Repair beats replacement Excellence in component and parts repair

An MTU Aero Engines Company

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Repair beats replacement MTU Maintenance is the world’s largest inde-pendent provider of commercial engine mainte-nance services. The company has built a solidreputation for its innovative, high-quality andcost-effective repairs. A subsidiary of MTUAero Engines, Germany’s leading engine manu-facturer, MTU Maintenance benefits from itsparent’s almost 100 years of experience inthe development and production of aircraftengines.

MTU Maintenance has grouped all activitiesrelating to the repair of components, modulesand accessories for aircraft engines and in-dustrial gas turbines under the umbrella ofMTU Repair Services. The company operatesa worldwide network of maintenance, repairand overhaul shops, among them renownedcenters of excellence, all of which stand outfor their unique expertise in the fields of com-ponent repairs and specialized high-tech repairprocesses.

MTU’s Repair Services offer an impressiveportfolio of repair processes that cover theentire engine and meet the most stringentrequirements—for maximum benefit to cus-tomers. Be it the repair of individual blade orvane sets, the recovery of parts from retiredengines or full support under a tailor-madeservice arrangement—MTU provides optimumsolutions to satisfy its customers’ requirementsand needs.

MTU Maintenance’s motto is “repair beatsreplacement”. The high-tech repair processesdeveloped in-house and marketed under thetrademark MTUPlus are the company’s hallmark.These innovative techniques help increaserepair rates, ensure unique quality standards,improve reliability and reduce maintenancecosts thus giving the company a clear compet-itive edge. Airlines, maintenance providers andparts brokers worldwide rely on MTU’s repaircompetence.

Highly precise laser drilling at MTU.

Worn blade tips are restored to their originalcontour by laser powder cladding.

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MTU Repair Services provide comprehensiveservices, its portfolio running the whole gamutfrom repairs of all core components of theengine (life-limited parts, hot-section and cold-section airfoils, cases and frames and com-bustor) and module repairs (high-pressure andlow-pressure turbines, high-pressure and low-pressure compressors) all the way to acces-sory repairs. The service offerings are roundedoff by the recovery of replacement parts fromretired engines: The company disassemblesretired engines, repairs usable parts and certi-fies them for continued operation.

Additionally, customers can opt for MTU’sTotal Part Care (TPC) service package, an all-round carefree solution comprising mainte-nance and repair, technical and logistic supportand spare parts services.

Thanks to its one-of-a-kind repair expertiseMTU Repair Services are setting benchmarksin the industry worldwide. Apart from OEMrepair processes (in accordance with enginemanual standard or special repairs), it useshigh-tech methods that have been developed

in-house and certified by regulatory agencies,such as the Federal Aviation Administration(FAA) and the European Aviation Safety Agency(EASA).

With these proprietary repair processes, inparticular the innovative MTUPlus techniques,the company achieves levels of restorationthat are unique worldwide. MTU repairs com-ponents where others would long have resort-ed to new parts to replace worn or damagedones. This benefits the environment and savesthe customer money. Thanks to innovativerepair processes, in particular for cost-effec-tive engine components, the material costsand hence the maintenance costs incurred bythe customer can be continuously reduced.

Customers can benefit from MTU’s unrivaledcompetence also when it comes to the refur-bishment of engine-run components. Underspecial material salvation programs, independ-ent MTU experts inspect parts that are con-sidered unserviceable to determine whetherthey can be repaired and re-used or not.

MTU Repair Services

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Special requirements call for imaginative andeffective solutions. The specialists of MTU Re-pair Services go the extra mile to satisfy theircustomers’ demands. Working closely togetherwith their customers, they tailor services andrepairs to suit the specific individual needs.The results are high customer satisfaction andsuccessful cooperation.

MTU offers repair services for the followingengine and industrial gas turbine types:

Engines:• CF34-3/-8/-10• CF6-50• CF6-80C2• CFM56-3/-5B/-7B• PT6A• PW200• PW300• PW500• PW2000• PW6000• V2500-A1/-A5/-D5• GE90• GP7000

Industrial gas turbines:• LM2500/LM2500+• LM5000• LM6000

Customers can have all of these engines andindustrial turbines tested in MTU’s test cells.MTU Maintenance boasts high-performanceand advanced test facilities that are designedfor a wide range of engine tests.

