Fan Module

CFM56-7B

CFM56 Symposium
June 2017 – Milan
Contents

Fan Module
• Handling Damages
Fan Containment Case
• Lug 103-104 – B1 Flange

Fan Frame Shroud V-Groove

• Wear Strip Criteria
• SB 72-0996 Feedback

Fan Frame Shroud Corrosion

• Prevention
• Repair

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 Fan Module
Handling Damages

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Containment Case – Fan Frame Shroud
Handling damages
4Q16 Sept 2017 4Q17
Criteria for FFS Containment Case Containment Case
B6 / B7 / B8 flanges Criteria on Area 3A Criteria on Area 3B

Sept 2017 4Q17 1Q18

Containment Case Fan Frame Shroud Containment Case
Extension A1 + B1 Flange Handling Boss 2nd Extension B1 Flange
2017- Flanges criteria - DICA coverage
Dec. 2016 : Introduction of
Flanges criteria

Significant reduction of provided DICA

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Containment Case
Area 3 – Outer Skin
Background
• Several cases reported with impacts on Area 3 Outer Skin
• Area 3 is main area for the Fan Blade Retention
• ESM Criteria : not serviceable
Area 3A
• 43 CSC Cases analyzed to define a criteria consistent with the reported findings
• 80% of Findings located in Area 3A

Depth Length
0,07 mm 5,8 mm
Average Average
0.0028 inch 0,23 inch
95% of < 0,23 mm 95% of < 18,5 mm
findings < 0.009 inch findings < 0.73 inch

Criteria approved
• P/N 817-818 : Generic criterion in Area 3A of 0.6 mm (0.024 inch) depth approved
• P/N 840 : Generic criterion in Area 3A of 1 mm (0,040 inch) depth approved
• Definition of a criteria in Area 3B is under study for P/N 840
Criteria publication scheduled 4Q17
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Containment case
A1 Flange
Area Area Area
Criteria Extension will be published in ESM A B E
on some areas of the A1 Flange

Area
Area Area
Area A Area A C
D F
Axial Length : 0,157 in Axial Length : 0,2125 in
Radial Length : 0,157 in Radial Length : 0,157 in
Circumferential Length : 0,591 in Circumferential Length : 0,787 in

Area B Area B
Axial Length : 0,118 in Axial Length : 0,2125 in
Radial Length : 0,197 in Radial Length : 0,2125 in
Circumferential Length : 0,787 in Circumferential Length : 0,787 in

Area D Area D
Length : 0,276 in Length : 0,276 in
Depth : 0,0197 in Depth : 0,0394 in
Distance between 2 findings : 0,894 in Distance between 2 findings : 0,894 in

ESM criteria will be published Sept 2017 – DICA Available

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Containment case
B1 Flange
Background
• CSC Cases reported with findings :
– On Radius between 2 lugs
– In Area C but on lugs with no criteria in ESM
– On the face out of Area C : Impact, Fretting
– On Radius between Flange and Containment Case Skin

Extension
a) On lugs without criteria

Actual Criteria will be added on 23 lugs, except #82 -> #87, #91 -> #93, #95, #98, #99

Criteria will be published Sept 2017 – DICA Available

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 Containment case
B1 Flange
Extension
b) Impacts out of Area C
52 Cases analyzed reported with impacts on B1 Flange out of ESM Criteria
Impacts Distribution by Lug
60
50
40
30
20
10
0
79 12 24 23 75 67 84 87 85 11 13 20 15 19 66 68 82 99 10 17 22 26 30 103104

Definition of new criteria will consider :

 Most impacted lugs reported through Cases
 Specific type of impact reported : Impact, Fretting…
 Equipment attached on lug

Extended Criteria approval scheduled 1Q18

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Fan Frame Shroud
Handling Bosses
Background
• Several Cases reported with impacts on RH and LH Handling Boss : Nicks, Dents, Scratches

Repair Proposal
• Blending per SPM 70-41-11 (Hand Blending) or SPM 70-41-12 (Power Blending)
• Cleaning per SPM 70-21-13 (Steam Cleaning)
• Acid Etching per SPM 70-53-11 (Local Swab Etching)
• FPI per SPM 70-32-21 (Portable Water – Washable)
• Spot Touch-Up Of Alodine per SPM 70-62-14

Repair Approval scheduled 4Q17

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 Containment Case
B1 Flange Lugs 103-
104

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Containment Case
B1 Flange – Lugs 103/104 – Outer Skin
Background
• Lugs 103-104 of B1 Flange used to attach Fire Detector Bracket
• Cases of cracked lugs reported during scheduled maintenance
check
• According to AMM, no dispatch allowed
– SB 72-0580 has to be performed

Request
• Allow a Continue-In-Service to avoid AOG Situation
Criteria approved
• CFM/Boeing approved a CIS of 10 Cycles in case of cracked lug :
– Only 1 of both lugs is cracked / broken
– Second lug remains undamaged under visual inspection
– Fire and Overheat Detection System – Operational Test is performed
without fault (26-10-00-710-801)
– SB 72-0580 must be perform once CIS has expired

