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Repair beats replacement Excellence in part and accessory repair services An MTU Aero Engines Company

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Repair beats replacement Excellence in part and accessory repair services

An MTU Aero Engines Company

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World-class repair solutions MTU Maintenance is a leading provider ofcommercial maintenance services for aircraftengines and industrial gas turbines. A businessunit of MTU Aero Engines, Germany’s majorengine manufacturer, MTU Maintenance oper-ates a worldwide network of maintenance, re-pair and overhaul facilities and representativeoffices. Included among them are centers ofexcellence for parts and component repair.With over 35 years of experience, MTU Mainte-nance has built a strong reputation for inno-vative, high-quality and cost-effective repairsolutions.

The central tenet of MTU is that ‘repair beatsreplacement’. With this in mind MTU Mainte-nance has combined all activities relating tothe repair of components, modules and acces-sories for aircraft engines and industrial gasturbines into its MTU Repair Services unit.MTU offers an impressive portfolio of contin-uously improving repair processes that coverthe entire engine and meet the most stringentof standards. Whether the repair of singlemodules or piece parts, the disassembly andrepair of parts from retired engines, or com-prehensive customized parts repair servicepackages — MTU provides optimized solutionsto satisfy customer requirements.

The unique, high-tech repair processes devel-oped internally are patented and branded underthe trademark MTUPlus repairs. Extensive ex-pertise in the field of component repair, inconjunction with the technologically advancedrepair processes, give MTU the competitiveedge. This is why airlines, maintenance pro-viders and parts suppliers continue to rely onMTU’s repair competence—worldwide.

Laser cutting of an engine HPC component.

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No two customer requests are the same; assuch MTU Repair Services provides creativeyet comprehensive engineering and repairsolutions tailored to satisfy its customers in-dividual needs. Its portfolio covers repairs ofall core components and modules of the en-gine, as well as accessories.

Aside from OEM repair processes, enginemanual standard or special repairs, MTURepair Services uses high-tech methods thatare internally developed and certified by therelevant regulatory agencies, such as theFederal Aviation Administration (FAA) and theEuropean Aviation Safety Agency (EASA).

MTU firmly believes in the restoration of wornor damaged parts, as a superior option to re-placement with new parts. In utilizing its pro-prietary repair processes, MTU is able to simul-taneously reduce material, maintenance andenvironmental costs, whilst passing thesebenefits on to the customer.

If customers require a guaranteed supply ofparts and the worldwide availability of repairand support services they can opt for MTU’sTotal Part Care (TPC®). This solution comprisesof maintenance and repair, technical and lo-gistical support as well as spare parts services.

The specialists of MTU Repair Services pridethemselves on their ability to work alongsidethe customer to ensure an individually tailoredservice package. This approach ensures bestin class customer service and high levels ofsatisfaction.

MTU Repair Services

Visual inspection of engine modules prior to repair at MTU Maintenance Berlin-Brandenburg.

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MTU Maintenance offers repair services for awide range of parts, components and acces-sories as outlined in the table below. The port-folio covers standard and specialized OEMrepairs through to internally developed MTUPlus

high-tech repairs. As a matter of process,everything from piece part up undergoes rig-orous inspection and testing utilizing MTU’sstate-of-the-art technologies.

Widebody jetsCF6-50CF6-80C2GE90-110B/-115BGP7000Narrowbody and regional jets CF34CFM56-3CFM56-5BCFM56-7PW2000PW6000V2500Business jetsJT15D*PW300PW500TurbopropsPT6APW100*HelicoptersPT6B/-C/-T*PW200Industrial gas turbinesLM2500LM2500+LM5000LM6000

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Fan LPC airfoils

HPC airfoils

Combustor HPT airfoils

LPT airfoils

Cases &frames

Gearbox AccessoriesIn-house repair capabilities

(SAC)

(SAC)(SAC)

(LPT)

� existing repair capability � planned X not applicable * Repair capabilities within the PWC network

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Visual inspection of the high-pressure compressor of a GE90 engine.

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Global network with ‘one faceto the customer’

MTU Repair Services can draw on the supportof MTU Maintenance’s global network of re-pair shops and representative offices locatedacross the globe. Within this network, MTUoperates centers of excellence for a uniquerange of repair services. Presenting itself with‘one face to the customer’, MTU Repair Serv-ices coordinates all aspects regarding therepair of parts and components at its respec-tive locations in order to increase service effi-ciency. Experts from the MTU Repair Servicesteam serve individual regions and marketsallowing them to be familiar with the specificneeds of each customer.

