD.

Mix the C01-161 abradable material. Refer to Subtask 72-00-01-350-008 (paragraph 5.N.).

Subtask 72-00-01-350-015

WARNING:

USE EYE PROTECTION WHEN YOU CUT MATERIAL OR PARTS. THE PARTICLES CAN CAUSE DAMAGE TO YOUR EYES.

AE.

Cut a piece of C10-142 polyester film or C10-137 vacuum bag film to use it as a cover for the repair area as follows:

(1)

The cover must be 10.0-12.0 inches (254-304 mm) larger than the repair area.

Subtask 72-00-01-350-016

AF.

Use a C10-108 brush and the Teflon spatula to rub the C01-161 abradable material on all the surfaces of the repair areas and do as follows:

(1)

Make sure that there is no caught air in the C01-161 abradable material when you apply it.

Subtask 72-00-01-350-017

AG.

Apply the remaining C01-161 abradable material. Refer to Figure 911 and as follows:

(1)

Put a small quantity of the C01-161 abradable material at one end of the repair to make the thickness higher than the remaining abradable seal and as follows:

(a)

Use sufficient C01-161 abradable material to fill approximately 3.0-4.0 inches (77-101 mm) of the circumferential length of the repair.

(2)

Put the cover on the C01-161 abradable material and do as follows:

(a)

Pull the cover tightly and hold it in the correct position with C10-136 tape or with your hands.

(3)

Use the profile template or the wooden roller to make the material agree with the contour of the adjacent material.

CAUTION:

DO NOT PUSH THE MATERIAL MORE THAN 3.0-4.0 INCHES (77-101 MM), OR IT WILL SQUEEZE UP BEHIND THE PROFILE TEMPLATE OR WOODEN ROLLER.

(4)

Do Subtask 72-00-01-350-017 (paragraph 5.AG.(1)) thru Subtask 72-00-01-350-017 (paragraph 5.AG.(3)) again until the repair area is completely filled.

(5)

Keep the cover in the correct position until the C01-161 abradable material cure is completed.

Subtask 72-00-01-110-007

AH.

Remove the unwanted abradable material from around the repair as follows:

WARNING:

ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.

(1)

Use a C10-182 cleaning cloth moist with C04-035 isopropyl alcohol.

Subtask 72-00-01-220-099

AI.

Do an inspection of the C01-161 abradable material as follows:

(1)

If the C01-161 abradable material moves, use the wooden roller on the cover to smooth the C01-161 abradable material back to the contour of the material that is adjacent to the repair.

Subtask 72-00-01-370-007

AJ.

Cure the C01-161 abradable material. Refer to Subtask 72-00-01-370-001 (paragraph 5.R.).

Subtask 72-00-01-350-018

AK.

Remove the tape and the cover.

Subtask 72-00-01-140-005

WARNING:

AL.

Sand the forward fan case abradable seal repaired area to agree with contour of the adjacent area, as follows:

(1)

Use C10-141 abrasive paper.

(2)

Use the profile template as a guide when you repair areas larger than 6.0 inches (152 mm) maximum axial dimension.

NOTE:

Subtask 72-00-01-220-100

AM.

Do a visual inspection of the surface of the forward fan case abradable shroud as follows:

(1)

Make sure that the repair area has the same contour as the C01-161 abradable material adjacent to the repair area.

(2)

If necessary, fill the unwanted voids in the abradable shroud repair area as follows:

(a)

Do Subtask 72-00-01-350-008 (paragraph 5.N.) again to prepare the C01-161 abradable material.

(b)

Use a C10-108 brush to rub the C01-161 abradable material on the voids and fully wet the surfaces of the void.

(c)

Use the Teflon spatula to make the C01-161 abradable material smooth and agree with the contour of the abradable shroud repair area.

(d)

Do Subtask 72-00-01-140-005 (paragraph 5.AL.) again to make the repair area smooth.

(3)

If the forward fan case repair area does not agree with the inspection limits, do the repair again.

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Figure 901 (Sheet 1 ) Forward Fan Case

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Figure 901 (Sheet 2 ) Forward Fan Case

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Figure 901 (Sheet 3 ) Forward Fan Case

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Figure 902 Profile Template

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Figure 903 Cross-Section of Typical Damage

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Figure 904 Cross-Section of the Prepared Damage Area

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Figure 905 Types of Router Cut

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Figure 906 Steel Rod

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Figure 907 Teflon Spatula

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Figure 908 Adhesive Cartridge

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Figure 909 Cross-Section with the Honeycomb Core Filled

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Figure 910 Cross-Section with Glass Fiber Repair Ply Lay Up

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Figure 911 Cross-Section of Completed Repair

GE Designated: - CONFIDENTIAL Subject to the restrictions on the media