Appendix 2 85 Template 8
REPAIR SUBSTANTIATION CHECKLIST - GEARBOX HOUSING ASSEMBLY
PART FAMILY (SHAFTS, GEARS, HOUSINGS)
Categories of Gearbox Housing Assembly Part Family (shafts, gears, housings). Determine which repair description best fits the repair proposal. If no repair description is appropriate, contact the FAA Advisor for guidance.
CATEGORIES
OF REPAIRS
REPAIR DESCRIPTION
1. Restoration of Protective Coating Includes Touch Up Coating
2. Weld or Braze Repair This repair excludes detail part replacement
3. Weld or Braze Repair Includes detail part replacement
4. Assembly and/or Disassembly This repair assembles, disassembles, removes and replaces detail parts, or subassemblies without use of permanent attachment techniques (i.e.; welding or brazing). Assembly is either bolted or riveted.
5. Sulfidation or Corrosion Repair
6. Blend Repair
7. Dimensional Restoration by Coating or Plating
8. Bushing/Helicoil Repair
9. Straightening, Re-twist, or Reforming Repair This repair includes straightening of bent knife edges
10. Surface Treatment Repair This repair includes peening, vibratory tumble (e.g.; restoration of surface finish/texture)
11. Machining Repair This repair includes lapping, skim cut, non-conventional machining
12. Restoration of Adhesives, Bonding Agents, Potting Compounds.
Appendix 2 86
CATEGORIES OF REPAIR Req No.
Repair Design Requirements to be Identified and Substantiated. Repair Properties and Requirements to be Identified and Substantiated.
1. Applicable Degradation Modes: Select all that apply based on the function of the part and its operating environment in the engine. This section provides the background for establishing the substantiation requirements.
a. Thermo-mechanical fatigue
b. Oxidation
c. Corrosion
d. Elevated temperature-induced changes (creep, diffusion, ageing, temperature gradients)
e. Wear due to: adhesion, abrasion, corrosion, erosion, cavitation, fretting, oxidation
f. High-cycle fatigue
g. Rubbing, foreign object impact damage, O3 chemical attack, etc.
Appendix 2 87
CATEGORIES OF REPAIR Req No.
Repair Design Requirements to be Identified and Substantiated. Repair Properties and Requirements to be Identified and Substantiated.
2. Select all mechanical, metallurgical, and physical properties of the part affected by the repair design and assess their impact on the part’s airworthiness:
Mechanical Properties:
a. Stress-Strain
b. Fracture Toughness
c. Fatigue Strength (S-N, Goodman, Dwell Time)
d. Creep
e. Tensile Properties (Yield, Strength, Elongation)
f. Hardness
g. Young’s Modulus
h. Natural Frequencies
Metallurgical Properties:
i. Chemical Composition (Alloy constituents)
j. Microstructure (grain size – shape - boundary precipitates, gamma prime size and volume fraction, etc.)
k. Melting Point
l. Corrosion Resistance
m. Oxidation Resistance
n. Wear Resistance (Consider wear types in (1)(e))
o. Crack Propagation Rate
Physical Properties:
p. Density (weight)
q. Coefficient of Thermal Expansion
r. Refractive Index (X-Rays)
s. Center of Gravity
t. Polar Moment of Inertia
Appendix 2 88
CATEGORIES OF REPAIR Req No.
Repair Design Requirements to be Identified and Substantiated.
3. Select all Material Properties/Characteristics for weldments or brazed joints that apply and evaluate them and their interface with the parent metal. The effect of any changes to the part’s metallurgy as a result of welds or braze should be evaluated for airworthiness.
a. Microstructure (grain size, grain shape, grain boundary precipitates, gamma prime size and volume fraction, etc.)
b. Porosity (weldment)
c. Diffusion Zone (brazing)
d. Heat Affected Zone (welding)
4. Coating & Plating Material Properties Characteristics & Processes:
a. Deposited Material Composition
b. Thickness, Coverage & Uniformity
c. Microstructure
d. Hardness
e. Sintering
f. Strip Process
g. Residual Stress
h. Lubricant Properties
i. Spalling Resistance
j. Thermal Resistance
k. Erosion Resistance
l. Bonding (Interface Contamination)
m. Environmental Resistance
n. Diffusion Zone
o. Hydrogen Embrittlement Free (Plating)
p. Compatibility With Base Material
Appendix 2 89
CATEGORIES OF REPAIR Req No.
