* * * FOR ALL
TASK 72-00-01-300-806
1 . Repair for the Fan Stator Module Assembly.
A.This procedure gives instructions to repair the fan stator module assembly (forward fan case) by applying abradable material and a wet lay-up to the damaged trench filler panel facesheet (facesheet) and honeycomb areas. Refer to Figure 901.
NOTE:
This repair only applies to the trench filler areas before and after the abradable shroud.
B.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.
NOTE:
For 72-00-01, Inspection 001. Refer to TASK 72-00-01-200-801 (72-00-01, INSPECTION).
(4)Visual Inspection.
(a)Do an inspection of the forward fan case (83500) for:
8Holes and punctures in the trench filler facesheet of area A. Refer to Figure 902.
Maximum repairable limit:
In area A axially, a maximum of 7.00 inches (177.8 mm) in circumferential length, and a maximum of 0.25 inch (6.3 mm) in depth if there is a minimum distance of 6.00 inches (152.4 mm) between the repair areas and there are no more than three repair locations in each trench filler panel.
C.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)
 
2264M12G01  
2264M12G03  
2264M12G04  
--
D.Proprietary/Complex Process Statement.
(1)None.
2 . Tools, Equipment, and Materials.
NOTE:
You can use equivalent alternatives for tools, equipment, and consumable materials.
A.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, U.S.A.
 
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, U.S.A.
 
Grinder, Right Angle Drive, 45105A11 (small right-angle drive grinder)
McMaster-Carr
 
P.O. Box 4355
 
Chicago, IL 60680-4355, U.S.A.
 
Telephone (630) 833-0300
 
Fax: (630) 834-9427
 
or local purchase
 
Heat Lamp
Local Purchase
 
Thermocouple
Local Purchase
 
Acrylic Spatula
Local Purchase
 
Adhesive Cartridge
Local Purchase
(3)Locally Manufactured Tools.
 
Description
Figure
 
Steel Rod
908
 
Teflon Spatula
909
B.Consumable Materials.
 
Code No.
Description
 
C01-017
Resin, Epoxy, Liquid
 
C01-024
Catalyst
 
C01-122
RTV, Silicone Elastomer (RTV-157 adhesive)
 
C01-155
Adhesive, Paste, Two Part (paste adhesive)
 
C01-161
Abradable Seal Material (abradable material)
 
C03-029
Coloring Pigment, Lamp Black (carbon black)
 
C04-035
Solvent, General (isopropyl alcohol)
 
C05-003
Marking Pens
 
C10-108
Brush, Disposable, Natural Bristle (brush)
 
C10-122
Cloth, Glass (AMS3824A) (glass cloth)
 
C10-133
Film, Polymer FEP, Un-perforated, 0.001 in. (0.03 mm) thick (FEP film)
 
C10-136
Tape, Pressure Sensitive (tape)
 
C10-140
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)
C.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
 
