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 Ceramic Coated Turbine Blade
Burning Visual Aid
Pratt and Whitney, Chris Pettigrew, 5/15/2008

Burning: Oxidation of the airfoil that has resulted in the apparent loss of base
or parent material

Exposed Base metal

area, no apparent loss
of material, light gray
in color

Ceramic and dirt

At right and below, area of

oxidized metallic bond coating,
between ceramic and base
metal, very black in appearance,
base metal not exposed

Exposed base metal

area, some apparent
loss of base material
 Ceramic Coated Turbine Blade
Burning Visual Aid
Pratt and Whitney, Chris Pettigrew, 5/15/2008

Area of oxidized metallic bond

coating, no base metal exposed, rut
appearance is due to lifting and
curling of ceramic and bond coating
edges and dirt

Oxidized bond
Exposed base metal area, coating
no apparent loss of base
material, light gray

Burn through: Burning which has progress through base metal, exposing
internal passages

1) Area of oxidized metallic bond coat, blue;

2) Area of apparent base metal loss, red;
3) Burn through to internal passage, black

Severe airfoil burn through

 Optimum BSI View to Detect Internal
Corrsion/Sulfidation
PWA 107217A Supplement
Anthony King
12-Aug-2015

Warning– This document contains technical data the export of which is or may be restricted by the Export Administration Act and Export Administration Regulations
(EAR), 15 C.F.R. parts 730-774. Diversion contrary to U.S. law is prohibited. The export , re-export, transfer or re-transfer of this technical data to any other
company, entity, person, or destination, or for any use or purpose other than that for which the technical data was originally provided by P&W, is prohibited without
prior written approval from P&W and authorization under applicable export control laws. EAR export Classification: ECCN 9E991.
 Trailing edge crack
with linear surface
pattern indicating
parent metal
distortion and
blocked internal
passages.

Fractured
blade with
blocked
Inspect outer trailing edge
half span of (TE) cooling
blade trailing slots
edge cooling
slots

Pratt & Whitney Proprietary

Export Classification: 9E991
 EXAMPLES:
optimum view angle that clearly illustrates indications of internal corrosion/sulfidation.

Pratt & Whitney Proprietary

Export Classification: 9E991
 PWA 107217, Chg. A
PW4000-112”, 2nd Turbine Blade, Internal
Sulfidation Reference Card
Page 1 of 4
(Typical Observations)

Figure 1, showing typical convex side small white area versus large
white area, PW4090 models only.

Figure 1A, close up of typical convex side large and

small white area, PW4090 models only. If present,
airfoil concave side must be inspected.
Figure 1B showing very small
white area inline with one cooling
hole this is not an indication of
hole,
internal sulfidation.

Photo Number 05D0694

Warning– This document contains technical data the export of which is or may be restricted by the Export Administration Act and Export Administration Regulations (EAR),
15 C.F.R. parts 730-774. Diversion contrary to U.S. law is prohibited. The export , re-export, transfer or re-transfer of this technical data to any other company, entity,
person, or destination, or for any use or purpose other than that for which the technical data was originally provided by P&W, is prohibited without prior written approval from
P&W and authorization under applicable export control laws. EAR export Classification: ECCN 9E991.
 PWA 107217, Chg. A
PW4000-112”, 2nd Turbine Blade, Internal
Sulfidation Reference Card
Page 2 of 4
(Typical Observations)

Figure 2 showing
Fi h i
cooling hole reduction
or blockage.

Fully Blocked

Figure 2A showing multiple slots with Figure 2B showing of sulfidation

evidence contamination in cooling holes. clear (no sulfidation) cooling holes.

