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 of commercial maintenance services for aircraft engines and industrial gas turbines. A business unit of MTU Aero Engines, Germany s major engine manufacturer, MTU Maintenance operates a worldwide network of maintenance, repair and overhaul facilities and representative offices. Included among them are centers of excellence for parts and component repair. With over 35 years of experience, MTU Maintenance has built a strong reputation for innovative, high-quality and cost-effective repair solutions. The central tenet of MTU is that repair beats replacement. With this in mind MTU Maintenance has combined all activities relating to the repair of components, modules and accessories for aircraft engines and industrial gas turbines into its MTU Repair Services unit. MTU offers an impressive portfolio of continuously improving repair processes that cover the entire engine and meet the most stringent of standards. Whether the repair of single modules or piece parts, the disassembly and repair of parts from retired engines, or comprehensive customized parts repair service packages MTU provides optimized solutions to satisfy customer requirements. The unique, high-tech repair processes developed internally are patented and branded under the trademark MTU Plus repairs. Extensive expertise in the field of component repair, in conjunction with the technologically advanced repair processes, give MTU the competitive edge. This is why airlines, maintenance providers and parts suppliers continue to rely on MTU s repair competence worldwide. Laser cutting of an engine HPC component. 3
MTU Repair Services Visual inspection of engine modules prior to repair at MTU Maintenance Berlin-Brandenburg. No two customer requests are the same; as such MTU Repair Services provides creative yet comprehensive engineering and repair solutions tailored to satisfy its customers individual needs. Its portfolio covers repairs of all core components and modules of the engine, as well as accessories. Aside from OEM repair processes, engine manual standard or special repairs, MTU Repair Services uses high-tech methods that are internally developed and certified by the relevant regulatory agencies, such as the Federal Aviation Administration (FAA) and the European Aviation Safety Agency (EASA). If customers require a guaranteed supply of parts and the worldwide availability of repair and support services they can opt for MTU s Total Part Care (TPC ). This solution comprises of maintenance and repair, technical and logistical support as well as spare parts services. The specialists of MTU Repair Services pride themselves on their ability to work alongside the customer to ensure an individually tailored service package. This approach ensures best in class customer service and high levels of satisfaction. MTU firmly believes in the restoration of worn or damaged parts, as a superior option to replacement with new parts. In utilizing its proprietary repair processes, MTU is able to simultaneously reduce material, maintenance and environmental costs, whilst passing these benefits on to the customer. 4
MTU Maintenance offers repair services for a wide range of parts, components and accessories as outlined in the table below. The portfolio covers standard and specialized OEM repairs through to internally developed MTU Plus high-tech repairs. As a matter of process, everything from piece part up undergoes rigorous inspection and testing utilizing MTU s state-of-the-art technologies. In-house repair capabilities Widebody jets CF6-50 CF6-80C2 GE90-110B/-115B GP7000 Narrowbody and regional jets CF34 CFM56-3 CFM56-5B CFM56-7 PW2000 PW6000 V2500 Business jets JT15D* PW300 PW500 Turboprops PT6A PW100* Helicopters PT6B/-C/-T* PW200 Industrial gas turbines LM2500 LM2500+ LM5000 LM6000 Fan X X X X X X X X LPC airfoils X X X HPC airfoils Combustor (SAC) (SAC) (SAC) HPT airfoils * * * * LPT airfoils * * * * Cases & frames (LPT) Gearbox Accessories * * * * existing repair capability planned X not applicable * Repair capabilities within the PWC network Visual inspection of the high-pressure compressor of a GE90 engine. 5
