PHILIPPINE STATE COLLEGE OF AERONAUTICS

INSTITUTE OF ENGINEERING AND TECHNOLOGY

AERONAUTICAL ENGINEERING DEPARTMENT
LABORATORY MODULE 03: Repair Techniques

LABORATORY
MODULE 04:
Repair Techniques

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

20 minutes
30 minutes
45 minutes
45 minutes
30 minutes
70 minutes
20 minutes
50 minutes
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

REPAIRS
The decision to repair or replace a turbine engine component is based on many
factors. For example, mandatory replacement may be specified for certain parts in the
overhaul manual instructions. On the other hand, some parts may be inspected for
serviceability and repaired or replaced as necessary. If repairs can restore
serviceability to a defective part, the remaining service life projections must be
considered. Furthermore, repairs that must be built up or welded to serviceable limits
typically require specialized equipment and facilities.

Plasma Coating
One popular technique used to build up a component and restore it to its original
dimensions is plasma coating. The plasma coating process has proven to be a
valuable means of extending the service life of blades and vanes and reducing
overhaul costs. Plasma coating involves spraying an atomized metallic material onto
the base metal of a part at a high velocity and at a high heat.

To better understand the concept of plasma coating, watch these videos through the
links below:

Supplemental Video on Plasma Coating:

https://www.youtube.com/watch?v=JvL6aGdZqbA

&
https://www.youtube.com/watch?v=-mcWhRg5w2A

Ceramic Coating

Another application of this process is referred to as ceramic coating and is used to

coat compressor parts for corrosion protection. In addition, the ceramic coating
produces a smooth surface that reduces air friction and surface drag, improving a
compressor's performance. Some experimental processes are now used to apply

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

ceramic materials on many of an engine's hot section components including

combustors, turbine nozzle diaphragms, turbine disks, turbine blades, and vanes.

Supplemental Video on Ceramic Coating:

https://www.youtube.com/watch?v=rn1D_pBdmpw

In addition to the various types of coating processes used to build up engine

components to serviceable limits, there are several welding methods that are used to
make engine repairs.

Electron Beam Welding

Electron beam welding is a relatively new technique that is used to make repairs to
compressor airfoils constructed from titanium alloys. When done properly, electron
beam welding is as strong as or stronger than a new blade or vane, making it possible
to rework some compressor airfoils that would otherwise be rejected.

The primary difference between electron beam welding and other conventional
welding techniques is that electron beam welding produces a narrower bead. This is
possible because the welding process is done in a vacuum chamber which allows
better control over the oxygen level. Heat is concentrated in a smaller area using this
method, which subsequently reduces the stress on the base metal at the weld. As a
result, this method of repair can often be used when damage to an airfoil exceeds
blending or contouring repair limits. An insert of new material can be welded into place
and then ground to the airfoil's original shape. As with most welding procedures, heat-
treatment procedures are normally used to relieve stress in the area of the weld.

Supplemental Video on Electronic Beam Welding:

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

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

COMPRESSOR SECTION

One of the most common repairs made to a compressor section is the removal of
foreign object damage from blades and vanes by blending. Blending should be
performed parallel to the length of a blade using smooth contours to minimize stress
points. Common files, emery or crocus cloth, and Carborundum stones are commonly
used in blend repairs. Use of power tools is not permitted when blending because of
the increased possibility of creating a heat stress buildup or inflicting accidental
damage to adjacent areas.

A typical blend repair has a length to depth ratio of approximately 4 to 1 and is

completed in several steps:

1. the damaged area is scalloped by filing enough material away to create a

saddle or dished out shape.
2. a stone or finish file is used to smooth out score marks and radius the edges of
the repair.
3. the repair is polished with emery or crocus cloth to restore the original finish

Usually, repaired blades must be inspected by magnetic particle or dye penetrant

methods to verify that all damage has been removed. Repaired areas are often
marked with a felt tip dye marker to help maintenance personnel identify reworked
areas during future inspections.

The amount of damage that is permissible on engine fan blades, inlet guide vanes,
and compressor blades typically varies from engine to engine. Therefore, it is
important that the manufacturer's repair instructions be referred to before any repair
is made. As a general rule, nicks, dents, erosion, and scoring on the face of a fan
blade require no repair as long as the damage does not exceed 0.030 inch. The area
where the deepest damage is permitted is on a fan blade's leading edge above a mid-
span shroud. Damage in this area can typically extend into a blade up to 0.060 inch.

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

The areas where no damage is permitted include the fillet areas at a blade's base and
where a shroud meets the blade face.

The amount of damage that is permissible on hollow inlet guide vanes is typically much
less than the damage allowed on compressor fan blades. The reason for this is that
inlet guide vanes are typically hollow and the vane walls are constructed of thin
material. Based on this, blending out damage may result in inadvertently penetrating
a vane wall if too much material is removed. Furthermore, attempting to repair an inlet
guide vane by straightening, brazing, welding, or soldering is usually not permitted. As
a general rule, any sharp, V-shaped dent or any cracking and tearing of a guide vane
requires vane replacement. However, small, shallow dents can typically be left

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

unrepaired if they are rounded, have a gradual contour, and fall within the
manufacturer's specifications. In addition, trailing edge damage of an inlet guide vane
may be blended if one-third of the weld seam remains after a repair is made. Guide
vanes that are rubber filled can -usually be reused if some cracking exists as long as
the cracks extend inward from the outer airfoil and do not appear to be converging. In
addition, there can be no indication of pieces breaking away.