The MTU Maintenance group is a business unitof parent company MTU Aero Engines, Ger-many’s leading engine manufacturer and a keyplayer in the global engine industry for over80 years. MTU Maintenance takes full advan-tage of a global network of facilities based onhighly-specialized centers of excellence.

MTU Aero Engines MünchenThe Munich location is the center of excellencefor frames, cases and blisk repairs. Aside fromhigh-tech repair development, it also performsrepairs on components such as disks and sealrings.

MTU Aero Engines Polska With rapidly growing capabilities, its field ofexpertise lies in the repair of engine parts, suchas tubing and honeycomb seals.

MTU Maintenance Berlin-Brandenburg This location focuses on the repair and over-haul of small-sized aircraft engines and isMTU’s center of excellence for industrial gasturbines.

MTU Maintenance CanadaThe Vancouver facility is MTU’s center of ex-cellence for accessory and LRU management,in addition to performing engine MRO. Thefacility specializes in accessory repairs for fuel,pneumatic, hydraulic and oil systems. ItsAccessory Repair Centre (A.R.C.) has highlyadvanced rigs for testing all of these enginecomponents.

MTU Maintenance Hannover also provides support for the V2500 engine that powers the A320 family of aircraft.

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MTU Maintenance Zhuhai is the market leader in China.

Airfoil ServicesA Malaysian-based 50:50 joint venturebetween MTU Aero Engines and LufthansaTechnik, Airfoil Services Sdn. Bhd. (ASSB) is astate-of-the-art facility and MTU’s center ofexcellence for HPC and LPT airfoil repairs.

Ceramic Coating CenterSpecializing in high-tech coatings, such as the electron-beam physical vapor deposition(EB-PVD) technique, the Ceramic CoatingCenter (CCC) is a 50:50 joint venture betweenMTU Aero Engines and French engine makerSnecma.

MTU Maintenance DallasMTU’s center of excellence for on-wing andon-site services, the company provides rapidresponse to engine maintenance needs, wheth-er scheduled or unscheduled.

MTU Maintenance HannoverSpecializing in the repair and overhaul ofmedium-sized and large commercial engines, itis MTU’s largest parts repair facility and thecenter of excellence for high-tech repairs, suchas hot-section airfoils.

MTU Maintenance Lease ServicesAn 80:20 joint venture between MTU AeroEngines and Japan-based Sumitomo Corpora-tion, offering airlines, MRO providers andlessors short- and medium-term engine leaseoptions. It further provides comprehensiveasset and material management solutions.

MTU Maintenance Zhuhai A joint venture between MTU Aero Engines andChina Southern Air Holding Company, China’slargest airline group. The facility is China’smarket leader for engine MRO services.

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Additive machining at MTU Aero Engines in Munich.

MTU Maintenance Canada

IGT Service Center (Level II)

Representative offices

MTU Maintenance Dallas

Pratt & Whitney Canada Customer Service Centre Europe

Ceramic Coating Center

MTU Maintenance Lease Services B.V.

MTU Maintenance Berlin-Brandenburg is MTU’s centerof excellence for industrial gas turbines.

Preparing a CFM56 HPT for high-pressure grinding atMTU Maintenance Zhuhai.

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MTU Maintenance Canada provides service support forCF6 family engines and accessories.

MTU Maintenance Hannover

MTU Maintenance Berlin-Brandenburg

Pratt & Whitney Canada Customer Service Centre Europe

MTU Aero Engines Polska

MTU Aero Engines

MTU Maintenance Zhuhai

Airfoil Services

MTU Maintenance Dallas, a specialist in on-site services,also performs repairs in its shop, if required.

MTU Aero Engines Polska develops, manufactures andrepairs engine parts.

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High-performance engineering MTU Maintenance aims to repair parts ratherthan replacing them wherever possible. Along-side the OEM-licensed repairs, it also offersspecialized internally developed repairs andprocesses. All of these proprietary repairs areEASA/FAA approved and marketed under thetrademark MTUPlus repairs. The companyundertakes repair development, not only forengines in which it has a development or pro-duction stake, but also for those that do notform part of its OEM portfolio.