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Global network with one face to the customer MTU Repair Services can draw on the support of MTU Maintenance s global network of repair shops and representative offices located across the globe. Within this network, MTU operates centers of excellence for a unique range of repair services. Presenting itself with one face to the customer, MTU Repair Services coordinates all aspects regarding the repair of parts and components at its respective locations in order to increase service efficiency. Experts from the MTU Repair Services team serve individual regions and markets allowing them to be familiar with the specific needs of each customer. The MTU Maintenance group is a business unit of parent company MTU Aero Engines, Germany s leading engine manufacturer and a key player in the global engine industry for over 80 years. MTU Maintenance takes full advantage of a global network of facilities based on highly-specialized centers of excellence. MTU Aero Engines München The Munich location is the center of excellence for frames, cases and blisk repairs. Aside from high-tech repair development, it also performs repairs on components such as disks and seal rings. MTU Aero Engines Polska With rapidly growing capabilities, its field of expertise lies in the repair of engine parts, such as tubing and honeycomb seals. MTU Maintenance Berlin-Brandenburg This location focuses on the repair and overhaul of small-sized aircraft engines and is MTU s center of excellence for industrial gas turbines. MTU Maintenance Canada The Vancouver facility is MTU s center of excellence for accessory and LRU management, in addition to performing engine MRO. The facility specializes in accessory repairs for fuel, pneumatic, hydraulic and oil systems. Its Accessory Repair Centre (A.R.C.) has highly advanced rigs for testing all of these engine components. MTU Maintenance Hannover also provides support for the V2500 engine that powers the A320 family of aircraft. 8
MTU Maintenance Dallas MTU s center of excellence for on-wing and on-site services, the company provides rapid response to engine maintenance needs, whether scheduled or unscheduled. MTU Maintenance Hannover Specializing in the repair and overhaul of medium-sized and large commercial engines, it is MTU s largest parts repair facility and the center of excellence for high-tech repairs, such as hot-section airfoils. MTU Maintenance Lease Services An 80:20 joint venture between MTU Aero Engines and Japan-based Sumitomo Corporation, offering airlines, MRO providers and lessors short- and medium-term engine lease options. It further provides comprehensive asset and material management solutions. Airfoil Services A Malaysian-based 50:50 joint venture between MTU Aero Engines and Lufthansa Technik, Airfoil Services Sdn. Bhd. (ASSB) is a state-of-the-art facility and MTU s center of excellence for HPC and LPT airfoil repairs. Ceramic Coating Center Specializing in high-tech coatings, such as the electron-beam physical vapor deposition (EB-PVD) technique, the Ceramic Coating Center (CCC) is a 50:50 joint venture between MTU Aero Engines and French engine maker Snecma. MTU Maintenance Zhuhai A joint venture between MTU Aero Engines and China Southern Air Holding Company, China s largest airline group. The facility is China s market leader for engine MRO services. MTU Maintenance Zhuhai is the market leader in China. 11
MTU Maintenance Canada MTU Maintenance Lease Services B.V. Pratt & Whitney Canada Customer Service Centre Europe Ceramic Coating Center MTU Maintenance Dallas IGT Service Center (Level II) Representative offices Additive machining at MTU Aero Engines in Munich. MTU Maintenance Berlin-Brandenburg is MTU s center of excellence for industrial gas turbines. Preparing a CFM56 HPT for high-pressure grinding at MTU Maintenance Zhuhai. 9
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 Canada provides service support for CF6 family engines and accessories. MTU Maintenance Dallas, a specialist in on-site services, also performs repairs in its shop, if required. MTU Aero Engines Polska develops, manufactures and repairs engine parts. 10
High-performance engineering MTU Maintenance aims to repair parts rather than replacing them wherever possible. Alongside the OEM-licensed repairs, it also offers specialized internally developed repairs and processes. All of these proprietary repairs are EASA/FAA approved and marketed under the trademark MTU Plus repairs. The company undertakes repair development, not only for engines in which it has a development or production stake, but also for those that do not form part of its OEM portfolio. MTU Maintenance benefits from both technical expertise in engine maintenance and the specialist knowledge of MTU Aero Engines as an engine manufacturer. The company focuses on developing and providing intelligent repair solutions for high-value parts, which can result in significant cost reductions for the customer. This is facilitated by a highly qualified and motivated team of engineers who draw upon extensive experience gathered through 35 years of providing MRO services. In addition, MTU Maintenance closely cooperates with universities and research institutions, thereby ensuring that it continuously employs the latest technologies. Sample services: Hardware condition monitoring Development and approval of alternative repairs and processes Best practice engineering, technical support and consulting Failure and damage analysis Shot peening of a CF34-3 blisk. 12