Global network with one faceto the customer

MTU Repair Services can draw on the supportof a global network of repair shops, centers of excellence for a unique range of services,which are located in Europe, North Americaand Asia. An efficient service unit, MTU RepairServices handle all aspects of the repair ofparts and components for aircraft engines andindustrial gas turbines within MTU Mainte-nance, true to the principle of “one face tothe customer”. Each customer has one con-tact to take care of all of its repair needs—nomatter where in the world the work is carriedout. Streamlined operating structures ensuresmooth and fast processing of repair orders.The Repair Services’ experts for individualregions and markets are thoroughly familiarwith the specific needs and requirements ofeach customer.

MTU Maintenance Hannover is the center-piece of the group’s worldwide network. Thelargest shop of the parts repair business is thecenter of excellence for high-tech repairs andis busy developing new repair techniques. MTUMaintenance Berlin-Brandenburg performspart repairs for General Electric CF34-seriesengines and all Pratt & Whitney Canada smalland mid-sized engines. It is MTU’s center ofexcellence for the maintenance of industrialgas turbines and draws on its aero engine ex-pertise to repair these aeroderivatives.

The Munich location is home to MTU’s head-quarters and is the company’s largest facility.At this site, manufacturing and repair tech-niques for all segments, including the compa-ny’s maintenance shops, are developed. Thiswork is performed in close cooperation withexperts from the Hannover and Ludwigsfeldelocations and the design center of MTU AeroEngines North America (MTU AENA) in RockyHill, U.S. Moreover, the Munich location is thecenter of excellence for frames, cases & bliskrepairs. The shop also performs repairs oncomponents such as disks and seal rings.

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The latest addition to MTU’s global network isMTU Aero Engines Polska in Rzeszów, a shopwith rapidly growing capabilities that is cur-rently focusing on the repair of tubes.

In the important growth market Asia MTUoperates two shops: MTU Maintenance Zhuhaiin China, a 50/50 joint venture with ChinaSouthern Airlines, specializes in the mainte-nance, repair and overhaul of the CFM56 andV2500 engines and is the leading MRO pro-vider for these engine types in China. AirfoilServices Sdn. Bhd. in Kuala Lumpur, Malaysia,a 50/50 joint venture with Lufthansa Technik,is the high-tech repair shop for high-pressurecompressor and low-pressure turbine blades.

MTU Maintenance Canada in Vancouver holdsall OEM licenses required for the repair andoverhaul of GE CF6-50 and CFMI CFM56-3engines. Apart from the repair of accessoriesthe shop is also responsible for line replace-able unit (LRU) management within the MTURepair Services network.

MTU Maintenance Hannover specializes in medium- tolarge-size engines.

Vancouver-based MTU Maintenance Canada is MTU’scenter of excellence for accessories.

MTU Maintenance Zhuhai is the largest engine mainte-nance provider in China.

MTU Aero Engines is headquartered inMunich.

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MTU Maintenance Canada Ltd. Ceramic Coating Center S.A.S.MTU Maintenance Hannover GmbHMTU Maintenance Berlin-Brandenburg GmbHPratt & Whitney Canada Customer Service CentreEurope GmbHMTU Aero Engines Holding AGMTU Aero Engines GmbHMTU Aero Engines Polska Sp.z.o.o.

MRO Production and Repair CenterLevel II IGT Shop Sales and MarketingField Service/Mobile Repair Team

Airfoil Services Sdn. Bhd.MTU Maintenance Zhuhai Co. Ltd.

MTU Maintenance Berlin-Brandenburg provides supportfor industrial gas turbines.

Customer Service Centre Europe GmbH (CSC) isresponsible for organizing support services for P&WCengines.

MTU Aero Engines Polska in Rzeszów is the youngestmember of MTU’s network of companies.

Airfoil Services Sdn. Bhd. (ASSB) in Malaysia repairsairfoils for various engine types.

Ceramic Coating Center (CCC) specializes in the depo-sition of highly advanced ceramic coatings.

