January 2012 | Company Overview | Company Confidential Page 1

WELCOME AMATA B.GRIMM POWER

V64.3 GT ComponentsRepair Development27th August 2013

January 2012 | Company Overview | Company Confidential Page 2

Repair Capabilities of V64.3- V64.3 Turbine Blade Row 1- V64.3 Turbine Blade Row 2- V64.3 Turbine Vane Row 2

January 2012 | Company Overview | Company Confidential Page 3

V64.3 GT SamplesV64.3 Tla 2 (Blade Row 2) Serial No.

Group 7 (2009)

TG209

TG239

TG303

TG285

Group 9 (2012)

PV731

PV830

PV761

V64.3 Tla 1 (Blade Row 1) Serial No.

Group 1 (2000)

SA265

SA473

SA269

SA267

Group 2 (2001)WB597

WB479

WB549

Group 3 (2004)SM024

SM083

Group 4 (2006)

ANA13

CSA92

CCK69

AMZ76

AMZ11

Group 6 (2007)DTB55

DJV44

V64.3 Tle 2 (Vane Row 2) Serial No.

Group 8 (2009)

QU42

QU60

QU40

QU52

QU43

QU7

QU4

Ok65

Ok67

Ok32

Group 10 (2012)

OK40

OK31

OK8

OK69

SC16

SC28

SC4

Sample QuantityTla 1 (Blade Row 1) = 16 eaTla 2 (Blade Row 2) = 7 eaTle 2 (Vane Row 2) = 17 ea

January 2012 | Company Overview | Company Confidential Page 4

General Incoming Inspection ProcessIncoming inspection scope Receiving inspection to verify part number, serial number and quantities. Disassembly Cooling insert (for Vane Row 2). Verify material type by XRF Scanning analysis. Remove sample of base material and processed within the metallurgical

laboratory to material microstructure evaluation and verify coating type. Removal of Coatings by Grit Blasting and Chemical Stripping processes. Heat tint to verify remnant of coating. Solution Heat treatment to restore material properties. Perform Fluorescent penetrant Inspection. Perform Visual Inspection and mapping of all defects. Perform full Dimensional inspections. Perform wall thickness measurements with Ultrasonic inspections. Digitally photograph the as received, as cleaned and after inspection condition

of the components. Prepare detailed inspection report listing all results of inspections, listing of

replacement parts needed and detailed listing of repair scope to be performed.

January 2012 | Company Overview | Company Confidential Page 5

General Incoming Inspection Process

Blade Row 1 Blade Row 2 Vane Row 2

As Received Condition

January 2012 | Company Overview | Company Confidential Page 6

General Incoming Inspection Process

Disassembly Cooling insert, using cut off wheel blend remove seem weld to disassembly then marking and keep separate each serial no.

Cooling Insert

Disassembly Cooling Insert

January 2012 | Company Overview | Company Confidential Page 7

General Incoming Inspection ProcessXRF Scanning analysisTo confirm material type and compositionTo confirm Heat treatment programTo confirm Weld wire and Braze alloy powder

Blade Row 1 (In 738) Blade Row 2 (In 738) Vane Row 2 (In 939)

January 2012 | Company Overview | Company Confidential Page 8

General Incoming Inspection ProcessMetallurgical Analysis Micro structure Coating type Heat treatment program Weld ability

Lab sample

January 2012 | Company Overview | Company Confidential Page 9

General Incoming Inspection Process

Blade Row 1 Blade Row 2 Vane Row 2

Grit Blast to cleaning and remove coating

January 2012 | Company Overview | Company Confidential Page 10

General Incoming Inspection ProcessApply wax to protect chemical acid attack during stripping.

Apply Wax on root serration Apply Wax on Platform no coat areas.

January 2012 | Company Overview | Company Confidential Page 11

General Incoming Inspection ProcessChemical Stripping to remove metallic coating.

Vane Row 2Blade Row 1

January 2012 | Company Overview | Company Confidential Page 12

General Incoming Inspection ProcessHeat tint to verify remnant coating

Accept Heat tint (Blue or Grey)

Residual coating(Brown or Gold)

January 2012 | Company Overview | Company Confidential Page 13

General Incoming Inspection ProcessSolution Heat Treatment Improve material properties

Vacuum Furnace Heat treatment program

Heat Treatment Record Chart

January 2012 | Company Overview | Company Confidential Page 14

General Incoming Inspection ProcessV64.3 Blade Row 1 – Scanning Electron Microscope (SEM ), after post weld HT