Typical PW4090 Typical PW4084

Figure 3 showing linear pattern within large white spot, trailing edge
deformation and local ceramic spallation, convex side.
Photo Number 05D0694
Warning– This document contains technical data the export of which is or may be restricted by the Export Administration Act and Export Administration Regulations (EAR),
15 C.F.R. parts 730-774. Diversion contrary to U.S. law is prohibited. The export , re-export, transfer or re-transfer of this technical data to any other company, entity,
person, or destination, or for any use or purpose other than that for which the technical data was originally provided by P&W, is prohibited without prior written approval from
P&W and authorization under applicable export control laws. EAR export Classification: ECCN 9E991.
 PWA 107217, Chg. A
PW4000-112”, 2nd Turbine Blade, Internal
Sulfidation Reference Card
Page 3 of 4
(Typical Observations)

Figure 3A showing linear pattern forward of cooling slots, concave side

of airfoil

Figure 3B showing Figure 3C showing trailing edge distortion

excessive trailing edge tip typical for all models
rub, typical for all models

Photo Number 05D0694

Warning– This document contains technical data the export of which is or may be restricted by the Export Administration Act and Export Administration Regulations (EAR),
15 C.F.R. parts 730-774. Diversion contrary to U.S. law is prohibited. The export , re-export, transfer or re-transfer of this technical data to any other company, entity,
person, or destination, or for any use or purpose other than that for which the technical data was originally provided by P&W, is prohibited without prior written approval from
P&W and authorization under applicable export control laws. EAR export Classification: ECCN 9E991.
 PWA 107217, Chg. A
PW4000-112”, 2nd Turbine Blade, Internal
Sulfidation Reference Card
Page 4 of 4
(Typical Observations)

Figure 3D showing local ceramic Figure 3E showing faint linear pattern.

coating spallation, PW4090 only. These faint linear patterns are not cause
for a reduced inspection interval.

Figure 4 showing external

evidence of sulfidation
attack, typical all models.

Figure 5 showing typical convex

side trailing edge crack
crack. Note size
of white area. Figure 5A showing cooling slot cracks
on concave side.
Photo Number 05D0694
Warning– This document contains technical data the export of which is or may be restricted by the Export Administration Act and Export Administration Regulations (EAR),
15 C.F.R. parts 730-774. Diversion contrary to U.S. law is prohibited. The export , re-export, transfer or re-transfer of this technical data to any other company, entity,
person, or destination, or for any use or purpose other than that for which the technical data was originally provided by P&W, is prohibited without prior written approval from
P&W and authorization under applicable export control laws. EAR export Classification: ECCN 9E991.
 E. A. No : 10KCB20

REV. LTR. A
ENGINEERING AUTHORIZATION
East Hartford,CT 06108
1 PAGE
OF 5
PROPOSED BY: Bailey, Douglas
PHONE: 860-565-9836
MODEL(S): PW4090,PW4074,PW4074D,PW4077,PW4077D,PW4084D

SUBJECT: STAGE 1 TURBINE BLADE, TIP BURN THROUGH, EXTENDED BORESCOPE INSPECTION LIMITS -
DISCRETIONARY USE
APPLICABLE P/N(s): 56L301, 52L301, 53L301, 54L001, 54L201, 54L301, 53L201, 53L901,
54L401, 55L401, 55L301, 52L031-001, 54L301-001, 54L201-001,
54L001-001

ATA NUMBER(s) 72-52-07

ACTION: This Engineering Authorization provides technical data for extended

continue in service burning, burn through and radial cracking limits
for the PW4000-112 Inch Series Stage 1 Turbine Blades. These limits,
that are provided in the pages contained herein, may be utilized by
both Pre & Post SB 72-289 blade configurations. This Engineering
Authorization will supersede REA 10KCB20 and will be distributed at
the discretion of PW4000 Customer Technical Services (CTS).

Data contained herein has been evaluated technically by the Type

Certificate Holder and determined to be compliant with all applicable
Federal Aviation Regulations, original type design and airworthiness
standards. The action contained herein will not affect the design
intent of the subject part, and airworthiness is not compromised.

NOTE: FAA approval for this EA is only conveyed by attachment of a FAA DER signed and numbered FAA form 8110-3 marked "Approve"
or approval letter from FAA Engineering.
DER
ENDORSEMENT