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High-performance engineering

One of the hallmarks of the company is itsrepair development, not only for engines inwhich MTU has a development or productionstake, but also for engines that do not formpart of the company’s OEM portfolio. Both,OEM-licensed repairs, as required by the manu-facturers, as well as highly specialized repairprocesses developed by MTU Maintenance(MTUPlus, DER) are the mainstay of the repairbusiness.

Technology leaders never rest. MTU’s repairprocesses undergo continuous developmentand optimization. The portfolio of high per-formance MTUPlus repairs keeps growing, andthe company is expanding its joint repair devel-opment activities with General Electric, whichcurrently focus on the CF34 engine.

The key to success is a highly qualified teamof about 1,400 engineers that can draw on an extensive in-house OEM experience and know-

how. To ensure the necessary transfer ofknowledge they closely cooperate with univer-sities and research institutions. These strongdevelopment teams provide intelligent solu-tions, which means significant cost reductionsfor the customer.

MTU has a distinct advantage over its com-petitors: The company combines technicalexpertise in complete engine maintenance withthe specialist know-how of an engine manu-facturer that also develops innovative enginecomponents and materials. MTU owes its suc-cess also to the highly advanced technologiesit developed under the many military programsin which it had or has a stake.

Patching, a technique developed by MTU, is the only process approved for repairing blisk airfoils worldwide.

Services:• Hardware condition monitoring• Development and approval of alternative

repairs and processes• Best practices engineering, technical

support and consulting• Failure and damage analyses• Certifications and licenses:

– EASA, FAA, CAAC– ISO 9001, EN 9100, EN 9110, ISO 14001

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MTUPlus repairs: Top qualitywith high-tech processes

As a production facility and independent pro-vider of MRO services, MTU Maintenance candraw on extensive experience and technicalexpertise in the development of repair pro-cesses which are independent of or comple-ment those of the OEMs. The result are high-tech repairs which are unrivaled worldwide.These repairs have been branded as MTUPlus

repairs. MTUPlus technologies are proprietaryrepair processes that have been developed in-house. They are approved by aviation author-ities, such as FAA and EASA.

These innovative and highly cost-effective ad-vanced repair technologies enable MTU Main-tenance to meet individual customer require-ments with even greater flexibility. MTUPlus pro-

cesses are based on first-class know-how andsatisfy the most demanding criteria, extendingthe service life of components, increasingrepair yield and improving part functionality.MTU-repaired parts stand out by their above-average performance and extended on-wingtimes.

In close cooperation with each customer, MTUMaintenance further optimizes highly efficientprocesses and develops new repairs which areunique in the world of engine maintenance.Engine airfoils, for example, can be given asecond lease on life, thus reducing capital ex-penditures, saving resources and protectingthe environment.

Low-pressure plasma spraying of a V2500 airfoil. Advanced laser machines ensure highly precise drillingand welding.

Key technologies:• Laser welding• Laser drilling• Laser powder cladding• High-velocity oxy-fuel (HVOF) spraying• Vacuum brazing• Vacuum plasma spraying• High-pressure water jet stripping• High-speed grinding• Heat treatment• Autoclave airfoil cleaning• Cubic boron nitride (CBN) tip restoration• Fluoride ion cleaning (FIC)• Electron-beam physical vapor deposition

(EB-PVD)• Chemical vapor deposition of platinum

aluminide coatings (Pt-Al CVD coating)• Non-destructive testing (NDT): ultrasonic,

eddy current, magnetic particle inspec-tions, X-ray, etc.

• PVD coating (physical vapor deposition)• EB welding• Adaptive milling• Adaptive electro-discharge machining

Benefits:• Highest quality standards• High repair yields• Reduced maintenance costs• Improved reliability • Higher EGT margin

(exhaust gas temperature)

Thanks to its comprehensive and leading-edgerepair expertise MTU Maintenance can repairall core components of an engine. The com-pany uses highly sophisticated repair process-es to restore parts, such as blisks and com-bustors, to top-notch condition.

A coating facility at MTU MaintenanceHannover.