MTU Maintenance benefits from both technicalexpertise in engine maintenance and the spe-cialist knowledge of MTU Aero Engines as anengine manufacturer. The company focuses on developing and providing intelligent repairsolutions for high-value parts, which can resultin significant cost reductions for the customer.This is facilitated by a highly qualified andmotivated team of engineers who draw upon

extensive experience gathered through 35years of providing MRO services. In addition,MTU Maintenance closely cooperates withuniversities and research institutions, therebyensuring that it continuously employs the lat-est technologies.

Shot peening of a CF34-3 blisk.

Sample services:• Hardware condition monitoring• Development and approval of alternative

repairs and processes• Best practice engineering, technical

support and consulting• Failure and damage analysis

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MTUPlus repairs: Top qualitystandards with high-techprocesses

A main component of MTU Maintenance’shigh-performance engineering is the in-housedevelopment of repair processes alternate to those of the OEMs. The majority of thesehave been grouped under the brand nameMTUPlus repairs. These are based on first-rateknowledge and satisfy the most demandingcriteria: extending the service life of compo-nents, increasing repair yield and improvingpart functionality. All of these technologiesare proprietary and have been approved bythe relevant aviation authorities, such as theFAA, EASA and CAAC.

MTUPlus repairs stand out due to their innova-tion and high cost-efficiency which allows thecompany to meet individual customer require-ments with greater flexibility. Customers ben-efit from excellence in reliability and quality,and reduced maintenance costs for MTU-re-paired parts.

One such example is the MTUPlus Under-Plat-form Coating, which is able to give engine air-foils a new lease on life. By utilizing a patentedhigh chromium coating, sufficient protectionagainst severe corrosion from sulphur andalkaline deposits can be attained for high-pres-sure turbine blades. This results in reducedmaintenance costs, less material wastage anda positive environmental outcome.

These cutting-edge technologies allow thecompany to provide repairs for all core com-ponents of an engine. The MTUPlus repair port-folio includes:

High-speed grinding of a whole compressor module.

Advanced laser machines ensure highly precise drillingand welding.

Turbine• MTUPlus Balance Stripping • MTUPlus Brazing• MTUPlus Complete Protection System• MTUPlus Flexible Laser Healing• MTUPlus Internal Airfoil Cleaning• MTUPlus Laser Powder Cladding Tip Repair • MTUPlus Multiply Plasma Coating• MTUPlus Tip Protection• MTUPlus Under Platform Coating

Fan/Compressor• MTUPlus Engine On-Wing Cleaning• MTUPlus ERCoateco Erosion-Resistant Coating

Combustor• MTUPlus Dimple Spad Replacement

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Thermal coating of an IGT life-limited part.

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 manufacturers’ manuals in orderto meet the most rigorous of quality standards.MTU Maintenance offers a wide range oflicensed high-tech repair processes for theentire spectrum of LLPs. In addition to OEMrepairs, the company develops its own repairsfor life-limited parts.

Recent high-tech process developments haveopened up entirely new opportunities in life-limited parts repair. Integrally bladed disks,so-called blisks, for example, were consideredirreparable at first and had to be replacedwhen damaged. Through the clever implemen-tation of innovative technologies, MTU hassucceeded in developing advanced repair pro-cesses to restore blisks to prime condition.Today, MTU is a global leader in blisk technol-ogy with sample programs including thePW300, PW500, CF34, PW6000, GE90 andthe GP7000 engines.

Key processes:• Adaptive milling• Chromium and nickel plating and stripping• Laser welding• Non-destructive testing• Plasma spray coating• Surface treatments

Fault detection on a turbine disk.

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Airfoils Cold-section airfoilsMTU Maintenance has a wide range of repaircapabilities for fan, as well as low- and high-pressure compressor airfoils. Tip welding, sur-face finish restoration and coating applicationsfor the cold-section airfoils are standard pro-cesses at MTU. Additionally, the company hasdeveloped special repair techniques, such asthe erosion-resistant coating MTUPlus ERCoateco.

Erosion is a major cost driver for engine oper-ation. Its effects lead to increased materialcosts due to higher scrap rates, higher fuelconsumption and shorter on-wing times.MTUPlus ERCoateco is an advanced nano-coatingtechnology which optimally protects com-pressor airfoils from erosive attack, both in-creasing service life and improving efficiency.

MTUPlus Tip Protection applied to engine compressorblades.

Adaptive milling of a CF34 fan blade’s leading egde.