72-00-01
Repair 003
 
72-00-01
Repair 007
 
--
SAE ARP 5144 Heat Application for Thermosetting Resin Curing
D.Expendable Parts. None.
E.SPD Information. None.
F.Special Solutions. None.
G.Test Specimens. None.
3 . Dimensional Information.
Subtask 72-00-01-220-140
A.Refer to Figure 902 for specified dimensions and locations.
NOTE:
The dimensional data identified within this 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 72-00-01-930-008
A.If necessary, make the locally manufactured tools that follow:
(1)Make the steel rod. Refer to Figure 908.
(2)Make the Teflon spatula. Refer to Figure 909.
Subtask 72-00-01-220-141
B.Do an inspection of the glass fiber facesheet as follows:
(1)Look for damage on the facesheet. Refer to Figure 903 and do as follows:
Subtask 72-00-01-350-093
(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:
1Use a C05-003   marking pen.
Subtask 72-00-01-210-002
(2)Lightly tap the facesheet with the steel rod. Listen to the sound it makes and do as follows:
NOTE:
The different thickness of the facesheet 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.
Subtask 72-00-01-350-118
(3)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.
(4)If the damaged area extends out of area A, you cannot repair the forward fan case with this procedure. Refer to Figure 902.
Subtask 72-00-01-350-094
C.If you found damage in the aft section of the trench filler, pull the aft seal from the repair area as follows:
(1)Use an acrylic spatula to unbond the aft seal around the repair area.
(2)Use an acrylic spatula to remove all the RTV-157 adhesive from the repair area.
(3)Clean the forward fan case 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. 4.
Subtask 72-00-01-110-020
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
(b)Use C04-035   isopropyl alcohol.
Subtask 72-00-01-350-095
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.
(4)Sand the forward fan case with C10-141   abrasive paper to make the repair area smooth and do as follows:
(a)Remove all the remaining RTV-157 adhesive from the repair area.
(b)Make the repair area a constant matte finish.
NOTE:
A matte finish has a constant dull appearance with no shine or luster.
Subtask 72-00-01-160-016
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.
(5)Use clean, dry compressed air that contains no oil to clean the repair area.
Subtask 72-00-01-350-096
(6)Clean the forward fan case 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. 4 or Composite Cleaning Method No. 5.
Subtask 72-00-01-350-097
D.Apply masking to the surfaces around the 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. 3.
Subtask 72-00-01-350-121
WARNING:
USE EYE PROTECTION WHEN YOU CUT MATERIAL OR PARTS. THE PARTICLES CAN CAUSE DAMAGE TO YOUR EYES.
E.Cut and remove the damaged and disbonded facesheet material from the forward fan case as follows:
WARNING:
DO NOT BREATHE THE PARTICLES WHEN YOU DRILL 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.
CAUTION:
DO NOT DRILL DEEPER THAN NECESSARY OR DAMAGE TO THE FACESHEET CAN OCCUR.
(1)Drill a hole through the facesheet at each corner of the area that you identified in Subtask 72-00-01-350-093 (paragraph 5.B.(3)) to cut out as follows:
(a)The hole must have a minimum diameter of 0.5 inch (13 mm).
(2)Cut along the mark around the area that you will remove as follows:
(a)Use a small, right-angle drive grinder with a small cut-off disk.
(3)Start at a corner and carefully pull the damaged facesheet from the honeycomb.
Subtask 72-00-01-350-122
F.Remove the loose or damaged honeycomb from the forward fan case. 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 as result of a temporary repair the honeycomb cells are filled with RTV silicone rubber or other filler materials.
Subtask 72-00-01-220-142
G.Do an inspection of the honeycomb cells and the facesheet in the forward fan case repair area as follows:
Subtask 72-00-01-360-022
(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.
1Use Absorbed Moisture Removal - Method 3 (Hot Air Dryer) and do as follows:
aIncrease the temperature of the repair area to a maximum of 180°F (82°C).
bKeep the temperature of the repair area at a maximum of 180°F (82°C) until you cannot see the liquid.
cContinue to dry the repair area for a minimum of 30 minutes more after you cannot see the liquid.
Subtask 72-00-01-350-099
(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:
1Use Honeycomb Cleaning Method No. 4.
Subtask 72-00-01-110-021