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Life-limited parts Life-limited parts (LLPs) are among the mostcost-intensive parts of an engine. The repairof such parts is highly challenging and mustcomply with manufacturer’s manuals and meetthe most stringent quality standards. The com-pany’s experts provide solutions to these ever-changing challenges and offer a wide range of high-tech repairs, including licensed repairprocesses for the entire spectrum of LLPs.Moreover, MTU also develops its own repairsfor life-limited parts. Its customers benefit froma broad range of in-depth, top-quality repairs.

Recent high-tech process developments haveopened up entirely new opportunities in partsrepair. Integrally bladed disks, so-called blisks,for example, were considered unrepairable atfirst and had to be replaced when damaged.Through the clever implementation of innova-tive technologies, MTU has succeeded in devel-oping advanced repair processes to restoreblisks to mint condition. It was on the EJ200military program that the company developedthe comprehensive capabilities needed forblisk repair. Now commercial customers canbenefit from these developments as well, sinceMTU, the global expert in blisk technology,plans to transfer the sophisticated blisk repairtechnologies also to commercial engines, forexample, the PW300, PW500, CF34, PW6000,GE90 and the GP7000 engines.

Key processes:• Plasma spray coating• Surface treatments• Non-destructive testing (NDT): ultra-

sonic, eddy current, magnetic particle and fluorescent penetrant inspections

• Chromium and nickel plating and stripping

• Laser welding• Adaptive milling

Turbine disks can be repaired within defined limits only.

Machining of an LM2500 gas turbine shaft. The heavy-weights are maintained by the Ludwigsfelde shop.

Shafts are highly stressed, life-limited parts.

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Cold-section airfoils For fan, low-pressure compressor (LPC) orhigh-pressure compressor (HPC) airfoils, MTU’srepair shops provide high quality and individu-ally developed airfoil repair processes whichcontribute substantially to smooth and reliableengine operation. Repairs such as tip welding,surface finish restoration and coating applica-tions for the cold-section airfoils are standardprocesses at MTU. In addition, the companyhas developed special repair techniques, suchas MTUPlus ERCoatnt Erosion Coating. Thiscoating excels by its multi-layer structure andoptimally protects compressor blades fromerosive attack thus increasing their service lifewhile at the same time improving efficiency.

Key processes:• Surface finish repairs• Tip welding• Adaptive machining• Chord width restoration (CWR)• Ultrasonic inspection by immersion

(fan blades)• Application of anti-friction coatings

(dovetail coating)• MTUPlus ERCoatnt Erosion Coating• MTUPlus Engine On-Wing Cleaning

Adaptive milling is also used in the repair of fan blades.

Compressor blades are provided with protective coatings for improved wear resistance.

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Hot-section airfoils Hot-section airfoils are subjected to extremelyhigh stresses in engine operation, which arecaused by high temperatures and pressures.To make sure these parts can reliably performto full potential highly specialized repairs andtreatments are needed. MTU Maintenance offers a broad spectrum of processes for therepair of hot-section airfoils.

MTU has, for example, succeeded in develop-ing an innovative technique for re-hardfacingworn tips of turbine blades: MTUPlus Tip Pro-tection. The protective coatings thus producedare capable of resisting wear much betterthan coatings applied using conventional OEMprocesses. Another textbook example of MTU’sunbeatable repair engineering expertise isMTUPlus Balance Stripping, a process duringwhich each blade is continuously measured todetermine exactly how much coating material

must be removed. With this stripping method,blades can be repaired three times during theirservice life instead of once only.

Key blade processes:• MTUPlus Tip Protection• MTUPlus Laser Powder Cladding (tip repair)• Full repair/rejuvenation• Electron-beam physical vapor deposition

(EB-PVD) of thermal barrier coatings (TBC)• Laser drilling• Adaptive milling• MTUPlus Balance Stripping • Chemical vapor deposition (CVD)• Platinum aluminide coating• MTUPlus Under-Platform Coating

Key vane and shroud processes:• Fluoride ion cleaning (FIC)• MTUPlus Brazing• Throat area control/restoration• Chemical vapor deposition (CVD)• Thermal barrier coating (TBC)• MTUPlus Airfoil Replacement Technology

Low-pressure plasma spraying is one of several coating processes used by MTU.

