What was found
ENGINE MODEL FJ44-2C, WAS RETURNED TO OUR REPAIR STATION FOR UNSCHEDULED REPAIR. ENGINE SERIAL NUMBER 126312 WAS INSTALLED IN THE RIGHT-HAND (NR 2) POSITION OF THE AIRCRAFT. FLT CREW REPORTED HEARING AN ABNORMAL NOISE DURING CLIMB, ACCOMPANIED BY LIGHT VIBRATIONS, ALL ENGINE PARAMETERS REPORTED TO REMAIN WITHIN NORMAL LIMITS. ON SUBSEQUENT ENG START, ANOTHER ABNORMAL NOISE NOTICED BY FLT CREW; THEY PROCEEDED WITH TAKEOFF. DURING TAKEOFF ROLL, LOUD BANGS WERE REPORTED, ACCOMPANIED BY LACK OF PERFORMANCE ON NR 2 ENGINE. POST-FLT INSP REVEALED FAN ROTOR HAD CONTACTED THE INLET CASE SHROUD. PRODUCT SUPPORT DIRECTED A BORESCOPE INSP OF ENG’S COMPRESSOR SECTION, WHICH REVEALED FOD DAMAGE TO THE INTERMEDIATE PRESSURE COMPRESSOR ROTOR & THE HPC ROTOR. DUE TO LEVEL OF ENG DISASSEMBLY REQUIRED TO FACILITATE REPAIRS, PRODUCT SUPPORT DIRECTED REMOVAL OF ENG FOR RETURN TO OUR REPAIR STATION FOR REPAIR. AFTER INDUCTION INTO OUR REPAIR STATION, DISASSEMBLY OF ENG REVEALED ONE LIBERATED 2ND-STAGE I.P. COMPRESSOR ROTOR BLADE. DAMAGE TO THE DOWNSTREAM HPC ROTOR BLADES ARE EVIDENCE OF SECONDARY DAMAGE RESULTANT FROM THE LIBERATED I.P. ROTOR BLADE.