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
2Use C04-035   isopropyl alcohol.
3Clean the honeycomb to approximately 1.0 inch (25 mm) below the top of the cells.
Subtask 72-00-01-350-100
(3)If there is oil contamination on the facesheet repair area, do as follows:
(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:
1Use Composite Cleaning Method No. 4.
Subtask 72-00-01-110-022
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
2Use C04-035   isopropyl alcohol.
Subtask 72-00-01-140-014
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.
H.Sand the forward fan case facesheet to make a taper in the glass fiber facesheet. Refer to Figure 904 and as follows:
(1)If the taper extends out of area A, you cannot repair the facesheet with this procedure.
(2)Use a sanding disk of 1.0 inch (25 mm) in diameter in a small right-angle drive grinder.
(3)Make the taper 0.5 inch (13 mm) in width.
Subtask 72-00-01-350-102
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.
CAUTION:
REMOVE ONLY A MINIMUM QUANTITY OF MATERIAL FROM THE FACESHEET. DAMAGE TO THE FACESHEET WILL MAKE THE REPAIR LARGER.
I.Prepare the surface of the remaining glass fiber facesheet as follows:
(1)Manually sand the surface until the surface has a constant matte finish.
NOTE:
A matte finish has a constant dull appearance with no shine or luster.
(2)Use C10-141   abrasive paper.
Subtask 72-00-01-160-018
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.
J.Use clean, dry, compressed air that contains no oil to clean the dust from the forward fan case repair area.
Subtask 72-00-01-350-103
K.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.
Subtask 72-00-01-110-023
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
(2)Use C04-035   isopropyl alcohol.
Subtask 72-00-01-350-104
L.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 to protect it until you apply the C01-161   abradable material.
Subtask 72-00-01-360-023
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 C10-140   GLOVES WHEN YOU MIX OR APPLY ADHESIVE.
WARNING:
THIS ABRADABLE MATERIAL 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 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 MATERIAL TO PREVENT BURNING AND DECOMPOSING. DO NOT USE MATERIAL 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 HAS BEEN STORED BELOW ROOM TEMPERATURE, MAKE SURE THAT THE ADHESIVE IS PERMITTED TO REACH ROOM TEMPERATURE BEFORE YOU OPEN THE CONTAINER. CONDENSATION CAN REDUCE THE STRENGTH OF THE EPOXY.
M.Mix the C01-161   abradable material as follows:
(1)Alternative Procedure Available. Prepare the C01-161    abradable material found in the 1.5 pounds (680 grams), equal to 1 pint (473 milliliters), kit as follows:
NOTE:
More than one mix can be used for larger repairs.
(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 for approximately 4-5 minutes until you see no streaks of the two components.
NOTE:
The pot life of the C01-161   abradable material is approximately 20 minutes at a temperature of 77°F (25°C).
(d)If necessary, increase the pot life of the C01-161    abradable material by applying a thin layer of the mixed adhesive on a metal surface until it is used.
Subtask 72-00-01-360-025
(1).A.Alternative Procedure. Prepare the C01-161   abradable material found in the 6.0 oz (170 g) adhesive cartridge. Refer to Figure 910 and as follows:
(a)Remove the cinch tape from the cartridge.
(b)Pull the dasher rod up to 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:
1Make sure that the dasher touches the two ends of the cartridge when it operates through its full movement.
2Complete 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 72-00-01-360-034
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 C10-140   GLOVES WHEN MIXING OR APPLYING ADHESIVE.
WARNING:
IF THE ABRADABLE MATERIAL 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 C01-161   ABRADABLE MATERIAL TO PREVENT BURNING AND DECOMPOSING. DO NOT USE C01-161   ABRADABLE MATERIAL THAT HAS BEEN PUT IN WATER.
CAUTION:
IF THE ADHESIVE HAS BEEN STORED BELOW ROOM TEMPERATURE, MAKE SURE THAT THE ADHESIVE IS PERMITTED TO REACH ROOM TEMPERATURE BEFORE YOU OPEN THE CONTAINER. CONDENSATION CAN REDUCE THE STRENGTH OF THE EPOXY.
N.Put the C01-161   abradable material in the honeycomb cells. Refer to Figure 905 and as follows:
(1)Remove the masking that you applied in Subtask 72-00-01-350-104 (paragraph 5.L.) for the protection of the honeycomb cells. Keep the masking around the repair area to prevent spills.