The blades are cleaned prior to coating.

Ceramic coatings are applied at CeramicCoating Center.

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Cases and frames Cases and frames are among the most highlystressed parts in an engine. They are sub-jected to high levels of mechanical stressesduring operation; for example frames carryingthe engine mounts which transfer the thrust tothe airframe, and cases that must be capableof withstanding pressures of up to 30 bar.Such harsh operating conditions call for com-plex and demanding repair processes such astechnologically advanced welding as well asplasma repair processes.

At MTU, such advanced technologies enablethe replacement of complete sections of highlystressed parts. Along with its proven expertise,these technologies give MTU the edge when itcomes to substantially improving the reliabilityand quality of repaired parts.

Key processes:• Weld repairs• Dimensional restoration• APS (Atmospheric plasma spraying) and

wire-feed plasma spraying• LPPS (low-pressure plasma spraying)• Flange/section replacements• Rub-coat renewal• Electron-beam welding• Laser welding• Painting

Repair of a CF6 compressor casing by means of wirearc spraying.

Inert-gas shielded welding is mostly performed manually at MTU Maintenance.

Heat treatments are an important part ofengine component repairs.

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Combustor Highly compressed air coming from the com-pressor section is mixed with fuel and ignitedin the combustor. The resulting heat causes thegases to expand to many times their originalvolume which, in turn, results in the expulsionof highly energized gases from the combustor.Exposure to such extreme temperatures makeit essential to protect combustor parts usingtechnologies and features such as thermal bar-rier coatings and air cooling holes. To provideoptimum protection, MTU Maintenance hasdeveloped unique and reliable repair processesfor critical, highly stressed combustor compo-nents which ensure the highest standards ofreliability and extend on-wing times. Repairs,such as weld section replacement and dimpleoverhang replacement, render whole-scale re-placement redundant.

Key processes:• Extensive weld repairs• Thermal barrier coating (TBC)• Section replacements• MTUPlus Dimple Spad Replacement

In comparison with conventional repairs, MTU-developed solutions have been shown to opti-mally restore the cooling air flow.

Combustion chambers also require regular maintenance.

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Accessory repair & LRU management

Rounding up the whole gamut of engine over-haul and component repairs, MTU Maintenancealso refurbishes and repairs engine acces-sories. Accessories include parts, which arenot integral to the engine but are essential forits operation, such as starters, fuel and hy-draulic pumps, actuators, sensors, valves andtubing.

MTU’s Repair Services offer a first-class com-prehensive spectrum of fast and reliable acces-sory repairs, which is constantly being widenedand fine-tuned. Customers benefit in manyways from this new service portfolio: MTUMaintenance performs repairs of the highestquality repairs that satisfy the most stringentstandards, while turnaround times are signifi-cantly reduced. This pays off for the customersas their engines are returned as quickly aspossible to revenue service.

The repair of accessories requires expertiseand experience. MTU Maintenance has both.MTU Aero Engines has been handling practi-cally all aviation propulsion systems in servicewith the German Air Force for decades and isresponsible for their technologically advancedaccessories.

Services:• Bench checks• Repairs• Overhaul (refurbishments)

MTU maintains accessories for the following engine types:• V2500 • CF6-50 • CF6-80 • CFM56 • PW2000 • CF34

MTU Maintenance has developed all-roundcarefree service packages under which it notonly repairs line-removed accessories but alsoprovides support for all of the customer’s linereplaceable units (LRU) that include engineaccessories such as oil coolers, starters orfuel pumps. Customers can choose from sev-eral support levels ranging from maintenanceand repair services to comprehensive LRUmanagement and support programs. Full LRUmanagement is part of MTU Maintenance’sTotal Part Care (TPC) program.

Visual inspections are normally performed by airline technicians, as on the V2500 which is shown here.

MTU Maintenance’s repair portfolio alsoincludes accessories.

Accessories are put through their paces at MTU Mainte-nance Canada, MTU’s center of excellence for acces-sories.