Group 1 Group 2 Group 3

Group 4 Group 6

January 2012 | Company Overview | Company Confidential Page 15

General Incoming Inspection ProcessV64.3 Blade Row 2 – Scanning Electron Microscope (SEM ), after post weld HT

Group 7,NOTE: This sample need to be re-scan

Group 9

January 2012 | Company Overview | Company Confidential Page 16

General Incoming Inspection ProcessFull F.P.I inspection

Under black light Under white light

January 2012 | Company Overview | Company Confidential Page 17

General Incoming Inspection ProcessV64.3 Blade Row 1 - Scrap Condition

Cracks on Airfoil, G2

Cracks on Airfoil, G3

Cracks on Airfoil, G1

Cracks on Airfoil, G2

January 2012 | Company Overview | Company Confidential Page 18

General Incoming Inspection ProcessV64.3 Blade Row 1 – Repairable Condition

Wear on Tips area, G6 Wear on Tips area, G6 Wear on platform area, G4

January 2012 | Company Overview | Company Confidential Page 19

General Incoming Inspection ProcessV64.3 Blade Row 2 – Repairable Condition

Wear and Missing material on Tips area, G7

Wear and Missing on Tips area, G9

Missing material on Leading edge.

January 2012 | Company Overview | Company Confidential Page 20

General Incoming Inspection ProcessV64.3 Vane Row 2 – Repairable Condition

Missing material on Leading edge, G10

Crack on Leading edge, G8 Wear on Platform side face, G8

January 2012 | Company Overview | Company Confidential Page 21

V64.3 Blade Repair processBlade Repair Workscope Remove Cracks, Eroded Material, Oxidation by blending. Weld blade Tips, Platform wear and Missing Material. Use Weld wire In-625. Performed braze repair surface craze crack on airfoil. Restore Tip Heights dimension by CNC Machining Performed EDM trailing edge to restore original cooling hole dimension. Perform correction of shroud lifting if in repairable condition. Intermediate Inspection (Dimensional, NDT, Cooling holes and Visual). Post Weld Heat Treatment per alloy specification. Inspection (Dimensional, NDT, Visual)

January 2012 | Company Overview | Company Confidential Page 22

V64.3 Blade Repair process

Using carbide burr remove oxidation on weld area.

Weld repair Tips wear

V64.3 Blade Row 1 – Weld repair practice

Blend to original contour, G6

January 2012 | Company Overview | Company Confidential Page 23

V64.3 Blade Repair process

Using carbide burr remove oxidation on weld area.

Weld repair Tips wear and Missing material on LE, G9

V64.3 Blade Row 2 – Weld repair practice

Blend to original contour, G7

January 2012 | Company Overview | Company Confidential Page 24

V64.3 Blade Repair process

The Surface craze crack on airfoil these conditions will be performed braze repaired, G3

V64.3 Blade Row 1 – Braze repair practice

Apply braze alloy with clean brush on airfoil to coverage surface craze crack.

Apply braze alloy with syringe on surface craze crack as show in the defect mapping.

January 2012 | Company Overview | Company Confidential Page 25

V64.3 Blade Repair process

After applied braze alloy on craze crack area (compare with defect mapping)

V64.3 Blade Row 1 – Braze repair practice

Apply Green stop off to prevent braze alloy flow on non repair area.

Apply White stop off to prevent block inside cooling holes.

January 2012 | Company Overview | Company Confidential Page 26

V64.3 Blade Repair process

After diffusion in the vacuum furnace.

V64.3 Blade Row 1 – Braze repair practice

Blend all braze areas to restore component profile.

Accepted visual and F.P.I inspection.

January 2012 | Company Overview | Company Confidential Page 27

V64.3 Blade Repair process

Visual cooling hole block condition.

V64.3 Blade Row 2 – EDM cooling holes practice

Setup Blade on EDM machine.

Accepted cooling hole inspection.