Date : 03/21/2012

This document is the property of United Technologies Corporation (UTC). You may not possess, use, copy or disclose this document or any information in it, for any
purpose, including without limitation to design, manufacture, or repair parts, or to obtain FAA or other government approval to do so, without UTC's express written
permission. Neither receipt nor possession of this document alone, from any source, constitutes such permission. Possession, use, copying or disclosure by anyone
without UTC's express written permission is not authorized and may result in criminal and/or civil liability.
WARNING - This document contains technical data the export of which is or may be restricted by the Export Administration Act and the Export Administration Regulations
(EAR), 15 C.F.R. parts 730-774. Diversion contrary to U.S. law is prohibited. The export, re-export, transfer or re-transfer of this technical data to any other company,
entity, person, or destination, or for any use or purpose other than that for which the technical data was originally provided by P&W, is prohibited without prior written
approval from P&W and authorization under applicable export control laws. EAR Export Classification identified on the following page(s).
06/2011 © United Technologies Corporation 2010 - Unpublished Work - All Rights Reserved
 E.A. No: 10KCB20

ENGINEERING AUTHORIZATION REV. LTR. A

East Hartford, CT 06108
2 PAGE 5
OF

1. The following burning, burn through and crack limits are applicable to Pre and Post SB 72-289 Stage 1 turbine blade
configurations.

2. This EA may be utilized at the discretion of CTS.

3. A short mission operation is defined as an hour to cycle ratio of 1.7 or less.

4. All other existing BSI limits published in the B777 AMM apply for other areas and distress modes.

5. If the limits below are exceeded remove the engine within 5 cycles.

6. Operators are requested to provide photos to P&W, CTS from each BSI performed per these reduced
intervals. Data to include time and cycles between each BSI to document progression.

HPT 1ST STAGE BLADE AREA B AND C BURNING, BURN THROUGH AND RADIAL CRACKING
DAMAGE LIMITS

OBSERVED SEE REGULAR REDUCED ADDITIONAL REDUCED

CONDITION FIGURE INSPECTION INSPECTION INSPECTION REQUIREMENT
653, (50 CYCLE UNLESS STATED
AREA DIFFERENTLY)

Burning and B and C Two burned areas Two burned areas Any amount of burning, Re-
Erosion of blade (except 0.000 – 0.500 inch 0.500 – 0.750 inch inspect in 120 cycles for long
base metal leading (0.00 – 12.70 mm) (12.70 – 19.00 mm) mission or 200 cycles for
edge) diameter or 0.000 – diameter or 0.200 – short mission. See Material
0.200 sq. inch (0.00 – 0.440 sq. inch (130 – Burn Through limits below.
130 sq. mm) area. 285 sq. mm) area.

Material Break B None allowed None allowed Any number of burn

Through or Burn through/open areas provided
Through into total open area in areas B and
internal cavity C combined does not exceed
0.060 sq. inches (39 sq. mm)
for each blade, with a
maximum of five stage 1
blades allowed. Re-inspect in
60 cycles for long mission or
120 cycles for short mission.

If combined burn through in

areas B & C exceeds 0.050
sq. inches (32 sq. mm) and
burning/erosion in areas B &
C exceeds either 0.750 inch
(19.00 mm) diameter or 0.440
sq. inches (285 sq. mm), then
engine should be removed
within 10 cycles.

Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is subject to
the restriction on the title page of this document
 E.A. No: 10KCB20

ENGINEERING AUTHORIZATION REV. LTR. A

East Hartford, CT 06108
3 PAGE 5
OF

OBSERVED SEE REGULAR REDUCED ADDITIONAL REDUCED

CONDITION FIGURE INSPECTION INSPECTION INSPECTION REQUIREMENT
653, (50 CYCLE UNLESS STATED
AREA DIFFERENTLY)

Material Break C, tip None allowed None allowed One area 0.000 – 0.030 sq.
Through or Burn inches (0.00 – 19 sq. mm) for
Through into each blade, with a maximum
internal cavity of five stage 1 blades
allowed. Re-inspect on a 500
hour/150 cycle inspection
interval.

One area 0.000 – 0.060 sq.

inches (0.00 – 39 sq. mm) for
each blade, with a maximum
of five stage 1 blades
allowed. Re-inspect in 60
cycles for long mission or
120 cycles for short mission.

If area exceeds 0.060 sq. inch

(39 sq. mm), then engine
should be removed within 10
cycles.