Criteria published June 2017 AMM

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 Fan Frame Shroud
V-Groove

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V-Groove Wear Strip – SB 72-0975
Background
• Serviceable criteria for post SB 72-0975 parts proposed during last WTT
– Wear/Fretting : Any Amount
– Disbonded Strips :
1. Area B: Maximum cumulative length on 13° (= 7.09 in or 180 mm).
2. Area T : Maximum angular sector of 42 °
3. The 2 criteria can be combined

Request
• Rewrite the wording to make it simpler regarding Area T limits

Criteria approved
1. Disbonded / Missing strips allowed on not more than 180 mm cumulated on Area B
2. Disbonded / Missing strips allowed on not more than 580 mm on Area T
3. Area T is located between Strut #11 and Strut #3

Criteria will be published for AMM released October 2017

DICA Available
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V-Groove SB 72-0996
Background
• Repair procedure published to protect V-Groove from fretting with V-Blade
• Avoid appearance of wear -> Prevent scrapping parts at Shop Visit
• Recommended at each C-Check
Feedback
• First Airlines applied SB On-Wing : No technical difficulties reported
• First FFS under SB 72-0996 inspected in Shop Visit : Wear on V-Groove
serviceable as is

• Template can be shared to help “tracking” FFS under SB 72-0996

– Measure level of wear and determine impact on FFS Scrap Rate

Early feedback demonstrates good improvement with SB 72-0996

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 Fan Frame Shroud
Corrosion

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Corrosion prevention
Sept. 2016 4Q17
Standard parts with Anti-Corrosion grease
coating in production for FFS Repair

Oct. 2016 1Q18

Standard parts with FFS : Anti-corrosion grease
coating in field under anchor nuts in production
Standard parts with Aluminum pigmented coating
• Introduction of Hi-Kote Coating
– In production: September 2016
– In field: October 2016 per SB 72-1002

Repair with anti corrosion grease

• Containment case
– Repair 008
• Fan Frame Shroud
– Repair 001, 004

Repair update scheduled 4Q17

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Outer Skin Corrosion
Background
• Corrosion found on acoustic panels / profile struts
attachment holes and under anchor nuts
• Extension of corrosion from the holes to the skin
Existing repairs for acoustic panels and Strut Fairing holes

Acoustic panels Profile struts

Repair Summary
attachment holes attachment holes
Repair 043 : ESM Published Published
Drilling AMM Published Published
Repair 044 ESM Published N/A
Bushing AMM Repair publication Aug’2017 N/A
Repair 052 ESM N/A Publication scheduled Sept’17
Bushing AMM N/A N/A
Repair 049 ESM Published Published
Blending AMM Published Published

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Outer Skin Corrosion
Several cases reported with corrosion under anchor nuts extended from 1.38” (35 mm)
diameter allowed by Blending repair (Repair 049)

CIS of 8000H published Feb 2017 in AMM when remaining thickness after blending
0.142” < T < 0.157” (3,6 mm < T < 4mm) and a Blended diameter D < 3” (D < 76 mm)

CFM will extend Repair 049 to same blended diameter of 3” (76 mm) in both
AMM/ESM, under condition that T > 0.157” (T > 4mm) without limit of Cycles/Hours

Repair approval scheduled 2Q18

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Strut Fairing Attachment holes – Repair 052

Goal of repair
• To remove corrosion in Strut Fairing attachments holes
Repair Proposal
• Bushing only if corrosion limited to hole
• Washer only if corrosion limited to outer skin
• Bushing and Washer if corrosion extends from hole
Status
• Bushing will be same as Repair 044
• Washer will have different geometry than Repair 044
• Technical feasibility proved by application of Repair 044

Repair will be available at Piece Part Level -> Sept’17

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12 Strut-Hub Attachment Areas
Background
• Several cases reported with corrosion on inner skin on 12 Strut-Hub Attachment Areas
• Blending Repair (Repair 016) not allowed in 24 mm Diameter centered around holes

• Bushing Repair (Repair 050) not cover corrosion on inner skin (Bushing shoulder on Outer
Skin)
• Cold Gas Spray industrialization on-going

Request
CFM to study alternate solution to deal with corrosion on Forbidden Area
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12 Strut-Hub Attachment Areas

Repair Proposal
• Holes spot face machining
• FPI
• Spot Touch-up of Alodine
• Local Manufacturing of bushings and washers
• Bushing installation
• Inner Diameter machining
Technical specifications
• All 96 holes to be repaired
– Ensure good assembly of FFS with 12 Strut-Hub
• Bushing in overflow compared to FFS Profile
– Ensure no loose or loss of tightening with the 12 Strut-Hub
• To facilitate assembly, pre-heat of FFS may be needed (60°)
– Avoid interference between 12 Strut-Hub and bushings installed on FFS

Alternate Repair approval scheduled Dec 2017

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Corrosion – Summary
Work on preventive and corrective actions

Standard parts with Aluminum pigmented coating

• In production : done in Sep. 2016
• In Field : done in Oct. 2016

Anti-corrosion grease under anchor nuts

• In production : Scheduled 1Q18
• In Field : Repair scheduled 4Q17

Corrosion under anchor nuts

• CIS of 8000h in AMM : Done in Feb . 2017
• Extension of Repair 049 scheduled 2Q18

Strut Fairing attachment holes

• Scheduled Sep. 2017

12 Strut hub interface

• Cold Gas Spray : Study is on going.
• Bushing Repair : Scheduled Dec. 2017

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 Thank You – Grazie

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