CFM Turbofan Engine Module

CFM56-3 Familiarization Training Manual MTU Maintenance Zhuhai Co. Ltd.
Jiang Weixing, George Gravelle, Training Department/ Human Resources Revision Date: Feb.20,2004
Core Major Module

Purpose:
Provi de the energy to dri ve the LPT

Components:
The core major module consists of eight maintenance modules as follows: HPC rotor, HPC front stator, HPC
rear stator, combustion case, combustion chamber, HPT nozzle, HPT rotor, HPT shroud and first stage LPT
nozzle.
Description:
HPC rotor is a nine stage, high speed, unitized spool-disk structure. The rotor consists of fi ve major parts: the
front shaft, the 1st and 2nd stage spool, the third stage disk, the 4th through 9th stage spool and the compressor
rear (CDP) seal.
HPC front stator, consists of: front casing hal ves, extension casing halves (configuration 1), IGV’s and first 5
stages of stator vanes. The IGV’s and the 1st through 3rd stage vanes are variable, the 4th and 5th stage vanes
are fixed. The
HPC rear stator consists of: rear casing hal ves, liners (Configuration 1), three stages of fixed vanes, and vane
shrouds. The rear stator is located inside the front stator extension and is cantilever-mounted to the rear stator
support. The rear stator support outer fl ange is mounted between the compressor front stator extension and the
combustion case.
Combustion case is a fabricated structural weldment located between the HPC and the LPT. It provi des
structural interface, transmits engine axial loads, and provi des gas flow path between the compressor and the
LPT.
Combustion chamber contained in the combustion case, consists of outer and inner cowls, 20 primary and 20
secondary swirl nozzles, dome, and outer and inner liners.
Core Major Module (Cont.)
HPT nozzle is a single stage, air-cooled assembl y that mounts in the combustion case and directs the gas flow
from the combustion chamber onto the blades of the HPT at the opti mal angle.
HPT rotor is a single stage, air-cooled turbine. Structurally, the rotor consists of the front shaft, the forward air
seal, the disk, and the rear shaft. The HPT rotor dri ves the HPC rotor and is directly connected to it by a bolted
flange to form what is essentially a single core rotor.
HPT shroud and 1st stage LPT nozzle is located in the aft section of the combustion case. It forms the interface
between the core section and the LPT module of the engine. The forward flange of the assembly is rabbeted and
bolted to the inner surfaces of the combustion casing. The aft flange is bolted between the combustion casing aft
flange and the LPT stator forward flange.
Core Major Module – High Pressure Compressor
Compressor Section
The compressor section provi des compressed air for combustion and bleed air from stages 5 and 9 for engine and
aircraft use.
5th stage air
Is extracted through bleed manifol d segments just aft of the stage 5 stator and is directed into forward and aft air
extraction manifol ds. The forward manifol d provi des air for turbine clearance control and stage 1 LPT nozzle
cooling. The aft manifol d provi des a bleed source for aircraft use.
9th stage air
Is extracted through a gap between the rear stator case and combustion case (just aft of stage 9 rotor). Stage 9
manifol d provi des the aircraft with the high pressure source of bleed air.
HPC Rotor
HPC Rotor Description:
The HPC rotor is a 9 stage, high speed, unitized s pool-disk structure. The rotor consists of fi ve major
components:
- Front shaft, Stage 1-2 spool, Stage 3 disk, Stage 4-9 spool
- HPC rear rotating (CDP) air seal
HPC Rotor Components:
Front shaft
The front shaft is bolted between the stage 1 and 2 spool and the stage 3 disk, and is the forward support for the
rotor. The shaft is splined to and secured to the IGB horizontal bevel gear by a coupling nut. The IGB contains
the thrust bearing (No. 3 ball bearing) for the core engine. The front shaft is made of a titanium alloy.
Disk and Spools

The stage 1 and 2 spool and the stage 3 disk are made of titanium alloy forgings and retain the stages 1-3 blades
in axial slots. The stages 4-9 spool is made of a nickel alloy and retains stages 4-9 blades in circumferential
grooves. The disk and stages 4-9 spool are internally cooled by LPC booster discharge air which enters the rotor
through holes in the front shaft. There are abrasi ve coated seals between the rotor blade stages for improved
compressor performance.
Blades:
The stages 1-3 blades are made of a titanium alloy. The stage 4-9 blades are made of a nickel alloy. The first
three stages of blades are secured in the disk and spool axial slots by retaining rings; the blades in the stages 4-9
are secured in the circumferential grooves by locking lugs. All blades are replaceable wi thout disassembling the
rotor.
HPC Rotor (cont.)
Number of rotor blades per Stage
Stage 1 – 38 blades
HPC Rotor (cont.)