MTU Plus repairs: Top quality standards with high-tech processes A main component of MTU Maintenance s high-performance engineering is the in-house development of repair processes alternate to those of the OEMs. The majority of these have been grouped under the brand name MTU Plus repairs. These are based on first-rate knowledge and satisfy the most demanding criteria: extending the service life of components, increasing repair yield and improving part functionality. All of these technologies are proprietary and have been approved by the relevant aviation authorities, such as the FAA, EASA and CAAC. MTU Plus repairs stand out due to their innovation and high cost-efficiency which allows the company to meet individual customer requirements with greater flexibility. Customers benefit from excellence in reliability and quality, and reduced maintenance costs for MTU-repaired parts. One such example is the MTU Plus Under-Platform Coating, which is able to give engine airfoils a new lease on life. By utilizing a patented high chromium coating, sufficient protection against severe corrosion from sulphur and alkaline deposits can be attained for high-pressure turbine blades. This results in reduced maintenance costs, less material wastage and a positive environmental outcome. These cutting-edge technologies allow the company to provide repairs for all core components of an engine. The MTU Plus repair portfolio includes: Advanced laser machines ensure highly precise drilling and welding. Turbine MTU Plus Balance Stripping MTU Plus Brazing MTU Plus Complete Protection System MTU Plus Flexible Laser Healing MTU Plus Internal Airfoil Cleaning MTU Plus Laser Powder Cladding Tip Repair MTU Plus Multiply Plasma Coating MTU Plus Tip Protection MTU Plus Under Platform Coating Fan/Compressor MTU Plus Engine On-Wing Cleaning MTU Plus ERCoat eco Erosion-Resistant Coating Combustor MTU Plus Dimple Spad Replacement High-speed grinding of a whole compressor module. 13
Life-limited parts Life-limited parts (LLPs) are among the most cost-intensive parts of an engine. The repair of such parts is highly challenging and must comply with manufacturers manuals in order to meet the most rigorous of quality standards. MTU Maintenance offers a wide range of licensed high-tech repair processes for the entire spectrum of LLPs. In addition to OEM repairs, the company develops its own repairs for life-limited parts. Recent high-tech process developments have opened up entirely new opportunities in lifelimited parts repair. Integrally bladed disks, so-called blisks, for example, were considered irreparable at first and had to be replaced when damaged. Through the clever implementation of innovative technologies, MTU has succeeded in developing advanced repair processes to restore blisks to prime condition. Today, MTU is a global leader in blisk technology with sample programs including the PW300, PW500, CF34, PW6000, GE90 and the GP7000 engines. Fault detection on a turbine disk. Key processes: Adaptive milling Chromium and nickel plating and stripping Laser welding Non-destructive testing Plasma spray coating Surface treatments Thermal coating of an IGT life-limited part. 14
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Airfoils Cold-section airfoils MTU Maintenance has a wide range of repair capabilities for fan, as well as low- and highpressure compressor airfoils. Tip welding, surface finish restoration and coating applications for the cold-section airfoils are standard processes at MTU. Additionally, the company has developed special repair techniques, such as the erosion-resistant coating MTU Plus ERCoat eco. Erosion is a major cost driver for engine operation. Its effects lead to increased material costs due to higher scrap rates, higher fuel consumption and shorter on-wing times. MTU Plus ERCoat eco is an advanced nano-coating technology which optimally protects compressor airfoils from erosive attack, both increasing service life and improving efficiency. MTU Plus Tip Protection applied to engine compressor blades. 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) MTU Plus ERCoat eco Erosion-Resistant Coating MTU Plus Tip Protection Adaptive milling of a CF34 fan blade s leading egde. 16