January 2012 | Company Overview | Company Confidential Page 28

V64.3 Blade Repair processV64.3 Blade – UT Wall Thickness Inspection

Record sheet Inspection area

January 2012 | Company Overview | Company Confidential Page 29

V64.3 Blade Repair processV64.3 Blade – Blade height inspection

Inspection fixture Record sheet

January 2012 | Company Overview | Company Confidential Page 30

V64.3 Blade Repair processV64.3 Blade – Squealer tip thickness and Platform wide

Inspection area

Record sheet

January 2012 | Company Overview | Company Confidential Page 31

V64.3 Blade Repair processV64.3 Blade – Chord wide inspection

Inspection area Record sheet

January 2012 | Company Overview | Company Confidential Page 32

V64.3 Blade Repair processV64.3 Blade – Dimension inspection by CMM

Blade Row 1 Blade Row 2

January 2012 | Company Overview | Company Confidential Page 33

V64.3 Blade Repair processV64.3 Blade Row 1 – UT Wall Thickness Inspection

Serial No.New Blade Repair Blade Scrap Blade

DS417 BE51792 SA269

Section

1

A 1.98 2.36 1.36

B 2.04 2.23 1.44

C 1.65 2.10 1.64

D 2.14 2.36 1.29

E 1.98 2.14 1.63

Section

2

A 2.02 2.25 1.28

B 2.30 2.59 1.42

C 1.83 2.48 1.35

D 2.32 2.09 1.47

E 2.14 2.04 1.29

Section

3

A 2.03 2.41 1.40

B 2.32 2.70 1.45

C 2.02 2.51 1.34

D 2.51 2.63 1.63

E 2.20 2.33 1.45

Section

4

A 2.21 2.41 1.38

B 2.65 2.88 1.63

C 2.25 2.51 1.31

D 2.51 3.10 1.53

E 2.33 2.73 1.39

Thickness checks to be taken at points A, B, C, D, E at heights 1-4.

Point D is 20 mm from TE, and point A&E is 10 mm from TE.

January 2012 | Company Overview | Company Confidential Page 34

V64.3 Blade Repair processV64.3 Blade Row 2 – UT Wall Thickness Inspection

Thickness checks to be taken at points A, B, C, D, E at heights 1-5.

Point D is 25 mm from TE, and point A&E is 15 mm from TE.

Serial No.New Blade Repair Blade Scrap Blade

EG51057 PF806 TG209

Secti

on 1

A 1.75 1.41 1.31

B 1.81 2.14 1.02

C 1.55 1.42 1.10

D 2.03 1.29 1.56

E 1.55 1.35 1.00

Secti

on 2

A 2.02 1.43 1.55

B 2.11 2.34 1.00

C 1.62 1.50 1.03

D 2.08 1.35 1.46

E 1.56 1.30 1.22

Secti

on 3

A 2.13 1.45 2.06

B 2.27 2.34 1.01

C 1.63 1.52 1.11

D 2.00 1.27 1.56

E 1.60 1.35 1.30

Secti

on 4

A 2.45 1.48 1.56

B 2.34 2.46 1.06

C 1.65 1.54 1.38

D 2.08 1.36 1.45

E 2.07 1.45 1.07

Secti

on 5

A 2.61 1.46 2.18

B 2.54 2.51 1.01

C 1.97 1.60 1.41

D 2.37 1.41 1.57

E 2.25 1.43 1.56

January 2012 | Company Overview | Company Confidential Page 35

V64.3 Blade Repair processV64.3 Blade Row 3 – Eddy Current Inspection

Serial No.

Section Hole No. LE CV CC TE

A

1  > 0.84  > 0.84  > 0.84  

2    > 0.84  > 0.84  

3    > 0.84  > 0.84  

8    > 0.84  > 0.84  

9    > 0.84  > 0.84  

10    > 0.84  > 0.84  > 0.84 

B

1   > 0.84  > 0.84  > 0.84  

2    > 0.84  > 0.84  

3    > 0.84  > 0.84  

8    > 0.84  > 0.84  

9    > 0.84  > 0.84  

10    > 0.84  > 0.84   > 0.84

C

1   > 0.84  > 0.84  > 0.84  

2    > 0.84  > 0.84  

3    > 0.84  > 0.84  

8    > 0.84  > 0.84  

9    > 0.84  > 0.84  

10    > 0.84  > 0.84   > 0.84

D

1   > 0.84  > 0.84  > 0.84  

2    > 0.84  > 0.84  

3    > 0.84  > 0.84  

8    > 0.84  > 0.84  

9    > 0.84  > 0.84  

10    > 0.84  > 0.84   > 0.84Repair part

January 2012 | Company Overview | Company Confidential Page 36

V64.3 Blade Repair processV64.3 Blade Row 3 – Eddy Current Inspection

Serial No.