Rear Seal
The compressor rotor rear rotating (CDP) air seal is a one-piece nickel alloy forging with abrasive, protecti ve-
coated sealing teeth. The seal is mounted to the aft flange of the stages 4-9 spool by a tight fitting rabbet diameter
and is axially clamped by the bolts and nuts securing the forward fl ange of the HPT rotor to the compressor.
HPC Rotor Airflow
An air duct through the inside diameter of the rotor forms a flow path for pressurizing and cooling air.
Pressurizing air from the forward sump flows between the air duct and LPT shaft. This air enters the aft sump
through holes in the HPT aft shaft and pressurizes the aft sump seals. Cooling air from the No. 3 bearing aft
stationary seal flows through holes in the compressor rotor front shaft through the compressor and HPT rotors
and enters into the LPT rotor through holes in the aft shaft of the HPT. This airflow is referred to as bore rotor
cavity cooling.
HPC Front Stator Assembly
Description
Configuration one (Titanium Stator Case)
The front casing halves are a matched set machined from a titanium forging. The extension casing hal ves are
also a matched set and are machined from an Inco 718 steel forging. The extension case attaches to the front case
with bolts and nuts which must not removed. Segmented liners make-up the stage 1-5 flow path. The front stator
forms the load carrying structure between the fan frame and the combustion case. Bleed air is extracted from
pads on the front case and extension for customer use, and for the HPT and LPT cooling. The stage 5 bleed
manifol ds have a controlled inside diameter that interfaces with the forward end of the rear stator.
HPC Front Stator Assembly Components (cont.)
Configuration two (steel stator case) (S/B 72-383)
The configuration two front case hal ves are made from an M152 steel forging. This forging replaces the titanium
front case / Inco 718 extension case forgings. The stage 1-5 flow path is a machined, integral part of the case,
instead of liners.
HPC Front Stator Assembly Components
Stator contains IGV’s and fi ve stator stages:
IGV’s 42 IGV’s
Stage 1 - 82 VSV’s
Stage 4 - 10 sectors of seven fixed vanes each
Stage 5 - 12 sectors of seven fixed vanes each
Stator vanes
The IGV and stages 1-3 vanes are variable; the stages 4 and 5 vanes are fixed. All stages of variable vanes are
shrouded. The IGV shrouds are made of an epoxy resin, and are in two 180 degree sections. Shrouds for stages 1,
2 and 3 are made of aluminum and are in 12 segments. IGV inner shroud mates with No. 3 bearing aft
stationary air/oil seal.
The fixed vanes, in stage 4 and 5, are fabricated into segments consisting of several vanes each. The fixed vanes
have removable interstage honeycomb shroud segments attached to their inner bands that interface with the
labyrinth ri b seals on the rotor spool di ameter.
Sector wear gui des protect the vanes, liners (configuration 1) and casing from wear.
HPC Front Stator Assembly Components
Variable Vane Actuati on
Actuation of the variable vanes is accomplished with hydraulically actuated bell crank assemblies mounted on
the front compressor stator at the 2 and 8 o’clock positions. Adjustable linkages connects the bell cranks to
actuation rings. Lever arms attached to the variable vanes connect to the actuation rings. Fuel from MEC is
used to operate the hydraulic actuators.
Variable stator vane attachment assembly
Typical for stages 1 through 3 Typical for IGV’s except inner trunnion bushing
Bushings are installed from the outer side of the stator case VSV hole and on the inside of each VSV hole an inner
washer provi des sealing for the compressor air path. The interstage seal retains the shroud pins in additi on to
sealing the area between the vane inner diameter and compressor rotor. In the actuation rings, at stages 1-3,
bushings are installed to interface with the lever arm of the VSV assembly.
For the IGV variable stage, the attachment assembly is the same at the case, lever arm and actuation ring as for
stages 1-3, but each IGV and inner trunnion bushing is assembled to the shroud segments and hel d in pl ace with
a retainer, or on some later designs, bolted to the forward shroud segment.
Stage 5 bleed manifol d, fourteen segments bolted to the inner flange of the forward aft compressor case, provi des
a flow path for the air extraction at the three large holes for customer 5th stage bleed (two in the upper half
extension case at 12 and 2:30 o’clock positions/ALF and one in the lower half extension case at the 8:30 o’clock
position/ALF). A new configuration has repl aced the fourteen segments with segments machined as an integral
part of the case. The forward flange of the HPC rear case rests on these brackets.
Extension case encloses rear stator case and contains threaded bosses at the 5 o’clock position/ALF for the outer
portion of stage 6-8 borescope pl ugs.
Borescope ports at all fi ve stages plus IGV’s at approximately 5 0’clock position/ALF.
Core engine major module di mensional data pl ate (5 o’clock ALF, attached to flange N)
Fourteen (14) bracket segments

