Name: GROUP 1 Title: REPAIR TECHNIQUES

Instructor: ENGR. ROY TRISTAN S. ROSALES, Date: 06/19/2024 Section: BSAEE 3-2
MEAM Page: 1 of 12 Signature:

PHILIPPINE STATE COLLEGE OF AERONAUTICS

INSTITUTE OF ENGINEERING AND TECHNOLOGY

LABORATORY PROJECT

GENERAL ELECTRIC GE9X

Submitted by:

Angala, John Joshua J.

Carcido, Ashley Dale A.

Coja, Alberto III M.

Cruz, Raybert O.

Cunano, Angelico Paolo I.

Dalanon, Kassandra Anne A.

Submitted to:
Engr. Roy Tristan S. Rosales

June 2023
Name: GROUP 1 Title: REPAIR TECHNIQUES

Instructor: ENGR. ROY TRISTAN S. ROSALES, Date: 06/19/2024 Section: BSAEE 3-2
MEAM Page: 2 of 12 Signature:

PLASMA COATING

Plasma coating is a well-established technique used to repair and extend the lifespan of turbine
engine components. It works by spraying a molten material onto the surface of the damaged
component. It is deemed to be a more cost-effective option than replacing a damaged component. It
can also use a wide variety of materials for coating depending on the specific needs of the component
and application. Plasma coatings are durable and can significantly extend the lifespan of turbine
engine components. It provides solutions on turbine defects, such as wear and tear, oxidation, and
corrosion.

Plasma Coating Process

● A plasma torch is used to create a high-temperature stream of ionized gas (argon) by passing
an electric arc through the gas. This strips the electrons from the atoms, creating a charged
soup of ions and electrons.

● The coating material, in powder form, is injected into the hot plasma stream that reaches up to
14000 K and rapidly melting the powdered material.
Name: GROUP 1 Title: REPAIR TECHNIQUES

Instructor: ENGR. ROY TRISTAN S. ROSALES, Date: 06/19/2024 Section: BSAEE 3-2
MEAM Page: 3 of 12 Signature:

● The molten material droplets are accelerated by the plasma stream towards the target surface
to be coated.

● Upon impact, the molten droplets rapidly cool and solidify, and bond with the surface to build a
layer.

CERAMIC COATING
Ceramic coating is used as a preventive measure for components to protect them from wear,
corrosion, and high temperatures; thus extending the lifespan of the component. It can also be used to
repair eroded surfaces to rebuild the lost material and restore the original profile of the component.
However, for significant damage, replacing the component is often the preferred and safer option since
it is more reliable and ensures safety. (A car can also have ceramic coating and undergo the same
process.)
Name: GROUP 1 Title: REPAIR TECHNIQUES

Instructor: ENGR. ROY TRISTAN S. ROSALES, Date: 06/19/2024 Section: BSAEE 3-2
MEAM Page: 4 of 12 Signature:

Ceramic Coating Process

● The surface of the component is thoroughly cleaned to remove any contaminants like
grease, oi, or dirt. An abrasive media is typically blasted to roughen the surface to create
better mechanical bonds.

● A bond coat is applied as an intermediate layer to ensure strong adhesion between the
ceramic top coat and the meal substrate.
● The final layer is the ceramic material. It is typically sprayed, like the plasma coating.

● The component is cooled and inspected for uniformity.

Name: GROUP 1 Title: REPAIR TECHNIQUES

Instructor: ENGR. ROY TRISTAN S. ROSALES, Date: 06/19/2024 Section: BSAEE 3-2
MEAM Page: 5 of 12 Signature:

ELECTRON BEAM WELDING

Electron beam welding is a new technique used to repair compressor airfoils made of titanium alloys.
This method, when done correctly, can repair some compressor airfoils that would otherwise be
rejected since it reworks these airfoils as strong as a new blade or vane

Unlike the other conventional welding techniques, a narrower bead is produced by electron beam
welding. This is made feasible by the fact that the welding procedure is carried out in a vacuum
chamber, which improves oxygen level control. Heat is concentrated in a small area and stress on the
base metal and weld is less than in other methods. This method can sometimes be used when
damage to an airfoil exceeds the limits that can be repaired by blending. Typically, new material is
welded in place and ground to the original airfoil shape. As with most welding procedures,
heat-treatment procedures are used to relieve stress in the area of the weld.