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Module repair/Teardownservices

Module repairCustomers who entrust an individual enginemodule to any of the MTU Maintenance facili-ties for overhaul also benefit from the excep-tional depth of repair offered by MTU. Pivotalto customer confidence in a job well done isMTU’s all-embracing know-how and long yearsof experience in the MRO business.

The module is disassembled, components areinspected and repaired, the module is thenreassembled and delivered to the customer.The level of disassembly and the scope of therework to be carried out are defined individu-ally for each engine and customer. In addition,customers can order additional services fromthe Total Part Care (TPC) program.

Top quality is guaranteed throughout by highlyqualified MTU personnel who are known in thebusiness for their expertise and customer ori-entation.

Teardown servicesOnce an engine has reached the end of itsservice life and is to be retired, it still remainsa valuable asset. For instance it makes goodeconomic sense for the owner to recycle vari-ous materials such as tungsten, titanium, nickeland aluminum as well as to repair salvageablecomponents. In doing so, customers, and in-deed the environment, profit from a genuinetreasure which retired engines provide.

MTU Maintenance has specialized in recoveringhigh-value replacement parts from retired en-gines, one example of which is high-pressurecompressor and turbine airfoils. Once repaired

to exacting standards, these parts are installedin engines which would have otherwise re-quired expensive new part replacements.Thanks to innovative repair processes devel-oped and continuously optimized by MTU, abroad range of engine parts can be refurbished.The reliability and quality of such refurbishedparts matches that of new parts.

MTU Maintenance carries out the entire rangeof services on behalf of its customers: fromthe teardown and disassembly of a retired en-gine to repair of the parts to the most exactingquality standards. Included in the service chainis the breakdown of modules into componentsthat are then cleaned and inspected to segre-gate scrap parts from serviceable ones.

A CF34 engine is inspected at MTU MaintenanceBerlin-Brandenburg.

Assembly of a fan casing at MTU’s Hannover shop.

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Total Part Care (TPC):the one-stop shop for parts

Total Part Care (TPC) is an innovative all-roundcarefree solution provided by MTU RepairServices for individual engine and industrialgas turbine parts. Similar to Total Engine Care(TEC), MTU has developed a one-stop shopservice package dubbed TPC for engine partswhich can be adapted to suit the customers’specific needs. Such integral service packagesare key to success. They also make economicsense for the customer, especially when themaintenance partner has the expertise andcomprehensive repair skills MTU has to offer.

TPC guarantees a smooth supply of spareparts and the worldwide availability of repairand support services, one such service beingthe round-the-clock AOG service. Customersopting for TPC enjoy more planning reliability.Moreover, first-class engine performance andlast but not least, extended on-wing life areensured.

Repair & overhaulComplete repair services including:• Subcontracting• Labor, material or fixed prices• Service bulletin incorporationAvailability of:• 100 % yield programs• OEM & FAA DER repairs

Technical supportAvailability of:• MTU proprietary repairs (MTUPlus, DER)• Repairs improving specific fuel

consumption• Repair development on request

(OEM & FAA DER approved)• Highly competent staff on call

Spare part serviceAvailability of:• Extensive warehouse services• AOG service• Components at various MTU locations;

new or overhauled to latest service bulletin standard

Logistics of parts Complete responsibility on behalf of the customer availability of:• Worldwide shipments and transportation• 24/7 support• Storage• Customs clearance• Supply chain value

Fully assembled: an LM2500 compressor casing.

Preparation of a V2500 high-pressure compressor forhigh-speed grinding.

Set management of fan airfoils for fan assembly.

With its many years of experience and highlyflexible services, MTU Repair Services canmeet every customer’s individual requirementsby offering tailor-made and cost-effective re-pair solutions of the highest quality.

Everything perfectly organized: MTU’s highlyadvanced parts storage systems.

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An MTU Aero Engines Company

MTU Maintenance Hannover GmbHMünchner Straße 3130855 Langenhagen • GermanyTel. +49 511 7806-0Fax +49 511 7806-2111hannover@mtu.dewww.mtu-hannover.de

MTU Repair ServicesTel. +49 511 7806-4084Fax +49 511 7806-4772 AOG +49 171 4314333 partsrepair@mtu.de