Core Major Module – Rear Stator Case
Description:
The rear stator assembly is located inside of the front stator assembl y extension and is cantilever mounted to the
rear stator support. The rear stator support outer flange is mounted between the compressor front stator
extension and the combustion case.
Cantile ver
support
Rear case rests on brackets

Core Major Module – Rear Stator Case (cont.)
Components:
Casing:
Casing halves (configuration one) Pre S/B 72-015
The rear casing hal ves are a matched set machined from an inconel forging. The casings have internally
machined circumferential slots that retain stage 6,7 and 8 stator vane segments and stages 6, 7, 8 and 9 liners.
Liners
Configuration one has replaceable liners between each stage of vanes. Liners provi de a rubbing surface for the
rotor bl ades. Configuration two is linerless. The rub coating is applied directly to the casing lands.
Liners
Description:
Post S/B 72-015
The rear casing quarters are a matched set machined from inconel castings. The upper and l ower hal ves are
permanently bolted together at 12 o’clock and 6 o’clock. The configuration two casings have internally machined
circumferential slots that retain stages 6,7 and 8 stator vane segments and stages 6,7,8 and 9 Metco 450 coated
rub lands.
Split Line
Vanes
The stage 6,7 and 8 stages vanes are manufacture in repl aceable vane segments. They have removable
honeycomb seals that meet with the knife edge seals on the compressor rotor.
Core Major Module – combustion section
Purpose
The combustion section is a place to effecti vely blend and burn the fuel/air mixture at the proper ratio for top
performance /efficiency of the engine.
Components:
The combustion case encloses the combustion chamber and high pressure turbine (HPT) components. The
combustion chamber, compressor rear stationary (CDP) seal, HPT nozzle assembly, HPT Rotor and HPT
shroud/stage 1 LPT nozzle assembly are mounted in and structurally supported by the combustion case. The
case mounts and positions the 20 fuel nozzles, two igniter plugs, and fuel manifol d.
High Pressure Turbine (HPT) HPT Shroud Support and Stage 1 LPT Nozzle
Core Major Module – Combustion Case
Description:
The combustion case is a fabricated structural wel dment located between the high pressure compressor (HPC)
and the low pressure turbine (LPT). It provi des the structural interface, transmits the engine axial load, and
provi des gas flow path between the compressor and LPT. The case incorporates the HPC outlet guide vanes
(OGV) and a diffuser for the reduction of combustion chamber sensitivity to the compressor air velocity profile.
There are six borescope ports: four for inspection of the combustion chamber and HPT nozzles, and two for
inspection of the HPT bl ades, HPT shrouds and the 1st stage LPT blades. The case has four ports for extraction
of compressor discharge air for aircraft systems use, four ports for introduction of 5th stage compressor air for
Stage 1 LPT cooling, and three ports for HPT shroud support cooling air for HPT Clearance Control . There is
also one port for the CDP (PS 3C) sensing tube which connects to the main engine control (MEC), two ports for
spark igniters (4 and 8 o’clock positions) and 20 ports for fuel nozzles.
Core Major Module – Combustion Chamber