Hot-section airfoils Hot-section airfoils are exposed to extreme conditions during engine operation. They must withstand exceptionally high temperatures and pressures. Therefore, highly specialized repairs and treatments are needed to make sure these parts can reliably perform at full potential. MTU Maintenance offers a broad spectrum of repair processes to increase the service-life of hot-section airfoils. One such process is MTU Plus Tip Protection, an innovative technique for re-hardfacing worn tips of turbine blades, which sets the benchmark for abrasion protection. Another example of MTU s repair engineering expertise is MTU Plus Balance Stripping: during this process, each blade is continuously measured to determine exactly how much coating material must be removed. Through this stripping method, blades can be repaired three times during their service life instead of just once. In addition to blade repairs, MTU Plus Airfoil Replacement Technology ensures complete reparability of hot-section vanes. The optimized coating technology brings any damaged vane back into serviceable condition. Guaranteeing a zero scrap rate, this method avoids the necessity for cost intensive new material usage. Key blade processes: Adaptive milling Chemical vapor deposition coating (CVD) Electron-beam physical vapor deposition coating (EB-PVD) Full repair/rejuvenation Laser drilling MTU Plus Balance Stripping MTU Plus Laser Powder Cladding (tip repair) MTU Plus Tip Protection MTU Plus Under-Platform Coating Key vane and shroud processes: Chemical vapor deposition (CVD) Fluoride ion cleaning (FIC) Thermal barrier coating (TBC) Throat area control/restoration MTU Plus Airfoil Replacement MTU Plus Brazing Engine turbine vane after fluoride ion cleaning. The blades are cleaned prior to coating. Handling of a LM2500 high pressure turbine blade. 17
Cases and frames Cases and frames are among the most highly stressed parts of an engine. During operation they are subject to high levels of mechanical strain. The repair technologies employed to restore these parts to serviceable condition are complex and demanding. Among these are technologically advanced welding and plasma repair processes. Field experience has shown that V2500 diffuser cases with an on-wing time of more than 25,000 flight hours tend to crack in the rear outer flange area. MTU Maintenance s flange replacement repair replaces the weakened cast flange by mating a new flange to the case wall. In a process unique to MTU, this can be accomplished without the need for prior machining. Utilizing electron beam welding technology, material removal is minimized, thereby retaining complete component strength in the repaired area. This advanced repair combines higher parts durability with cost effectiveness and a short processing time. A further example is microplasma-welding, a mechanical process which achieves high welding rates while reducing the risk of heat distortion of the parts. By keeping the heataffected zones appreciably smaller this process stands out as a distinctly material-friendly method. An engine case undergoing heat treatment during the repair process. 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. 18
Combustor The highest temperatures during engine operation occur in the combustor section. These extreme temperatures make it essential to protect combustor parts by using technologies and features such as thermal barrier coatings and air cooling holes. To provide optimum heat protection, MTU Maintenance has developed unique and reliable repair processes for critical, highly stressed combustor components, with the aim to extend on-wing times. Some of these, such as weld section and dimple overhang repairs fully avoid material replacement. MTU Plus Thermal Barrier Coating applies the internally developed Metco2460NS to the inner and outer liner, which improves thermo mechanical strength and is proven to avoid adverse spalling. In addition, increased isolation properties significantly reduce base material temperature. The cumulative effect is improved parts durability and lower scrap rates all of which result in reduced maintenance costs for the customer. Key processes: Extensive weld repairs Section replacements MTU Plus Dimple Spad Replacement MTU Plus Thermal Barrier Coating MTU Plus Thermal Barrier Coating of a CF6-80 combustor. 19