Radial Cracks A Up to 2 radial cracks Not applicable Up to 2 radial cracks to a

(except to a maximum of maximum of 0.200 inch (5
leading 0.100 inch (2.54 mm) mm) in length each. Re-
edge) in length each. inspect in 120 cycles for
short and long mission. Up
to 3 radial cracks to a max
.200 inch (5 mm) or 2 radial
cracks up to .300 inch (8 mm).
Remove engine within 10
cycles

Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is subject to
the restriction on the title page of this document
 E.A. No: 10KCB20

ENGINEERING AUTHORIZATION REV. LTR. A

East Hartford, CT 06108
4 PAGE 5
OF

EXAMPLES OF THE DISTRESS DEPICTED BY THESE LIMITS

Multiple Burn Through:

Total combined Area not to exceed 0.060 sq in (38.71 sq mm), maximum 5 blades per
engine. See text for interval.

Radial cracking in area A:

Up to 2 cracks, maximum of 0.200 inch (5.08mm)
length

Burning:
Requires re-inspection.
See text for interval

Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is subject to
the restriction on the title page of this document
 E.A. No: 10KCB20

ENGINEERING AUTHORIZATION REV. LTR. A

East Hartford, CT 06108
5 PAGE 5
OF

Typical Identification Of HPT 1st Stage Blade Inspection Areas

Figure 653

Pratt & Whitney Proprietary Information – ECCN 9E991 Use or disclosure of the data contained in this sheet is subject to
the restriction on the title page of this document
____________________________________________________________________________

SPECIAL INSTRUCTION NO. 8F-06, Revision B January 29, 2010

Borescope Inspection for Internal Sulfidation of the 2nd Stage Turbine Blade.

APPLICATION:

For PW4000-112 Inch Model engines as directed by Pratt & Whitney. Apply this inspection to
engines with 2nd stage turbine blades manufactured before December 2003 that may have suffered
internal contamination during blade abrasive tip processing.

THE REASON FOR SPECIAL INSTRUCTION:

Some 2nd stage turbine blades have experienced trailing edge airfoil cracking and fractures due to
internal airfoil sulfidation. When Rev A was released, 42 fracture events and 5 IFSD’s had occurred.
Borescope criteria has been developed that has been an effective tool in identifying pending blade
fractures. Since the release of Rev A, there have been several Unscheduled Engine Removals and
one IFSD caused by internal airfoil sulfidation in blades from the suspect population that had been
repaired and inspected to a 1.020 magnetoscop limit. In order to reduce the possibility of further
IFSD’s, performing the borescope inspection at reduced repetitive intervals is also being
recommended for engines containing blades from the suspect population that have been repaired
and inspected to a 1.020 magnetoscop limit.

THE REASON FOR REVISION :

This revision provides a reduced inspection interval for the PW4090 and PW4074/PW4077 engine
models that incorporate 2nd stage turbine blades manufactured prior to December 2003 that were
repaired and inspected to the 1.020 magnetoscop limits. These revised intervals are derived from a
recent fracture event and borescope findings resulting in unplanned engine removals. Both indicate
that the PW4090 and PW4074/PW4077 engines require lower inspection intervals to detect the
possibility of internal sulfidation with repaired blades before fracture occurs.

APPROVAL:

The part number changes and/or part changes specified in this Special Instruction obey the
applicable Federal Aviation Regulations and are FAA-Approved for the engine model(s) given.

DESCRIPTION:

Provide on-wing borescope inspection criteria and reduced inspection intervals for the detection of
2nd stage turbine Blade internal sulfidation.

Distribution Code Internal Reference No.

6319, 6320 CDP/JRM 03KCF76D, 03KCF76E/10KC144
Special Distribution: (2) Page 1 of 11
SPECIAL INSTRUCTION NO. 8F-06, Revision B
-2-
REFERENCES:

(1) Turbojet Engine Standard Practices Manual, Part No. 585005.

(2) PW4074, PW4077 Turbofan Engines, Illustrated Parts Catalog, Part Number 51A346

(3) PW4077D, PW4084D, PW4090, PW4098 Turbofan Engines, Illustrated Parts Catalog, Part
Number 51A742

(4) PW4074, PW4077 Turbofan Engines, Engine Manual, Part No. EM 51A345, Section 72-00-00,
INSP/CHK-05

(5) PW4077D, PW4084D, PW4090, PW4098 Turbofan Engines, Engine Manual, Part No. EM
51A751, Section 72-00-00, INSP/CHK-05

(6) Aircraft Maintenance Manual.