Key processes:• Adaptive machining• Application of anti-friction coatings

(dovetail coating)• Chord width restoration (CWR)• Surface finish repairs• Tip welding• Ultrasonic inspection by immersion

(fan blades)

• MTUPlus ERCoateco Erosion-Resistant Coating• MTUPlus Tip Protection

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Hot-section airfoilsHot-section airfoils are exposed to extremeconditions during engine operation. They mustwithstand exceptionally high temperaturesand pressures. Therefore, highly specializedrepairs and treatments are needed to makesure these parts can reliably perform at fullpotential. MTU Maintenance offers a broadspectrum of repair processes to increase theservice-life of hot-section airfoils.

One such process is MTUPlus Tip Protection, aninnovative technique for re-hardfacing worntips of turbine blades, which sets the bench-mark for abrasion protection. Another exampleof MTU’s repair engineering expertise isMTUPlus Balance Stripping: during this process,each blade is continuously measured to deter-mine exactly how much coating material mustbe removed. Through this stripping method,blades can be repaired three times duringtheir service life instead of just once.

In addition to blade repairs, MTUPlus AirfoilReplacement Technology ensures complete re-parability of hot-section vanes. The optimizedcoating technology brings any damaged vane

back into serviceable condition. Guaranteeinga zero scrap rate, this method avoids the ne-cessity for cost intensive new material usage.

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

• MTUPlus Airfoil Replacement• MTUPlus Brazing

Handling of a LM2500 high pressure turbine blade.The blades are cleaned prior to coating.

Engine turbine vane after fluoride ion cleaning.

Key blade processes:• Adaptive milling• Chemical vapor deposition coating (CVD)• Electron-beam physical vapor deposition

coating (EB-PVD)• Full repair/rejuvenation• Laser drilling

• MTUPlus Balance Stripping• MTUPlus Laser Powder Cladding (tip repair)• MTUPlus Tip Protection• MTUPlus Under-Platform Coating

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Cases and frames Cases and frames are among the most highlystressed parts of an engine. During operationthey are subject to high levels of mechanicalstrain. The repair technologies employed torestore these parts to serviceable conditionare complex and demanding. Among these aretechnologically advanced welding and plasmarepair processes.

Field experience has shown that V2500 dif-fuser cases with an on-wing time of more than25,000 flight hours tend to crack in the rearouter flange area. MTU Maintenance’s flangereplacement repair replaces the weakened castflange by mating a new flange to the case wall.In a process unique to MTU, this can be ac-complished without the need for prior machin-ing. Utilizing electron beam welding technolo-gy, material removal is minimized, therebyretaining complete component strength in therepaired area. This advanced repair combineshigher parts durability with cost effectivenessand a short processing time.

A further example is microplasma-welding, amechanical process which achieves highwelding rates while reducing the risk of heatdistortion of the parts. By keeping the heat-affected zones appreciably smaller this pro-cess stands out as a distinctly material-friendlymethod.

Key processes:• Atmospheric plasma spraying (APS) and

wire-feed plasma spraying• Dimensional restoration• Electron-beam welding• Flange/section replacements• Laser welding• Low-pressure plasma spraying (LPPS)• Microplasma-welding• Painting• Rub-coat renewal• Weld repairs

Inert-gas shielded welding of a case performed at MTU Maintenance.

An engine case undergoing heat treatment during therepair process.

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Combustor The highest temperatures during engine oper-ation occur in the combustor section. Theseextreme temperatures make it essential toprotect combustor parts by using technologiesand features such as thermal barrier coatingsand air cooling holes. To provide optimum heatprotection, MTU Maintenance has developedunique and reliable repair processes for criti-cal, highly stressed combustor components,with the aim to extend on-wing times. Someof these, such as weld section and dimpleoverhang repairs fully avoid material replace-ment.

MTUPlus Thermal Barrier Coating applies theinternally developed “Metco2460NS” to theinner and outer liner, which improves thermomechanical strength and is proven to avoidadverse spalling. In addition, increased isola-tion properties significantly reduce base mate-rial temperature. The cumulative effect isimproved parts durability and lower scraprates—all of which result in reduced mainte-nance costs for the customer.

MTUPlus Thermal Barrier Coating of a CF6-80 combustor.

Key processes:• Extensive weld repairs• Section replacements

• MTUPlus Dimple Spad Replacement• MTUPlus Thermal Barrier Coating

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CF6-50 engines standing on MTU MaintenanceCanada’s flowline

Disassembly of a V2500 engine on the teardown flow-line at MTU Maintenance Hannover.