Section Hole No. LE CV CC TE

A

1  > 0.84  > 0.84  > 0.84  

2    > 0.84  > 0.84  

3    > 0.84  > 0.84  

8    > 0.84  > 0.84  

9    > 0.84  > 0.84  

10    > 0.84  > 0.84  > 0.84 

B

1   > 0.84  > 0.84  > 0.84  

2    > 0.84  > 0.84  

3    > 0.84  > 0.84  

8    > 0.84  > 0.84  

9    > 0.84  > 0.84  

10    > 0.84  > 0.84   > 0.84

C

1   > 0.84  > 0.84  > 0.84  

2    > 0.84  > 0.84  

3    > 0.84  > 0.84  

8    > 0.84  > 0.84  

9    > 0.84  > 0.84  

10    > 0.84  > 0.84   > 0.84

D

1   > 0.84  > 0.84  > 0.84  

2    > 0.84  > 0.84  

3    > 0.84  > 0.84  

8    > 0.84  > 0.84  

9    > 0.84  > 0.84  

10    > 0.84  > 0.84   > 0.84New part

January 2012 | Company Overview | Company Confidential Page 37

(A)

(B)

(C)

V64.3 Blade Repair processV64.3 Blade Row 1 – Blade height inspection

Serial No.LE Tip (A) Middle Tip (B) TE Tip (C)

CV Mid CC CV Mid CC CV Mid CC

New Part DS417 133.02 132.97 132.90 135.74 135.74 135.62 138.60 138.51 138.41

Repair Part BE51792 129.22 129.61 129.29 132.38 132.57 131.98 135.55 135.67 134.97

Scrap Part DTB55 128.96 129.39 128.91 131.98 132.33 131.64 135.13 135.30 134.67

January 2012 | Company Overview | Company Confidential Page 38

V64.3 Blade Repair processV64.3 Blade Row 2 – Blade height inspection

Serial No. H1 H2 H3New Part EG51057 180.50 185.92 191.13

Repair Part PF806 177.44 182.73 188.47

Scrap Part PV761 179.45 184.92 189.34

(H2)

(H1)

(H3)

January 2012 | Company Overview | Company Confidential Page 39

V64.3 Blade Repair processV64.3 Blade Row 3 – Blade height inspection

Serial No. H1 H2 H3New Part EH50750 277.21 289.61 300.08

Repair Part MY861 274.16 287.57 297.20

Scrap Part

(H2)

(H1)

(H3)

LEMID

TE

January 2012 | Company Overview | Company Confidential Page 40

V64.3 Vane Repair processVane Repair Workscope Remove Cracks, Eroded Material, Oxidation layer by Blending. Weld Repair Cracks and Missing Material Correct airfoil bowing or bulging. Correct platform distortion. Intermediate Inspection (Dimensional, NDT, Cooling holes and Visual) Post Weld Heat Treatment per alloy specification. Inspection (Dimensional, NDT, Visual)

January 2012 | Company Overview | Company Confidential Page 41

V64.3 Vane Repair process

Using carbide burr remove oxidation on weld area, G8

Weld repair defects and Missing material on LE, G8

V64.3 Vane Row 2 – Repair practice

Blend to original contour, G8

January 2012 | Company Overview | Company Confidential Page 42

V64.3 Vane Repair processV64.3 Vane – Function fit inspection.

Inspection fixture Record sheet

January 2012 | Company Overview | Company Confidential Page 43

V64.3 GT Components Perform fluorescent penetrant inspection (FPI) of full component of all repair areas and pre-coat inspection

Blade Row 1 Blade Row 2 Vane Row 2

January 2012 | Company Overview | Company Confidential Page 44

QUALIFICATION OF SPECIFIC REPAIRSEngine run, service induced cracking (2 mm in length) showing heavy oxidation layer

Crack evaluation after the TST developed Hydrogen Fluoride cleaning process showing 100% oxidation removed

Micro evaluation of the Braze repair sample showing 100% fill obtained.

January 2012 | Company Overview | Company Confidential Page 45

QUALIFICATION OF SPECIFIC REPAIRS

OEM Repair Welding Qualification involves welding of ALL allowed areas within the repair specification limit to the maximum reparability limits.For material IN738 and IN939

January 2012 | Company Overview | Company Confidential Page 46

QUALIFICATION OF SPECIFIC REPAIRS

Qualification samples are fully processed through the entire repair cycle, including all heat treatments, Non-Destructive Testing processes and Dimensional inspections.For material IN738 and IN939 EVALUATE SIDE FACE [ 1 ]

EVALUATE CUT FACE [ 6 ]

Qualification part samples are removed from the repaired components in the repaired areas and reviewed for metallurgical requirements and micro-evaluations

January 2012 | Company Overview | Company Confidential Page 47

QUALIFICATION OF SPECIFIC REPAIRSCoating Qualifications are extremely critical with all surface areas being evaluated for adherence to the OEM specifications (SI2231 and SI3464)Actual coated parts are cut and evaluated at the micro level to ensure the coating quality meets the required specifications.

The Most advanced coating materials

and processes used

January 2012 | Company Overview | Company Confidential Page 48September 2009 | Company Overview | Company Confidential

Q & A