(7) All Operator Wire, PW4000/72-52/CTS:WHT:7-2-06-1, PW4000-112” 2nd Stage Turbine Blade
Internal Sulfidation, Cactus number, C6038-G52110

NECESSARY TOOLS:

Tool Number Name Manufacturer Availability Date

PWA 107217, Card, Reference Pratt and Whitney March 15, 2006
Change A

The above reference information indicates when the PWA tool will be available. If necessary, an
advance electronic version may be obtained by contacting your local Pratt and Whitney Service
Representative, or the photo’s in this Special Instruction can be used.

ADDED DATA:

Not applicable.
SPECIAL INSTRUCTION NO. 8F-06, Revision B
-3-
ACCOMPLISHMENT INSTRUCTIONS:

1. Determine if engine contains suspect 2nd stage turbine blades per instructions in Reference 7
All Operator Wire including suspect 2nd stage blades that were repaired and accepted to the
1.020 magnetoscop inspection limits.

2. Prepare engine for borescope per references 4,5 and 6

3. Perform the following borescope inspection at the intervals specified, where applicable
SPECIAL INSTRUCTION NO. 8F-06, Revision B
-4-

PW4090 2nd Stage Turbine Blade Sulfidation Fleet Management

Recommendations For Engines Containing Suspect Blades. Reference
Tool PWA 107217 Chg A, Visual Aid

T2 Blade Borescope Inspection Requirement Short Mission, less Long Mission, greater
than or equal to than 1.7hrs/cycle
1.7hrs/cycle
Initial Inspection Threshold

For engines with 2nd blades inspected to a magnetoscop limit of 600 cycles or 1020 600 cycles or 2000
1.060 or 1.020 during repair/overhaul, initiate reduced borescope hours since blade hours since blade
inspection interval at: overhaul overhaul
For engines with 2nd blades manufactured prior to December 2003, 3500 total cycles 2000 total cycles
or repaired blades that did not receive a magnetoscop inspection, since new on highest since new on highest
initiate reduced borescope inspection interval at: cycle blade cycle blade

Repetitive Borescope Inspection Interval

(The cycle or hour interval applies to whichever occurs first)
For engines with non-suspect parts: blades manufactured after Use MRB Intervals Use MRB Intervals
December 2003, or blades manufactured after December 2003
inspected to a magnetoscop limit of 1.020 during repair/overhaul.
For engines with repaired blades manufactured prior to December 300 cycles or 1000 300 cycles or 1000
2003 and inspected to a magnetoscop limit of 1.020 at repair. hours hours
For engines with blades manufactured prior to December 2003, or 150 cycles or 255 60 cycles or 500
repaired blades inspected to a magnetoscop limit of 1.060 or that hours hours
did not receive a magnetoscop inspection at repair
T2 Blade Inspection - Observed Condition Inspection Interval
Inspection of convex side shows no large white areas#. See Figure 150 cycles or 255 60 cycles or 500
1, 1A, and 1B hours hours
For white areas disposition.
Inspection of convex side shows large white areas#, but inspection 150 cycles or 255 40 cycles or 300
of concave side shows no evidence of sulfidation in trailing edge hours hours
cooling holes or on the airfoil external surfaces. No signs of airfoil
stretch or growth present, and no linear patterns ** within large
white area. See Figure 2B.
Indications of sulfidation detected inside the trailing edge cooling Remove in 50 cycles Remove in 30 cycles
holes, but no sulfidation is evident on the airfoil external surfaces. or 85 hours or 200 hours
No signs of airfoil stretch or growth present, and no linear
patterns** within large white area. See Figures 2 and 2A.
Sulfidation evident externally on airfoil surface, see Figure 4. Remove prior to Remove prior to
Evidence of airfoil stretching or growth, linear patterns** within further flight further flight
large white area, trailing edge deformation, or excessive tip rub.
Note: spallation of ceramic coating along the trailing edge can be
an indication of airfoil growth. See Figures 3, 3A, 3B, 3C, and 3D.
(reference 3E)
Crack indication anywhere on the airfoil in Areas A and B. Remove prior to Remove prior to
(Reference EM 51A751, 72-00-00 INSP/CHK-05, Figure 806.) See further flight further flight
Figures 5 and 5A.

