PHILIPPINE STATE COLLEGE OF AERONAUTICS

INSTITUTE OF ENGINEERING AND TECHNOLOGY

AERONAUTICAL ENGINEERING DEPARTMENT
LABORATORY MODULE 03: Repair Techniques

LABORATORY
MODULE 03:
Parts Inspection

POWERPLANT II – GAS TURBINE

ENGINE

Prepared by:
AERO FACULTY

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
LABORATORY MODULE 03: Repair Techniques

TABLE OF CONTENTS

TIME
TOPIC PAGE
ALLOTMENT

Inspection 4 20 minutes
Visual Inspection 4 30 minutes
Compressor Section Inspection 6 45 minutes
Combustion Section Inspection 7 45 minutes
Supplemental Readings 7 30 minutes
Turbine Section Inspection 7 70 minutes
Supplemental Video 8 20 minutes
Exhaust Section Inspection 9 50 minutes
Structural Inspection 9 90 minutes

TIME
ACTIVITY PAGE
ALLOTMENT

Laboratory Activity 1 11 307.4 minutes

HONESTY CLAUSE

As an institution of higher learning, students are expected to display highest degree

of honesty and professionalism in their class work, requirements, and activities; thus,
in no case that cheating—or any form of it, may it be plagiarism, copying other
students' works, and fabrication of materials—shall be tolerated. The college
assumes as a simple and minimal preferred of habits in academic matters that
students be truthful and that they publish for deposit solely the merchandise of their
personal efforts.

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 PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
LABORATORY MODULE 03: Repair Techniques

This module lists and explains the different repair techniques of parts of a gas
turbine engine.

LEARNING OUTCOMES

Course Learning Outcomes [CLO]

Module Learning Outcomes [MLO]

CLO 1. Understand the development of
the gas turbine engine and classify the
gas turbine engine in terms of their design MLO 1. Analyze the defects of Topic Learning Outcomes [TLO]
built through creating a timeline of aircraft gas turbine engine
important events in the development of components during overhauling
the gas turbine engine process and determining TLO 11. Remember the
structural failures in the acceptable repairs on components
CLO 2. Learn the design principles and of a gas turbine engine.
operation of gas turbine engines through parts.
summarization of the process of
producing thrust. MLO 2. Identify the components TLO 12. Recall repair and
CLO 5. To be able to classify and explain and parts that need repair or replacement procedures for
each type of power plant systems through replacement based on the components of a gas turbine
illustrative activities. defects. engine.
CLO 6. To be able to construct a gas
turbine engine using Computer Aided
Design by designing their own engine.
CLO 7. To be able to define and explain
principles of gas turbine operation
through summarization of the process of
producing thrust.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
LABORATORY MODULE 03: Repair Techniques

INSPECTION

After cleaning, and prior to inspection, the surfaces of some parts, e.g. turbine discs,
are etched. This process removes a small amount of material from the surface of the
part, leaving an even matt finish which reveals surface defects that cannot normally
be seen with the naked eye. The metal removal is normally achieved either by an
electrolytic process in which the part forms the anode, or by immersing the part for a
short time in a special acid bath. Both methods must be carefully controlled to avoid
the removal of too much material.

After the components have been cleaned they are visually and, when necessary,
dimensionally inspected to establish general condition and then subjected to crack
inspection. This may include binocular and magnetic or penetrant inspection
techniques, used either alone or consecutively, depending on the components being
inspected and the degree of inspection considered necessary.

VISUAL INSPECTION

Heavy maintenance inspections performed during overhaul start with a thorough

visual examination after the engine parts have been cleaned. Typically, an inspection
light and magnifying glass are used for close visual inspections.

Before conducting an actual inspection, it is advisable to review an engine's operation

logs for entries made since the last inspection. Entries of hot starts, hung starts, oil and
fuel pressure fluctuations, and overspeed or overtemperature incidents provide clues
to what type of defects may be found. The terms used to describe the types of defects
and damage found in turbine engines are similar to the terms used to describe damage
found in reciprocating engines.