(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 inch (10 mm) in depth.
(4)Use the Teflon spatula to make the C01-161   abradable material level or a small amount above the adjacent facesheet surfaces.
Subtask 72-00-01-110-024
O.Remove the unwanted abradable material from adjacent facesheet surfaces 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 72-00-01-220-143
P.Do an inspection of the C01-161    abradable material on the forward fan case repair area as follows:
(1)If the C01-161   abradable material moves, use the Teflon spatula to make the C01-161   abradable material smooth and level with the adjacent facesheet surfaces.
Subtask 72-00-01-360-026
WARNING:
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
Q.Cure the C01-161   abradable material in the forward fan case repair area. Refer to SAE ARP 5144 Heat Application for Thermosetting Resin Curing, and as follows:
(1)Let the C01-161   abradable material cure for a minimum of 24 hours at a temperature range of 77 to 100°F (25 to 38°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) as follows:
1Use a thermocouple to monitor the temperature.
2Keep 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:
It is possible to machine or sand the C01-161   abradable material after it was 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, the hardness of the C01-161   abradable material must be measured. It is also 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 72-00-01-350-107
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.
R.Sand the C01-161   abradable material on the honeycomb cells to make it smooth as follows:
(1)Use C10-141   abrasive paper.
(2)Make sure that the C01-161   abradable material is 0.000-0.005 inch (0.00-0.12 mm) above the adjacent facesheet surfaces.
Subtask 72-00-01-160-019
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.
S.Use clean, dry, compressed air that contains no oil to clean the dust from the forward fan case repair area.
Subtask 72-00-01-350-108
T.Clean the forward fan case 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. 4 or Composite Cleaning Method No. 5.
Subtask 72-00-01-110-025
WARNING:
ISOPROPYL ALCOHOL IS TOXIC AND FLAMMABLE. USE PERSONAL PROTECTION EQUIPMENT. USE IN A WELL-VENTILATED AREA.
(2)Use C04-035   isopropyl alcohol.
Subtask 72-00-01-220-144
U.Do an inspection of the surface of the C01-161   abradable material repair area as follows:
(1)Make sure that the repair area has the same contour as the adjacent facesheet surfaces.
(2)If the repaired area of the C01-161   abradable material is below the contour of the facesheet, do Subtask 72-00-01-360-023 (paragraph 5.M.) thru Subtask 72-00-01-220-144 (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. Do Subtask 72-00-01-360-023 (paragraph 5.M.) thru Subtask 72-00-01-220-144 (paragraph 5.U.).
Subtask 72-00-01-350-109
V.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 to protect the repair areas until you apply the wet lay-up.
NOTE:
This will keep the filled honeycomb cells clean until you apply the wet lay-up.
Subtask 72-00-01-350-110
W.Make a wet lay-up to use it a as cover for the forward fan case repair area as follows:
(1)If necessary, remove abradable shroud to correctly install the wet lay-up. Refer to TASK 72-00-01-300-801 (72-00-01, REPAIR 003) and Figure 906.
WARNING:
USE EYE PROTECTION WHEN YOU CUT MATERIAL OR PARTS. THE PARTICLES CAN CAUSE DAMAGE TO YOUR EYES.
(2)Cut two pieces of C10-122   glass cloth larger than the repair area on all sides. Refer to Figure 906 and as follows:
(a)For the forward repair area, the width of the cloths must be approximately 2.0 inches (51 mm) to make sure that you can install them between the abradable shroud and the forward acoustic liner.
(b)For the aft repair area, the bottom C10-122   glass cloth must be smaller on all sides than the top C10-122   glass cloth.
Subtask 72-00-01-360-027
WARNING:
EPOXY RESIN AND CATALYST ARE FLAMMABLE AND TOXIC TO SKIN, EYES AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION ARE REQUIRED. USE IN A WELL-VENTILATED AREA. WEAR POLYETHYLENE DISPOSABLE GLOVES OR CLEAN NYLON FILM GLOVES TO MIX AND APPLY THE EPOXY RESIN ADHESIVE.
WARNING:
DO NOT MIX QUANTITIES GREATER THAN 250 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 HAS BEEN STORED BELOW ROOM TEMPERATURE MAKE SURE THAT THE ADHESIVE IS PERMITTED TO REACH ROOM TEMPERATURE BEFORE YOU OPEN THE CONTAINER. CONDENSATION CAN REDUCE THE STRENGTH OF THE EPOXY.