Repair Design Requirements to be Identified and Substantiated.
5. Select Surface Treatment that applies (without material removal) and evaluate effect(s), if any, on airworthiness:
a. Burnishing
b. Peening
c. Butterfly Polish
d. Mass Media Finishing
6. Evaluate any degradation in the part’s function or durability due to the following processes, when applicable, and assess its impact, if any, on existing ICAs.
a. Machining, Milling, Broaching, or Grinding
b. Non-traditional Machining
c. Welding, Brazing or Coating
d. Straightening, Re-twisting, Reforming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
j. Cleaning (Chemical, power flash, Ultrasonic)
k. Residual Plating, Stripping, or Cleaning Agents
l. Stress Intensity Factor (Kt)
m. Heat Treatment (time, temp, atmosphere, etc.)
n. Plating
o. Dimensional Short-falls
p. Repetitive or Conflicting Repairs
q. Contamination
Appendix 2 90
CATEGORIES OF REPAIR Req No.
Repair Design Requirements to be Identified and Substantiated.
7. Establish the Applicability of the Repair and the Repair Processing Sequence or evaluate any changes to an existing repair sequence for potential impact on the airworthiness of the part.
8. Select all that may be potentially affected by the repair design and evaluate system effect(s):
a. Structural Strength, including major load paths
b. Heat Transfer
c. Secondary Airflow
d. Aerodynamics
e. Weight
f. Center of Gravity
g. Moment of Weight
Appendix 2 91
CATEGORIES OF REPAIR Req No.
Repair Design Requirements to be Identified and Substantiated.
12 Critical Measurable Characteristics
9. Bearing Bore:
a. Dimension
b. Location
10. Establish Measurable Characteristics and the allowable tolerances for the repaired part features and for any replacement detail(s) and give due consideration to mating part(s):
a. Surface finish/texture
b. Shotpeen intensity/coverage
c. Bearing bore dimensions and location characteristics
d. Pressure strength test
e. Flow capacity test
f. Dimensions, including heat
g. distortion effects Roundness Flatness Parallelism Concentricity True position tolerances Edge distance requirements Finish dimensions requirements
Appendix 2 92
CATEGORIES OF REPAIR Req No.
Repair Properties and Requirements to be Identified and Substantiated.
12 Critical Measurable Characteristics continued
11 Oil Nozzle Flow Test Repair Process Capability Technical Substantiation Requirements
12. Verification Plan with Significant Operations Identified for Repair Source Qualification
13. Process Demonstration (including variability requirements)
14. Part Demonstration/Inspection
15. Manufacturing requirements for fabrication of repair details or replacement sections used to accomplish repair:
Drawings/Specifications Quality Requirements Source Substantiation Requirements
Applicable 14 CFR Part 33 Requirements
Subpart A – General
16. 33.4 Instructions for Continuous Airworthiness (ICA's)
17. 33.5 Instruction manual for installing and operating the engine
18. 33.7 Engine ratings and operating limitations
19. 33.8 Selection of engine power and thrust ratings
Appendix 2 93
CATEGORIES OF REPAIR Req No.
Repair Properties and Requirements to be Identified and Substantiated.