Electron Beam Welding Process

There are many different varieties and sizes of electron-beam welding machine, but most follow a
similar operating process:

1) The two parts are cleaned thoroughly to remove contaminants and demagnetized if ferrous based
metals.

2) The parts are secured to their fixtures and attached to the welding machine’s Computerized
Numerical Control (CNC) operated work movement system. This can be programmed to maneuver the
parts into position and adjust during the process.

3) The vacuum chamber is sealed, and a vacuum created by expelling air from the chamber.

4) The electron beam is aligned with the joint then generated to the appropriate power. Beam
parameters can be manually, or CNC adjusted during the cycle to maintain consistent weld quality.

5) The electron beam welding cycle is initiated.

Name: GROUP 1 Title: REPAIR TECHNIQUES

Instructor: ENGR. ROY TRISTAN S. ROSALES, Date: 06/19/2024 Section: BSAEE 3-2
MEAM Page: 6 of 12 Signature:

6) After welding is complete, the vacuum chamber is re-pressurized, so it can be opened, and the
joined part removed.

7) Fixtures are removed, after which the part is subjected to a thorough inspection process.
Non-destructive Fluorescent Penetrant crack testing is the most common quality control method. This
is often used in tandem with visual inspection and/or radiography.

COMPRESSOR SECTION
These are the techniques the maintenance technician may opt to repair the compressor section of a
gas turbine engine:

Blending & Replacement

● General inspection procedures:

○ Each of the guide vanes (trailing edge and body) must be inspected using a light and a
mirror for certain damages such as cracks or other damages caused by foreign objects.
● Types of damage acceptable:
○ Small and shallow dents on the vane material that are rounded or gradual contour-type
● Concave surfaces of rubber-filled vanes with cracks from the inward to the outward part of the
airfoil as long as it does not seem to be breaking away
● Types of damage unacceptable:
○ Dents on the vane material that are sharp or V-type
○ Hollow vanes that have cracks or tears in their damaged locations
● Limitations to consider:
○ The thin-sheet construction of the hollow vanes limits the possible blending done to the
concave and convex surfaces which includes the leading edge
Name: GROUP 1 Title: REPAIR TECHNIQUES

Instructor: ENGR. ROY TRISTAN S. ROSALES, Date: 06/19/2024 Section: BSAEE 3-2
MEAM Page: 7 of 12 Signature:

● Factors to consider for trailing edge blending:

○ As long as there is still one-third of the weld seam after repair, blending of the trailing
edge is possible
● Important things to take note:
○ The inspection and repair of any part of the turbine compressor section must be done
according to the current information for evaluation and limits given by the manufacturer
for repairs.
Name: GROUP 1 Title: REPAIR TECHNIQUES

Instructor: ENGR. ROY TRISTAN S. ROSALES, Date: 06/19/2024 Section: BSAEE 3-2
MEAM Page: 8 of 12 Signature:

COMBUSTION SECTION
Repair techniques for aircraft engine combustion sections are very specialized and require highly
skilled technicians due to the demanding environment these parts endure. Here's a breakdown of the
process:

Inspection:

● Before repairs, the combustor is thoroughly inspected for damage like cracks, excessive wear,
erosion, and hot spots. This might involve:
○ Visual Inspection

○ Non-Destructive Testing (NDT) techniques

○ Dimensional Inspection
Name: GROUP 1 Title: REPAIR TECHNIQUES

Instructor: ENGR. ROY TRISTAN S. ROSALES, Date: 06/19/2024 Section: BSAEE 3-2
MEAM Page: 9 of 12 Signature:

Repair Techniques:

● Depending on the type and severity of the damage, different techniques are employed. Some
common methods include:
○ Welding: Tungsten Inert Gas (TIG) welding is a popular choice due to its precision and
minimal spatter. Electron Beam Welding (EBW) might also be used for specific
applications.