(3)Make an estimate of the quantity of C01-017   liquid epoxy resin that you will use.
(4)Mix the C01-017   liquid epoxy resin in a clean, metal container or paper container that has no wax.
(5)Mix the adhesive materials as follows:
(a)C01-017   liquid epoxy resin - 100 parts by weight.
WARNING:
DIETHYLENETRIAMINE IS TOXIC AND CAN CAUSE SEVERE DERMATITIS AND PERMANENT TISSUE DAMAGE. HIGH CONCENTRATIONS OF VAPOR ARE IRRITATING TO THE EYES AND MUCOUS MEMBRANES. USE ADEQUATE VENTILATION, EYE AND SKIN PROTECTION. IF DIETHYLENETRIAMINE TOUCHES THE SKIN, WASH THOROUGHLY WITH SOAP AND WATER AT ONCE.
(b)C01-024   catalyst - 12 parts by weight.
(c)C03-029   carbon black - 2.7 parts by weight.
(d) Mix the adhesive materials until there are no streaks.
NOTE:
The pot life of the mixed adhesive will be approximately 30 minutes.
(6)Prepare the two pieces of C10-122   glass cloth as follows:
(a)Put a sheet of C10-142   polyester film on a work bench or table.
(b)Apply a small quantity of adhesive on the C10-142    polyester film and do as follows:
1Use a clean, Teflon spatula to make the adhesive layer of approximately 0.010 inch (0.25 mm) in thickness.
(c)Put one C10-122   glass cloth on the adhesive and the C10-142   polyester film.
(d)Put a second piece of C10-142   polyester film on top of the C10-122    glass cloth and the adhesive.
(e)Use the Teflon spatula to remove all the caught air and the unwanted liquid adhesive.
(f)Do Subtask 72-00-01-360-027 (paragraph 5.W.(6)) again for the second C10-122   glass cloth.
Subtask 72-00-01-360-028
X.Apply the C10-122   glass cloth and adhesive layer on the forward fan case repair area. Refer to Figure 906 and as follows:
(1)Apply a layer of adhesive approximately 0.010 inch (0.25 mm) in thickness on the repair area that you sanded as follows:
(a)Use a new, clean C10-108   brush to apply the adhesive.
(b)Use the Teflon spatula to remove all the caught air and make the adhesive smooth.
(2)Apply the bottom C10-122   glass cloth and the adhesive to the repair area as follows:
Subtask 72-00-01-350-112
(a)Remove the polyester film from one side of the bottom C10-122   glass cloth as follows:
WARNING:
BE CAREFUL WHEN YOU USE SHARP OR POINTED TOOLS. THESE TOOLS CAN CAUSE AN INJURY TO YOU.
1Use a razor knife to separate the C10-142   polyester film layers from around the edges.
Subtask 72-00-01-360-029
(b)Put the bottom C10-122   glass cloth and adhesive on the repair area as follows:
1Put the bottom C10-122   glass cloth and adhesive in position to make an overlap of the repair area on all sides.
2Remove the top piece of polyester film from the bottom C10-122   glass cloth.
(3)Apply the top C10-122   glass cloth and adhesive to the repair area as follows:
Subtask 72-00-01-350-113
(a)Remove the polyester film from one side of the top C10-122   glass cloth as follows:
WARNING:
BE CAREFUL WHEN YOU USE SHARP OR POINTED TOOLS. THESE TOOLS CAN CAUSE AN INJURY TO YOU.
1Use a razor knife to separate the C10-122   glass cloth layers from around the edges.
Subtask 72-00-01-360-030
(b)Put the top C10-122   glass cloth and adhesive on the repair area as follows:
1Put the top C10-122   glass cloth and adhesive in position to make an overlap of the bottom C10-122   glass cloth.
2Remove the top piece of polyester film from the top C10-122   glass cloth.
(c)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:
1Use Bagging Method 1.
2If necessary, use C10-136   tape to cover the perforation holes of the forward acoustic liner located under the vacuum bag.
3Peel plies, edge breather cloths, caul plates, and heat blankets are not necessary.
4Let it cure for 24 hours at a room temperature of 65 to 85°F (18 to 29°C).
Subtask 72-00-01-350-114
Y.Remove the vacuum bag and all the masking from the repair area. Keep only the masking around the abradable repair area to give protection to the forward fan case from spills and drips.
Subtask 72-00-01-350-115
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.
Z.Sand the forward fan case repair area to get a smooth matte finish as follows:
NOTE:
A matte finish has a constant dull appearance with no shine or luster.
(1)Use C10-141   abrasive paper to make the repair area have a smooth transition to adjacent contour.
Subtask 72-00-01-160-020
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.
AA.Use clean, dry, compressed air that contains no oil to remove the dust from the forward fan case repair area.
Subtask 72-00-01-350-116