Description:
The combustion chamber is a short, annular structure. The design of the combustion chamber, along with the
swirler nozzles, and high pressure/temperature air, produces fuel-air mixing to provi de a uniform combustion
pattern and low thermal stresses. The combustion chamber, contained in the combustion case, consists of outer
and inner cowls, 20 pri mary swirl nozzles, dome, and outer and inner liners. The outer liner and inner cowl are
either bolted or wel ded to the dome. The inner liner and inner cowl are bolted to the dome at a common joint.
Components:
Dome
The dome consists of both cast and machined components. 20 primary s wirl nozzles and 20 secondary swirl
nozzles with venturi’s and sleeves are used to provi de mi xing of air and fuel. The entire surface of the dome is
cooled by a film of air.
Cowls
The inner and outer cowls are designed to provi de uniform and stable airflow profiles to the combustion
chamber.
Liners
The outer and inner liners are of an integral design with panel overhangs which contain closely spaced holes for
film cooling. Dilution holes are employed in the liners to provi de addi tional mixing and cooling air which lowers
the gas temperature at the turbine inlet. The outer liner contains two ferrules for the igniters. The Inner liner is
bolted between the HPT nozzle and the HPT nozzle support. The out liner mates with the inner surface of the
combustion case and is aligned by tabs. The aft end of the liners interface with the HPT through leaf seals.
Core Major Module – High Pressure Turbine Nozzle

Purpose:
Direct the combustion gasses onto the HPTR.

Description:
The high pressure turbine (HPT) nozzle is a single-stage air cooled assembly that is mounted in the combustion
case and directs the gas flow from the combustion chamber onto the bl ades of the HPT rotor at the optimal angle.
The major parts of the nozzle are 23 nozzles segments, outer support, and inner support. The aft support and
seal assembly and the aft stator seals, while not integral components of the HPT nozzle module are included since
they attach to the HPT stator parts.
Core Major Module – High Pressure Turbine Nozzle (cont.)

Components:
Nozzle segments
The HPT nozzle segments are assemblies of 2 vanes brazed into inner and outer platforms. Each vane is a cast
shell di vi ded into forward and aft compartments by an inner ri b. The vanes and platforms are cooled by
compressor discharge air (CDP) entering the vane compartments through inserts in the inner and outer ends of
vanes and exiting through the vane leading and trailing edges. The vanes and pl atforms are made of a high
strength cobalt base alloy with a protecti ve coating on the vane airfoils and on the platform flow path surfaces.
Trailing
HPT Nozzle Segment

Core Major Module – High Pressure Turbine Nozzle (cont.)

Inner and Outer supports
The nozzle inner and outer supports are both one-piece nickel base alloy rings. The major portion of the nozzle
axial load is carried by the inner support through the bolted flanges of the support and nozzle inner pl atforms.
The outer support carries a minor portion of the load.
Aft outer support and seal
The aft outer support is a one-piece nickel base alloy ring that provi des support for the four-step honeycomb seal
that mates with the HPT rotor inducer seal to help maintain the proper amount of cooling air flow and rotor
thrust.
Aft stator seals
The aft stator seal segments form a seal ring which controls the amount of cooling air leakage that passed
between the seal and the HPT bl ades.
Core Major Module – High Pressure Turbine Rotor
Description:
The high pressure turbine (HPT) rotor is a single-stage, air-cooled, high efficiency turbine. The rotor consists of
the front shaft, the front rotating air seal, the bladed disk, and the rear shaft. The HPT rotor dri ves the
compressor rotor and is directly connected to it by a bolted flange to form what is essentially a single core rotor.
The rotor is internally cooled by low pressure compressor (booster) discharge air. It has interference rabbeted
flanges for rigidity and stability. The four main structural parts are made of high strength nickel alloys.
Core Major Module –High Pressure Turbine rotor (cont.)