○ Brazing: This technique utilizes molten filler metal to join parts, suitable for narrow
cracks (less than 0.25mm).

○ Cladding: Worn or damaged surfaces can be built up with weld metal to restore their
dimensions

● In some cases, replacement of severely damaged components might be necessary.

Name: GROUP 1 Title: REPAIR TECHNIQUES

Instructor: ENGR. ROY TRISTAN S. ROSALES, Date: 06/19/2024 Section: BSAEE 3-2
MEAM Page: 10 of 12 Signature:

Strict Regulations:

● All repairs adhere to strict regulations set by aviation authorities to ensure the engine's safety
and performance. This involves following manufacturer's manuals and rigorous quality control
procedures.

TURBINE SECTION
These are the general techniques for the repair of a gas turbine engine turbine section including some
steps for inspection:
Turbine Blade Replacement

● Inspection of turbine blade assembly:

o A thorough visual inspection must be conducted to look for broken, cracked, or eroded
turbine blades
o Assess whether it will be more economical to replace the blades individually or replace
the entire turbine assembly based on the identified damages
● Blade assembly preparation:
o Prepare and arrange in order of diminishing moment-weight a complete set of 54 blades
in coded pairs (two blades with the same code letter) on a bench
o Look for the code letters at the rear face of the fir-tree section of each blade to identify
their moment-weight balance.
o The blades should be numbered with the heaviest moment-weight as 1 and 28, the next
as 2 and 29, and so forth, numbering all of the blades
Name: GROUP 1 Title: REPAIR TECHNIQUES

Instructor: ENGR. ROY TRISTAN S. ROSALES, Date: 06/19/2024 Section: BSAEE 3-2
MEAM Page: 11 of 12 Signature:
● Installation of blades:
o Put a number “1” mark on the face of the hub of the turbine disc
o Install the number 1 blade adjacent to the number 1 on the disc and install the remaining
blades consecutively in a clockwise manner while looking at the rear face of the turbine
disc following the numbering sequence
o Blades with the same code letters must be installed consecutively before proceeding to
the installation of the next code set of code letters

● Blade replacement:
o A blade that is deemed to be replaced causes its diametrically opposite blade to be
replaced as well for maintaining balance
o Computer programs must be used to determine the proper location of each turbine blade
for modern engines
● Final procedures:
o A final inspection must be done to check if the blades are securely and properly installed
o A balance check must also be done to ensure proper functioning and longevity
o All the changes must be documented aligning to the engine manufacturer’s technical
instructions and maintenance logs.
● Important things to take note:
o Procedures as well as the limitations considered must be in line with the specific engine
manufacturer's technical instructions
Name: GROUP 1 Title: REPAIR TECHNIQUES

Instructor: ENGR. ROY TRISTAN S. ROSALES, Date: 06/19/2024 Section: BSAEE 3-2
MEAM Page: 12 of 12 Signature:

EXHAUST SECTION
These are some of the general guidelines for a jet engine exhaust repair:
● Preliminary inspections:
○ Before repair, a thorough inspection of the exhaust section of a gas turbine engine due to
its vulnerability to heat cracking. This is mostly done in conjunction with the inspection of
the combustion section and turbine section
○ Specific damages to look for:
■ Cracks
■ Warping
■ Buckling
■ Hot spots - Suggest problems with the fuel nozzle or the combustion chamber
*All of these mostly happen on the exhaust cone and nozzle*
● Repair procedures:
○ There are similarities between the repair procedures of the exhaust section of most
turbine engines share similarities
○ However, there are also differences from manufacturer to manufacturer in terms of:
■ Nomenclature (names) for parts in the hot section
■ Disassembly procedures
■ Necessary tools
■ Repair methods and limitations
● Due to these similarities and differences, it is very important to refer to specific engine
manufacturer's technical instructions. However, most of these manuals are only available for
maintenance personnel, aircraft owners, manufacturers, and other individuals or organizations
closely tied to aircraft maintenance

References:
Federal Aviation Administration. (2023). Aviation Maintenance Technician Handbook–Powerplant
(FAA-H-8083-32B). United States Department of Transportation.