Teardown services Engines at the end of their service life remain a valuable asset. Even after the phase-out of the engine, owners can draw a profit by recycling various materials such as tungsten, titanium, nickel and aluminum as well as by repairing salvageable components. In doing so, not only the customers but also the environment benefit from retiring mature engines. MTU Maintenance has specialized in recovering high-value parts from retired engines, such as high-pressure compressor and turbine airfoils. Once repaired to strict standards, these parts can be re-installed in engines which would have otherwise required expensive new part replacements. Thanks to innovative repair processes developed and continuously optimized by MTU, a broad range of engine parts can be refurbished. The reliability and quality of such parts matches that of new ones. The company carries out the entire range of services on behalf of its customers from the disassembly of a runout engine into single components, to the repair of the parts. Cleaning CF6-50 engines standing on MTU Maintenance Canada s flowline and inspection to segregate scrap parts from salvageable ones is also included in the service. Disassembly of a V2500 engine on the teardown flow-line at MTU Maintenance Hannover. 20
Smart Repair Solutions Preparing for the balancing of a CF34-10 fan module. In response to current market trends, MTU Maintenance has introduced a new product offering called MTU Plus Mature Engine Solutions. The services are targeted at airlines and lessors who operate aging engines. Since material is the decisive factor when it comes to shop visit costs, MTU will perform a tailored evaluation of the engine hardware to find the most effective solution. Material can be salvaged from both customerowned engines and third party teardown engines. Besides parts evaluation and repair, the services performed may also include bag & tag teardown, extensive parts management as well as the storage and re-marketing of used serviceable material. Smart repair services focus on the intelligent combination of tailored workscoping, MTU Plus repairs and used serviceable material sourcing to maximize customer benefits at minimal cost. Non-destructive testing of engine blades in the thermography machine. 21
Accessory repair and LRU management MTU Maintenance also refurbishes and repairs engine accessories. These are parts, which are not core engine components but are essential for its operation, such as starters, fuel and hydraulic pumps, actuators, sensors, valves and tubing. MTU Repair Services offers a comprehensive spectrum of accessory repairs, which is being constantly widened and fine-tuned. Customers benefit from this additional in-house competence as their engines are returned as quickly as possible back into service. The repair of accessories requires expertise and experience. MTU Maintenance has both. The company has been supporting commercial customers for many years, and MTU Aero Engines has been handling the vast majority of aviation propulsion systems for the German Air Force and is responsible for their technologically advanced accessories. Further, a dedicated team of engineers is committed to the development of new accessory repair processes. MTU Maintenance has developed all-round carefree service packages under which it not only repairs line-removed accessories but also provides dependable and professional support for all of the customer s line replaceable units. Customers can choose from several state-ofthe-art support levels ranging from maintenance and repair services to comprehensive support programs up to complete LRU management. The latter can also be purchased as part of MTU Maintenance s Total Engine Care (TEC ) program. A brand new fuel control test rig at the accessories center of excellence in Vancouver. 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) Repair of engine harnesses and tubes in the Vancouver shop. 22
Total Part Care (TPC ): the one-stop shop for parts The high rack warehouse for small- to medium-sized engine components at MTU Maintenance Hannover s new logistics center. With its many years of experience in engine maintenance, MTU Repair Services offers customized and cost-effective parts provisioning solutions. Total Part Care (TPC ) is the company s innovative all-encompassing product for engine and industrial gas turbine parts, as well as accessories. TPC guarantees a smooth supply of spare parts and the availability of repair and support services irrespective of location. Customers give MTU Maintenance full logistical responsibility for their contracted parts supply with the assurance of fast turnaround times and on-time delivery. Assembly of a fan module at MTU Maintenance Zhuhai. 23
An MTU Aero Engines Company MTU Maintenance Hannover GmbH Münchner Straße 31 30855 Langenhagen Germany Tel. +49 511 7806-0 Fax +49 511 7806-2111 hannover@mtu.de www.mtu-hannover.de MTU Repair Services Tel. +49 511 7806-9084 AOG +49 171 4314333 partsrepair@mtu.de GER 01/15/H/00000/DE/EB/E