Front shaft
The front shaft forms the structural connection between the compressor rotor and the HPT rotor, and supports
the aft end of the compressor rotor.
Disk
The HPT disk is a forged and machined part that retains the turbine blades in axial dovetail slots. The inner part
of the disk is cooled by booster discharge air. The outer part of the disk is cooled by compressor discharge air.
Rear shaft
The rear shaft is bolted to the aft side of the disk at a rabbeted flange and forms the aft support for the HPT
rotor. The shaft is supported by the NO. 4 roller bearing which rides on the low pressure shaft. Repairable
abrasive-coated seals are machined as an integral part of the rear shaft.
Front rotating air seal
The front rotating air seal is bolted between the disk and the front shaft of the rotor. It forms a cavi ty between
itself and the disk to direct compressor discharge air against the disk web and out through the turbine blades.
The seal is a labyrinth inclined tooth form that reduces leakage past the seals. The seal teeth are abrasi ve coated
and repairable.
Blades
The blades are made of a high temperature nickel alloy with a high strength to weight ratio. They are a single-
shank design and are indi vi dually replaceable. The single-stage design allows for better air cooling and lower
metal temperature. The bl ades are internally cooled by compressor discharge air entering through the blade root
and exiting through holes in the leading edge ti p, and trailing edge.
Core Major Module – High Pressure Turbine Shroud and Stage 1 LPT Nozzle
Description:
The high pressure turbine (HPT) shroud and stage 1 low pressure turbine (LPT) nozzle assembly is located inside
the aft end of the combustion case. It forms the interface between the core section and the LPT module. The
forward flange of the assembly is bolted to the inner surface of the combustion case. The aft flange is bolted
between the combustion case aft flange and the LPT stator forward flange. The shroud/nozzle support assembly
has a thermal response (turbine clearance control) matched to the rotor to provi de optimum ti p clearance control
and structural stability. An air cavi ty between the shroud/nozzle support assembly and the combustion case
directs 5th and 9th stage compressor bleed air onto the support. This cooling air maintains a closer clearance
between the shrouds and the rotor blades.
The stage 1 LPT nozzles direct the core engine exhaust gas onto the stage 1 LPT bl ades. An air cavity between
the stage 1 nozzle support and the combustion case directs 5th compressor stage bleed air through the nozzle
vanes for cooling. After passing through the vanes, the air pressurizes and cools the cavity between the aft side of
the HPT rotor and the forward side of the LPT rotor.
The assembly is bolted between the LPT case forward flange and the combustion case aft flange. Borescope ports
at 5:30 and 8:30 o’clock are provi ded in the support to allow ins pection of the nozzle area.
Components:
Shroud/nozzle support assembly
The shroud/nozzle support assembl y forms the outer shell of the assembly and provi des an air space or manifol d
area between the outer shell and the combustion case. High pressure compressor bleed air is introduced into the
manifol d area to provi de cooling for the HPT shrouds and the LPT nozzles.
HPT Shroud and Stage 1 LPT Nozzle Support Assembly

Core Major Module – High Pressure Turbine Shroud and Stage 1 LPT Nozzle (cont.)
HPT Shrouds
The HPT shrouds have a smooth abrasive rub surface that is tolerant to localized blade ti p rubs and has good
resistance to erosion from hot exhaust gasses. The shrouds are hel d in place on the support by retainers and are
indi vi dually replaceable.

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CFM56-3 Familiarization Training Manual MTU Maintenance Zhuhai Co. Ltd.

Core Major Module

Provi de the energy to dri ve the LPT

Core Major Module (Cont.)

Core Major Module – High Pressure Compressor

5th stage air

9th stage air

Disk and Spools

HPC Rotor (cont.)

Number of rotor blades per Stage

HPC Rotor (cont.)

HPC Rotor Airflow

HPC Front Stator Assembly

Configuration one (Titanium Stator Case)

HPC Front Stator Assembly Components (cont.)

Configuration two (steel stator case) (S/B 72-383)

HPC Front Stator Assembly Components

Stator contains IGV’s and fi ve stator stages:

HPC Front Stator Assembly Components (cont.)

HPC Front Stator Assembly Components

Variable Vane Actuati on

HPC Front Stator Assembly Components (cont.)

Variable stator vane attachment assembly

HPC Front Stator Assembly Components (cont.)

Borescope ports at all fi ve stages plus IGV’s at approximately 5 0’clock position/ALF.

Fourteen (14) bracket segments

Core Major Module – Rear Stator Case

Rear case rests on brackets

Core Major Module – Rear Stator Case (cont.)

Casing halves (configuration one) Pre S/B 72-015

Core Major Module – Rear Stator Case (cont.)

Post S/B 72-015

Core Major Module – Rear Stator Case (cont.)

Core Major Module – combustion section

Core Major Module – Combustion Case

Core Major Module – Combustion Chamber

Core Major Module – High Pressure Turbine Nozzle

Direct the combustion gasses onto the HPTR.

Core Major Module – High Pressure Turbine Nozzle (cont.)

HPT Nozzle Segment

Core Major Module – High Pressure Turbine Nozzle (cont.)

Aft stator seals

Core Major Module – High Pressure Turbine Rotor

Core Major Module –High Pressure Turbine rotor (cont.)

Shroud/nozzle support assembly

HPT Shroud and Stage 1 LPT Nozzle Support Assembly

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