Teardown services Engines at the end of their service life remaina valuable asset. Even after the phase-out ofthe engine, owners can draw a profit by recy-cling various materials such as tungsten, titanium, nickel and aluminum as well as byrepairing salvageable components. In doingso, not only the customers but also the environ-ment benefit from retiring mature engines.

MTU Maintenance has specialized in recoveringhigh-value parts from retired engines, such ashigh-pressure compressor and turbine airfoils.Once repaired to strict standards, these partscan be re-installed in engines which wouldhave otherwise required expensive new partreplacements. Thanks to innovative repair pro-cesses developed and continuously optimizedby MTU, a broad range of engine parts can berefurbished. The reliability and quality of suchparts matches that of new ones.

The company carries out the entire range ofservices on behalf of its customers—from thedisassembly of a runout engine into single com-ponents, to the repair of the parts. Cleaning

and inspection to segregate scrap parts fromsalvageable ones is also included in the serv-ice.

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Smart Repair Solutions

In response to current market trends, MTUMaintenance has introduced a new productoffering called MTUPlus Mature Engine Solu-tions. The services are targeted at airlines andlessors who operate aging engines. Sincematerial is the decisive factor when it comesto shop visit costs, MTU will perform a tailoredevaluation of the engine hardware to find themost effective solution.

Smart repair services focus on the intelligentcombination of tailored workscoping, MTUPlus

repairs and used serviceable material sourcingto maximize customer benefits at minimal cost.

Material can be salvaged from both customer-owned engines and third party teardown en-gines. Besides parts evaluation and repair, theservices performed may also include “bag &tag” teardown, extensive parts management aswell as the storage and re-marketing of usedserviceable material.

Non-destructive testing of engine blades in the thermography machine.

Preparing for the balancing of a CF34-10 fan module.

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Accessory repair and LRU management

MTU Maintenance also refurbishes and repairsengine accessories. These are parts, which arenot core engine components but are essentialfor its operation, such as starters, fuel andhydraulic pumps, actuators, sensors, valvesand tubing.

MTU Repair Services offers a comprehensivespectrum of accessory repairs, which is beingconstantly widened and fine-tuned. Customersbenefit from this additional in-house compe-tence as their engines are returned as quicklyas possible back into service.

The repair of accessories requires expertiseand experience. MTU Maintenance has both.The company has been supporting commer-cial customers for many years, and MTU AeroEngines has been handling the vast majorityof aviation propulsion systems for the GermanAir Force and is responsible for their techno-logically advanced accessories. Further, adedicated team of engineers is committed tothe development of new accessory repair pro-cesses.

MTU Maintenance has developed all-roundcarefree service packages under which it notonly repairs line-removed accessories but alsoprovides dependable and professional supportfor all of the customer’s line replaceable units.Customers can choose from several state-of-the-art support levels ranging from mainte-nance and repair services to comprehensivesupport programs up to complete LRU man-agement. The latter can also be purchased aspart of MTU Maintenance’s Total Engine Care(TEC®) program.

Engine accessory portfolio:• CF34• CF6-50• CF6-80• CFM56• GE90• PW2000• V2500

IGT accessory portfolio:• LM2500/LM2500+• LM5000• LM6000

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

A brand new fuel control test rig at the accessoriescenter of excellence in Vancouver.

Repair of engine harnesses and tubes in the Vancouver shop.

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Total Part Care (TPC®): theone-stop shop for parts

With its many years of experience in enginemaintenance, MTU Repair Services offers cus-tomized and cost-effective parts provisioningsolutions. Total Part Care (TPC®) is the com-pany’s innovative all-encompassing productfor engine and industrial gas turbine parts, aswell as accessories.

Assembly of a fan module at MTU Maintenance Zhuhai.

The high rack warehouse for small- to medium-sized engine components at MTU Maintenance Hannover’s newlogistics center.

TPC® guarantees a smooth supply of spareparts and the availability of repair and supportservices irrespective of location. Customersgive MTU Maintenance full logistical responsi-bility for their contracted parts supply withthe assurance of fast turnaround times andon-time delivery.

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An MTU Aero Engines Company

MTU Maintenance Hannover GmbHMünchner Straße 3130855 Langenhagen • GermanyTel. +49 511 7806-0Fax +49 511 [email protected]

MTU Repair ServicesTel. +49 511 7806-9084AOG +49 171 4314333 [email protected]