** Note: Faint linear patterns can be seen on some new blades. They are typically seen along the entire T/E and
outside of the focus area. These faint linear patterns are not cause for a reduced inspection interval. See figure 3E.
# Small White areas may be visible due to normal engine operation. Small white areas typically appear uniformly
on all of the blades in a rotor. Large white areas typically only appear on some of the blades scattered within the
rotor. Very small white area shown in figure 1B is not an indication of sulfidation
 SPECIAL INSTRUCTION NO. 8F-06, Revision B
-5-
PW4074/PW4077 2nd Stage Turbine Blade Sulfidation Fleet Management
Recommendations For Engines Containing Suspect Blades. Reference
Tool PWA 107217,Chg A, Visual Aid

T2 Blade Borescope Inspection Requirement Short Mission, less Long Mission, greater
than or equal to than 1.7hrs/cycle
1.7hrs/cycle
Initial Inspection Threshold

For engines with 2nd blades inspected to a magnetoscop limit of 600 cycles or 1020 600 cycles or 2000
1.060 or 1.020 during repair/overhaul, initiate reduced borescope hours since blade hours since blade
inspection interval at: overhaul overhaul
For engines with 2nd blades manufactured prior to December 2003, 5000 total cycles 2500 total cycles
or repaired blades that did not receive a magnetoscop inspection, since new on highest since new on highest
initiate reduced borescope inspection interval at: cycle blade cycle blade

Repetitive Borescope Inspection Interval

(The cycle or hour interval applies to whichever occurs first)
For engines with non-suspect parts: blades manufactured after Use MRB Intervals Use MRB Intervals
December 2003, or blades manufactured after December 2003
inspected to a magnetoscop limit of 1.020 during repair/overhaul.
For engines with repaired blades manufactured prior to December 300 cycles or 1000 300 cycles or 1000
2003 and inspected to a magnetoscop limit of 1.020 at repair hours hours
For engines with blades manufactured prior to December 2003, or 150 cycles or 255 150 cycles or 1000
repaired blades inspected to a magnetoscop limit of 1.06 or that did hours hours
not receive a magnetoscop inspection at repair
T2 Blade Inspection - Observed Condition Inspection Interval

Inspection of convex and concave side shows no evidence of 150 cycles or 255 150 cycles or 1000
sulfidation in trailing edge cooling holes or on the airfoil external hours hours
surfaces. No signs of airfoil stretch or growth present, and no linear
patterns **. See Figure 2B.

Indications of sulfidation detected inside the trailing edge cooling 50 cycles 50 cycles
holes, but no sulfidation is evident on the airfoil external surfaces.
No signs of airfoil stretch or growth present, and no linear patterns**
. See Figures 2 and 2A.
Sulfidation evident externally on airfoil surface, see Figure 4. Remove in 25 Remove in 10 cycles
Evidence of airfoil stretching or growth, linear patterns**, trailing cycles
edge deformation, or excessive tip rub. See Figures 3, 3A, 3B, 3C,
and 3D. (reference 3E)
Crack indication anywhere on the airfoil in Areas A and B. Remove prior to Remove prior to
(Reference EM 51A751, 72-00-00 INSP/CHK-05, Figure 806.) See further flight further flight
Figures 5 and 5A.

** Note: Faint linear patterns can be seen on some new blades. They are typically seen along the entire T/E and
outside of the focus area. These faint linear patterns are not cause for a reduced inspection interval. See figure 3E.
SPECIAL INSTRUCTION NO. 8F-06, Revision B
-6-
Inspection Figures

Figure 1, showing typical convex side small white area versus large white area,
PW4090 models only

Figure 1A, close up of typical convex side large and small white area, PW4090 models only.
If present, airfoil concave side must be inspected.
SPECIAL INSTRUCTION NO. 8F-06, Revision B
-7-
Inspection Figures, continued

Figure 1B showing very small white area inline with one cooling hole, this is not an indication of
internal sulfidation