12 Subpart B – Design and Construction;
General
20. 33.14 Start-stop cyclic stress (low cycle fatigue)
21. 33.15 Materials
22. 33.17 Fire prevention
23. 33.19 Durability (Note that 33.19 is associated with 33.27; 33.63; 33.83; 33.87;
33.88; and 33.90)
24. 33.21 Engine cooling
25. 33.23 Engine mounting attachments and structure
26. 33.25 Accessory attachments
27. 33.27 Turbine, compressor, fan, and turbo supercharger rotors
28. 33.28 Electrical and electronic control systems
29. 33.29 Instrument connection Subpart E – Design and Construction;
Turbine Aircraft Engines
30. 33.62 Stress analysis
31. 33.63 Vibration
32. 33.65 Surge and stall characteristics (Note 2)
33. 33.66 Bleed air system
34. 33.67 Fuel system
35. 33.68 Induction system icing (operability aspects) (Note 2)
36. 33.69 Ignitions system
37. 33.71 Lubrication system
38. 33.72 Hydraulic actuating systems
39. 33.73 Power or thrust response
40. 33.74 Continued rotation
41. 33.75 Safety analysis
42. 33.76 Bird ingestion (operability aspects of ingestion)
Appendix 2 94
CATEGORIES OF REPAIR Req No.
Repair Properties and Requirements to be Identified and Substantiated.
12 Subpart E – Design and Construction;
Turbine Aircraft Engines
43. 33.77 Foreign object ingestion—ice (operability aspects of ingestion)
44. 33.78 Rain and hail ingestion
45. 33.79 Fuel burning thrust augmentor Subpart F – Block Tests; Turbine Aircraft Engines
46. 33.83 Vibration test
47. 33.85 Calibration tests
48. 33.87 Endurance test
49. 33.88 Engine overtemperature test
50. 33.89 Operation test (Note 2)
51. 33.90 Initial maintenance inspection
52. 33.91 Engine component tests (HCF/LCF bench testing)
Subpart F – Block Tests; Turbine Aircraft Engines
53. 33.92 Rotor locking tests
54. 33.93 Teardown inspection
55. 33.94 Blade containment and rotor unbalance tests (weight changes)
56. 33.95 Engine-propeller system tests
57. 33.96 Engine tests in auxiliary power unit (APU) mode
58. 33.97 Thrust reversers
59. 33.99 General conduct of block tests Part 33 -Appendix A – Instructions for Continued Airworthiness
Part 33 -Appendix B- Certification Standard Atmospheric Concentrations of Rain and Hail
Part 34 – Exhaust Emissions
Appendix 2 95 Template 9
REPAIR SUBSTANTIATION CHECKLIST – LOW PRESSURE COMPRESSOR (LPC) – HIGH PRESSURE COMPRESSOR (HPC) STATOR PART FAMILY – VANE
SECTOR (AND FULL RING) TYPE STATORS
Categories of LPC-HPC Stator Repair. Determine which repair description best fits the repair proposal. If no repair description is appropriate, contact the FAA Advisor for guidance.
CATEGORIES
OF REPAIRS
REPAIR DESCRIPTION
1. Restoration of Protective Coating (Paint, Aluminizing, Oil, etc.)
This repair includes touch-up coating
2. Weld or Braze Repair This repair excludes detail part replacement
3. Weld or Braze Repair This repair includes detail part replacement
4. Assembly and/or Disassembly This repair assembles, disassembles, removes and replaces detail parts, or sub - assemblies without use of permanent attachment techniques (i.e.; welding or brazing). Assembly is either bolted or riveted
5. Blend Repair
6. Dimensional Restoration by Coating or Plating
7. Surface Treatment Repair This repair includes peening, vibratory tumble (e.g.; restoration of surface finish/texture)
8. Straightening, Re-twist, or Reforming Repair This repair includes straightening of bent flanges
9. Restoration of Adhesives, Bonding Agents & Potting Compounds
Appendix 2 96
CATEGORIES OF REPAIR Req No.
Repair Design Requirements to be Identified and Substantiated. Repair Properties and Requirements to be Identified and Substantiated.
1. Applicable Degradation Modes: Select all that apply based on the function of the part and its operating environment in the engine. This section provides the background for establishing the substantiation requirements.
a. Thermo-mechanical fatigue
b. Oxidation
c. Corrosion
d. Elevated temperature-induced changes (creep, diffusion, ageing, temperature gradients)
e. Wear due to: adhesion, abrasion, corrosion, erosion, cavitation, fretting, oxidation
f. High-cycle fatigue
g. Rubbing, foreign object impact damage, O3 chemical attack, etc.