The terms used to describe the types of defects and damage found in turbine
engines are similar to the terms used to describe damage found in reciprocating
engines. These terms include:

Blending. A method of filing compressor or turbine blades and vanes to remove

damage and recon-tour them back to an aerodynamic shape.
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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
LABORATORY MODULE 03: Repair Techniques

Blistering Raised areas indicating a separation of a surface layer from a base metal.
Blistering is often evident as peeling or flaking of a metal plating.
Bow A stress-induced bend or curve in a blade's contour.
Bulge An outward bending or swelling caused by excessive pressure or weakening
due to excessive heat.
Compression A squeezing force which is produced by two opposing forces acting
on a part.
Creep A condition of permanent elongation in rotating airfoils caused by thermal
stress and centrifugal loading.
Dynamic Balancing A procedure which balances the main rotating assembly of a
turbine engine both in the rotational plane and along the rotor axis.
Electrolytic Action Breakdown of surfaces caused by electrical activity between
dissimilar metals. Electrolytic action is also known as galvanic corrosion.
Flowing The spreading out of a plated or painted surface caused by poor adhesion
to the base or excessive loading on the part's surface.
Glazing The development of a hard, glossy surface on bearing surfaces in the
presence of oil, heat, and pressure.
Growth A term used interchangeably with creep to indicate elongation of a
compressor or turbine blade.
Guttering Deep, concentrated erosion resulting from enlargement of cracks or
repeated exposure to a concentrated flame.
Profile The contour or aerodynamic shape of a blade or surface.
Shear A tearing force produced by two opposing parallel forces acting on a part.
Static Balancing A procedure which balances the main rotating assembly of a
turbine engine to help reduce vibration.
Tension A force which tends to pull an object apart.
Untwist A straightening and loss of blade curvature resulting from gas loads,
thermal stress, and centrifugal loading.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
LABORATORY MODULE 03: Repair Techniques

COMPRESSOR SECTION INSPECTION

A turbine engine's fan blades or first stage compressor blades are vulnerable to
damage caused by ingestion of foreign objects and erosion. Therefore, compressor
blades and vanes must be visually examined to detect cracks, dents, gouges, and
other defects caused by FOD.

Blade and vane erosion results from ingestion of sand, dirt, dust, and other fine
airborne contaminants. The abrasive effect of repeated ingestion can wear through a
blade's surface coating and into the base metal. Slipstreams around the engine core
of modern high bypass engines reduce
blade erosion by directing some of the
contaminants around, rather than through
a compressor.

Blade erosion is accumulative and occurs

over many hours of operation. Erosion
shows up as a loss of material on a blade's
leading edge and near a blade's root.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
LABORATORY MODULE 03: Repair Techniques

COMBUSTION SECTION INSPECTION

The types of defects that are acceptable for a given combustion section vary among
engine models. Therefore, when inspecting a combustion chamber, you must follow
the manufacturer's instructions. Typically, a combustion section is examined for the
same types of damage in both line maintenance and heavy maintenance inspections.
However, the method of inspection often differs. For example, when inspecting a
combustion chamber during line maintenance, a borescope is required. However,
during an overhaul, the entire combustion section is disassembled allowing a detailed
inspection without a borescope.

Some of the more common defects found during an inspection include cracks, burner
can shift, hot spots or scorched areas, warpage, and erosion. Combustion liners
should also be checked for excess weld material or slag around all welded seams.

A malfunctioning fuel nozzle can seriously damage a combustion liner. Hot spots on
a combustion liner result from flame contact due to a faulty or misaligned fuel nozzle
e.g., a partially clogged fuel nozzle often causes damage known as hot streaking in
a combustion section. Hot streaking usually consists of burn marks along the length
of a combustion section that result from unatomized fuel contacting the combustion
liner and then burning. Severe hot streaking can result in a flame passing through the
entire turbine section to the tailpipe.

Supplemental Readings on Combustion Section

Inspection:
https://www.aircraftsystemstech.com/2017/05/combustion-
section-inspection.html

TURBINE SECTION INSPECTION

The turbine section of an engine is subjected to a great deal of heat and stress.
Therefore, it is common to find damage in the form of cracking, warping, erosion, and
burning. Cracking is probably the most common type of damage found in a turbine

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
LABORATORY MODULE 03: Repair Techniques

engine, followed by erosion which is caused by the flow of gases and the impingement
of impurities in the gases on internal components.

• Turbine Nozzle Vanes

The hottest gases in a turbine engine pass through the first set of turbine nozzle
vanes. Because of this, small cracks are frequently found. Depending on the
size and orientation of the cracks, a small amount of cracking may be
acceptable.
• Turbine Disk
A turbine disk is typically inspected visually using a strong inspection light and
magnifying glass. Because of the centrifugal forces a turbine wheel is
subjected to, any cracks found on a turbine disk are cause for rejection and
replacement.
• Turbine Blades
Turbine blades routinely incur damage because of the extreme environment in
which they operate. Because of the potential for catastrophic engine failure
should a turbine blade fail, cracking is not permitted in a turbine blade. Of
particular concern during visual inspections are stress rupture cracks on
turbine blade leading and trailing edges. Turbine blades are more prone to
blade creep than compressor blades due to the high temperatures and
centrifugal loads imposed during each engine cycle.
Blade creep is divided into three stages, or classifications primary, secondary,
and tertiary. Primary creep occurs during an engine's first run when new
blades experience operational stresses for the first time. Secondary creep
occurs slowly during many hours of operation. Engine manufacturers take
secondary creep into consideration when establishing a turbine's service life.
Tertiary creep is a third stage which occurs at an accelerated rate after a
period of secondary creep. The onset of tertiary creep is attributed to hot starts,
overtemperature events, extended operation at high power settings, and blade
erosion.