Fully Figure 2 showing cooling hole reduction or blockage

Blocked

Figure 2A showing multiple slots with evidence Figure 2B showing of sulfidation

contamination in cooling holes clear (no sulfidation) cooling holes
SPECIAL INSTRUCTION NO. 8F-06, Revision B
-8-
Inspection Figures, continued

Typical PW4090 Typical PW4084

Figure 3 showing linear pattern within large white spot, Trailing edge deformation and
local ceramic spallation, convex side

Typical PW4090 Typical PW4084

Figure 3A showing linear pattern forward of cooling slots, concave side of airfoil
SPECIAL INSTRUCTION NO. 8F-06, Revision B
-9-
Inspection Figures, Continued

Figure 3B showing excessive trailing edge Figure 3C showing trailing edge distortion
tip rub, typical for all models typical for all models

Figure 3D showing local ceramic Figure 3E showing faint linear pattern .

coating spallation, PW4090 only. These faint linear patterns are
not cause for a reduced
inspection interval.
SPECIAL INSTRUCTION NO. 8F-06, Revision B
-10-
Inspection Figures, continued

Figure 4 showing external evidence of sulfidation attack, typical all models

Figure 5 showing typical convex Figure 5A showing cooling slot cracks on

side trailing edge crack. concave side.
Note size of white area
SPECIAL INSTRUCTION NO. 8F-06, Revision B
-11-
MATERIAL INFORMATION:

A. The material data that follows is for each engine.

FOR PW4074, PW4077 ENGINES:

New PN Qty Key Word Old PN Instructions –

Disposition
52L432 82 BLADE ASSY, 52L432 (R)
2ND STAGE HPT

52L542 82 BLADE ASSY, 52L542 (R)

2ND STAGE HPT
53L522 82 BLADE ASSY, 53L522 (R)
2ND STAGE HPT
53L342 82 BLADE ASSY, 53L342 (R)
2ND STAGE HPT

FOR PW4077D, PW4084D, PW4090, PW4090-3 ENGINES:

New PN Qty Key Word Old PN Instructions –

Disposition
52L442 82 BLADE ASSY, 52L442 (R)
2ND STAGE HPT

53L642 82 BLADE ASSY, 53L642 (R)

2ND STAGE HPT
53L472 82 BLADE ASSY, 53L472 (R)
2ND STAGE HPT

Parts Modification Conditions:

Not applicable.

Spare Parts Availability

(R) Inspect the part as specified in the Accomplishment Instructions.

B. Data on Interchangeable Parts:

Not applicable.
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 A- Cracks:

Qty (3) vanes have cracks in their concave sides

Vane # 5

Crack length = 9.5 mm long

Vane #30:

Crack length= 77.96mm long (5 cycles limit)

Vane # 42

Crack length = 11.90 mm long

B- Leading edge erosion:

Qty (12) vanes have eroded leading edge

 PW4000-94/100 HPT 2ND STAGE VANE
BORESCOPE INSPECTION REFERENCE CARD
PWA 106352 Rev.A

Concave airfoil with coating loss and minor burning combined with LE
coating loss, burning and crack (<1.3mm wide): Regular inspection interval

Concave airfoil with crack (<50mm long and <1.3mm wide) combined with
LE coating loss and burning (no burnthrough): Regular inspection interval

Concave airfoil with crack(>30 mm long and <1.3mm wide) combined with LE
burnthrough (internal cavity rib is not visible): Reduced inspection interval
3A1088-001
 Leading Edge

Cony , posed with

hole and crack
LE burnthrough and internal cavity Concave airfoil with burnthrough
rib exposed with visible crack area >13mm x 13mm or exposed
and hole. Provided it is not in convex side internal wall contains
combination with concave airfoil crack and/or hole.: Remove within
crack or burnthrough: Reduced 5 cycles
inspection interval

Cracks on inner and outer concave

platforms that do not extend into the
platform-to-airfoil fillet radii or within
6mm of platform edge: Regular
inspection interval

A= 80mm (ID platform to 01)

platform)

B= 80mm (LE to TE)

2nd Stage Vane Concave Airfoil

view with approx. dimensions. 03 A 1088-4