Typically, minor damage on the outer half of an axial-flow compressor blade is

repairable if the repaired area can be kept within the manufacturer's limits. However,
some manufacturers may allow damage to be left unrepaired if the damage meets
certain criteria. For example, if light damage to the leading or trailing edge of a
compressor blade is visible from either side of a blade, confined to the outer half of
the blade, well-rounded, and within acceptable limits, the damage may be left
unrepaired. On the other hand, damage on the inner half of a blade is critical. Minor
damage must be repaired or the blade must be replaced, depending on the severity
of the damage and the manufacturer's requirements. Cracks of any size on
compressor blades are unacceptable and require replacement of the blade.

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

COMBUSTION SECTION
Various methods are used to restore combustion section components. For example,
cracked components can typically be welded while some worn components can be
restored using a ceramic coating process that builds up component thickness.
However, most of the repair processes used on combustion components require the
use of specialized equipment that is generally found only at certified repair
stations.

Welding is the most widely used method for repairing cracks in combustion liners that
are outside of acceptable limits but within repairable limits. The exact type of welding
process used on a particular liner depends on the material used to build the liner.
Typically, combustion liners are constructed of stainless steel and can be repaired
using either inert gas or electron beam welding. However, once component has been
welded, it must be heat-treated to relieve any stress build up caused by the welding
process.

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

Supplemental Readings on Combustion Section

Inspection and Repair:
https://insights.globalspec.com/article/13692/gas-turbine-
inspection-and-repair-techniques

TURBINE SECTION

The amount of damage that is permitted in a turbine section varies from one
manufacturer to another. Therefore, it is imperative that you refer to the manufacturer's
instructions when tying to determine if a specific type of damage is acceptable. As a
general guideline, a maximum of three nicks, dents, or pits are permitted on the front
and rear face of a turbine blade. However, only one nick, dent, or pit is permitted within
a quarter inch of a fillet. Other areas where some minor damage may be permissible
include the leading and trailing edges. However, the amount of damage that is
serviceable is typically limited.

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

Another type of damage that is common to turbine blades is erosion. One method
used to repair erosion is to weld a new piece of blade into place using electron beam
welding techniques. Once a new piece is welded, the blade is ground to the
appropriate shape and heat treated to relieve any stress concentrations produced
during the welding process. Another technique used to repair erosion
is plasma coating. With this process, atomized metallic material is sprayed onto the
eroded section of a turbine blade in multiple coats. Once the coating process is
complete, a blade is ground to its original shape.

EXHAUST SECTION

Damage in an exhaust section that can typically be repaired includes minor warping,
buckling, and cracking. Warping and buckling are generally repaired by straightening
whereas cracks are typically welded. Additional repairs that can be accomplished by
welding include filling small holes with weld metal and replacing larger areas of
damage by welding a new piece of metal in position. Typically gas or electron beam
welding techniques are used to repair engine exhaust sections constructed of stain
less steel.

RESEARCH PAPER:
Do a research study about repair techniques used in a gas turbine engine. Use of
images, figures, and tables are encouraged, as well as, including additional topics and
information.

Input your work on a A4-sized paper with your complete name, year, section, course,
and signature over printed name indicating that you are accepting the terms provided
and indicated by the honesty clause; saved as PDF file with file name, “Surname –
LAB MODULE 04 Research Paper”; and submit on Google Classroom or any
Learning Management System (LMS) platform provided by the instructor on a
designated deadline.

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

Bibliography
Charles E. Otis, P. A. (2002). Aircraft Gas Turbine Powerplants. Jeppesen.

JAA ATPL - Oxford Aviation Jeppesen - Powerplant. (2001). Frankfurt, Germany: Jeppesen GmbH.

Royce, R. (1996). The Jet Engine - Fifth Edition. BIrmingham, England: GH Graphics Ltd.

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

RUBRIC FOR RESEARCH PAPER

NEEDS
EXCELLENT GOOD FAIR
CRITERIA IMPORVEMENT
(4 POINTS) (3 POINTS) (2 POINTS)
(1 POINT)
The topic is focused The topic is too
The topic is
narrowly enough for broad for the The topic is not
Topic focus focused but
the scope of this scope of this clearly defined.
lacks direction.
assignment. assignment.
In-depth The student has Cursory discussion
In-depth discussion
discussion & omitted pertinent in all the sections of
Depth of & elaboration in all
elaboration in content or the paper or brief
discussion sections of the
most sections of content runs-on discussion in only a
paper.
the paper. excessively. few sections.
Sometimes ties
For the most
together Does not tie
Ties together part, ties
information from together
information from all together
all sources. information. Paper
sources. Paper information from
Paper does not does not flow and
flows from one issue all sources.
flow - appears to be
to the next without Paper flows with
disjointedness is created from
the need for only some
apparent. disparate issues.
Cohesiveness headings. Student's disjointedness.
Student's writing Headings are
writing Students writing
does not necessary to link
demonstrates an demonstrates an
demonstrate an concepts. Writing
understanding of the understanding of
understanding of does not
relationship among the relationship
the relationship demonstrate
material obtained among material
among material understanding any
from all sources. obtained from all
obtained from all relationships
sources.
sources.
Unacceptable
Noticeable number of spelling
Minimal spelling
Spelling and No spelling &/or spelling & and/or grammar
&/or grammar
grammar grammar mistakes. grammar mistakes.
mistakes.
mistakes.

Cites most data Cites some data

Cites all data
obtained from obtained from
obtained from other
other sources. other sources.
sources. APA Does not cite
Citations APA citation Citation style is
citation style is used sources.
style is used in either
in both text and
both text and inconsistent or
references.
refrerences. incorrect.

Reference: Research Paper Rubric. (n.d.). Retrieved from

https://www.cornellcollege.edu/library/faculty/focusing-on-assignments/tools-for-
assessment/research-paper-rubric.shtml

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