Supplemental Video Turbine Section Inspection:

https://www.youtube.com/watch?v=xDajhAzG16k

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
LABORATORY MODULE 03: Repair Techniques

EXHAUST SECTION INSPECTION

Warping, buckling, and cracking are common defects found during inspections. A
malfunctioning fuel nozzle or combustion chamber can produce hot spots, or hot
streaking, on the exhaust cone and tailpipe. a fuel nozzle spraying a solid stream of
fuel can produce a flame long enough to burn the exhaust cone. By the same token,
if secondary airflow does not properly control the flame zone, the combustion flame
may be allowed to contact the exhaust cone or tailpipe. Warping in an exhaust duct
liner generally indicates the occurrence of a severe overtemperature event.

STRUCTURAL INSPECTION
Structural inspections are conducted using non-destructive testing methods such as
magnetic particle, fluorescent or dye penetrant, radiography, eddy current, and
ultrasonic. The purpose of a structural inspection is to detect hidden flaws that are
undetectable through visual inspection. For example, a hairline crack in a hot section
component may only be visible with a fluorescent or dye penetrant. As another example
any defects that exist below the surface of a component are detectable only through
magnetic particle, radiography, eddy current, or ultrasonic testing.

Magnetic Particle Testing

Magnetic particle testing can only be used on

ferrous materials. The particles may be applied in
either a dry form or wet in a solvent solution. The dry
form works best on cast or forged parts with rough
surfaces. A wet solution with fluorescent
particles and an ultraviolet lamp best detects fine
cracks in smooth surfaces.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
LABORATORY MODULE 03: Repair Techniques

Dye Penetrant

Dye penetrant test kits are available with red dye or green dye.
Red dye is convenient for daylight use because the developer may be sprayed from
a can on the tested part. The developer causes penetrant trapped in a surface defect
to turn red. The red mark or line on the part's surface is then clearly visible.
Green dye kits work best on parts which can be removed and placed in a drip tray.
After cleaning, a green fluorescent penetrating fluid is sprayed on the part and allowed
to dry. An ultraviolet lamp is then used in a darkened room to illuminate defects,
which show up as bright yellow-green lines.

Radiography

Radiography is a testing method which uses X-rays or

Gamma rays to penetrate a part and reveal hidden flaws.
This testing method requires special training and
licensing because it presents a hazard to personnel and
requires certain safety precautions. Defects missed by
visual and dye-penetrant methods are typically detected
by radiography. This method may occasionally be
utilized to verify suspected defects in an area which is
not easily accessible. However, several inherent
limitations of this method limit its usefulness in engine overhaul applications.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
LABORATORY MODULE 03: Repair Techniques

Eddy Current

Eddy current inspection locates

both surface and subsurface
discontinuities in metal parts. The
specialized test equipment
supplies alternating current at a
specified frequency to a test coil
which is held on the part to be
tested. The magnetic field pro-
duced by the test coil induces a
secondary magnetic field in the part being tested. The secondary magnetic field
causes eddy current flow in the part which is measured and analyzed electronically.
Discontinuities in a component disrupt the induced magnetic field and produce an
anomaly which is detected by the test equipment and analyzed.

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PHILIPPINE STATE COLLEGE OF AERONAUTICS
INSTITUTE OF ENGINEERING AND TECHNOLOGY
AERONAUTICAL ENGINEERING DEPARTMENT
LABORATORY MODULE 03: Repair Techniques

Ultrasonic Testing

Ultrasonic testing introduces high

frequency sound waves through a
part to detect discontinuities.
There are two types of ultrasonic
test equipment available; the
immersion type and the contact
type. Immersion equipment is
heavy and stationary while contact equipment is small and portable. Both types
beam sound waves through a part and display the response on a CRT for analysis.
Examination of the variations found in a standard response pattern provides
indications of discontinuities and flaws in a part.

Laboratory Activity 1

GTE Structure – Hot Section

Create the hot section of your designed gas turbine engine. Provide a 1:10
orthographic (realistic) and isometric views (realistic and xray views) of your engine
design. Submit your work saved as PDF file with file name, “Surname – Module 2
Laboratory Activity 1”; on Google Classroom or any Learning Management System
(LMS) platform provided by the instructor on a designated deadline.

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