AB.Clean the forward fan case 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. 4 or Composite Cleaning Method No. 5.
Subtask 72-00-01-220-145
AC.Do an inspection of the facesheet repair area. Refer to Figure 906 and as follows:
(1)Make sure that the repair area has a smooth transition to adjacent contour.
Subtask 72-00-01-360-031
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 C10-140   GLOVES WHEN YOU MIX OR APPLY 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 HAS BEEN STORED BELOW ROOM TEMPERATURE, MAKE SURE THAT THE ADHESIVE IS PERMITTED TO REACH ROOM TEMPERATURE BEFORE YOU OPEN THE CONTAINER. CONDENSATION CAN REDUCE THE STRENGTH OF THE EPOXY.
(2)If necessary, use C01-155   paste adhesive to fill the surfaces where more thickness is necessary as follows:
(a)Prepare the C01-155   paste adhesive as follows:
1Make an estimate of the quantity of the C01-155    paste adhesive that you will use.
2Use a clean metal or paper container that has no wax.
3Mix each component in the ratio that follows:
aPart A (adhesive) - 100 parts by weight.
bPart B (catalyst) - 17 parts by weight.
4Do not mix more adhesive than you can use in 90 minutes. The mixed C01-155   paste adhesive can be used until 90 minutes after the mixing procedure.
5Mix 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.
(b)Apply the C01-155   paste adhesive as follows:
1Use a new and clean C10-108   brush to fill the surfaces where more thickness is necessary.
2Apply a layer of C10-133   FEP film on the facesheet repair area.
3Use the Teflon spatula to rub the C10-133   FEP film to make the repair area smooth.
4Use a clean C10-182   cleaning cloth to remove the unwanted resin.
WARNING:
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
(c)Let the mixed adhesive cure. Refer to SAE ARP 5144, Heat Application for Thermosetting Resin Curing, and as follows:
NOTE:
The part can be handled after 24 hours at a room temperature of 65 to 85 °F (18 to 29 °C).
1Let the mixed adhesive cure for 5-7 days at a minimum temperature of 65°F (18°C).
(d)Do Subtask 72-00-01-350-115 (paragraph 5.Z.) thru Subtask 72-00-01-220-145 (paragraph 5.AC.) again.
Subtask 72-00-01-220-146
(3)Do an inspection of the forward fan case repair area. Refer to Subtask 72-00-01-220-141 (paragraph 5.B.) and as follows:
(a)If you find disbonds or delaminations, do the repair procedure again.
Subtask 72-00-01-360-032
AD.If necessary, bond the aft seal in its original position. Refer to Figure 907 and as follows:
Subtask 72-00-01-350-117
(1)Clean the aft seal bond 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. 4 or Composite Cleaning Method No. 5.
Subtask 72-00-01-360-033
(2)Apply C01-122   RTV-157 adhesive to the surfaces of the facesheet and the aft seal that you will bond.
(3)Push the aft seal against the facesheet.
(4)Use C10-136   tape to make sure that the bonded surfaces are correctly adjusted.
(5)Remove the unwanted adhesive. Adhesive must be flush or below the air flow surface.
(6)Let the C01-122   RTV-157 adhesive cure at a minimum ambient temperature of 65°F (18°C) for 24 hours.
Subtask 72-00-01-350-119
AE.If the polysulfide coating was removed or damaged during the repair, apply it. Refer to TASK 72-00-01-300-805 (72-00-01, REPAIR 007).
Subtask 72-00-01-350-120
AF.If necessary, apply the abradable shroud. Refer to TASK 72-00-01-300-801 (72-00-01, REPAIR 003).
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Figure 901   (Sheet 1 ) Fan Stator Module Assembly
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Figure 901   (Sheet 2 ) Fan Stator Module Assembly
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Figure 902   Facesheet Repair Area
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Figure 903   Typical Facesheet Damage
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Figure 904   Prepared Damaged Area
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Figure 905   Honeycomb Core Filled with Abradable Material
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Figure 906   (Sheet 1 ) Completed Repair
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Figure 906   (Sheet 2 ) Completed Repair
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Figure 907   Facesheet Repair Area
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Figure 908   Steel Rod
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Figure 909   Teflon Spatula
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Figure 910   Adhesive Cartridge