CFM56 Combustor Module

Reliability Overview

CFM56 Symposium
June 2017 – Milan
Agenda
Overview
Combustor cross-section/nomenclature
Removal drivers
Liner configurations
• Hot and sandy upgrades
• Liner condition data request

Field program: pre-tech insertion inner/outer liner

support cracking
• Background
• ESM/SB changes

AMM/inspection updates
2 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
Overview
Combustor exhibiting high on-wing reliability and low SV rate
• 3 % of UERs
• 2 % of SVs

CMAS attack of liners is primary cause of combustor removals

• Hot and sandy upgrades to address liner durability in CMAS environment

Recent IFSD event related to support leg cracking on pre-Tech

Insertion liners
• Proactive maintenance actions (SB and ESM changes) to improve
durability of pre-TI liners

Continuing support to AMM / ESM clarification to improve

inspections and maintainability
3 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
 Combustor Assembly Nomenclature

Outer Liner

Inner
Liner Inner Liner
Supports

Outer Liner
Supports
4 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
5B/7B Configurations Overview
Pre-Tech Insertion (Pre-TI) Tech Insertion (TI) HS188 (Improve Durability) (TI)

Thick TBC Thin TBC Thick TBC Thin TBC Thin TBC

TI Combustor Secondary dilution

moved forward on Multi-hole patches on
inner / outer liners 3rd panel of inner liner

NOx level
A
improvements

Outer Liner Inner Liner

Improved Durability
(HS188) combustor
Additional
multi hole
patches

Hot and sandy / CMAS

durability improvements
5 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
 Combustor Removal
Drivers

6 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
Combustor Removal Drivers
CFM56-5B+7B Combustor Removal Causes
35
30
CMAS
25
20 All Other

15
10
5
0
Inner Outer Distress Liner Chamber Dome Ferrule Igniter Deflector Swirler
Liner Liner Distress Retrofit
Distress Distress

Data from 2014 to present

Liner driven removals 76%

Confirmed CMAS at least 33% of liner driven removals

Inner/Outer liners drive majority of recent combustor removals

CMAS primary driver of liner distress, especially in hot and sandy regions

7 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
CMAS Distress Mode – Liners
Typical combustor removals in hot/sandy environments due
to outer liner burn-through
Root cause understood - CMAS
1. CMAS results in thermal barrier coating (TBC) spallation
2. Temperature increases and overhang closes
3. Film cooling disrupted
4. Distress proceeds downstream axially aligned with each cup

CMAS (Ca-Mg-Aluminosilicate)
• Low melting alloyed oxide
deposit that causes
deterioration of TBC by
destroying compliance of
TBC columns

8 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
 CMAS Recommended
Configurations

9 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
CMAS Recommended Configuration
Pre-Tech Insertion Combustor Liners
Typical distress occurs on outer liners first
• TBC spall due to CMAS attack
• Typical of hot and sandy regions (can occur in any environment however)

Recommended for hot and sandy regions:

1. Multi-hole patch
• Will reduce CMAS and TBC Spallation
• Panel 1 TBC temperature decrease
• SB 72-0799 (5B) and 72-0817 (7B)
2. Thin TBC
• Less prone to spallation
• SB 72-0816 (5A), 72-0765(5B), 72-0691(5C) and 72-0835 (7B)
3. 1317M56G14 Outer Liner
• Advanced TBC - better resistance to CMAS attack
• SB 72-0845 (5A), 72-1004 (5B), 72-0734 (5C) and 72-0889 (7B)

Note: Thick TBC recommended for customers operating in neutral

(low risk of CMAS) environments
10 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
CMAS Recommended Configuration
Tech Insertion Combustor Liners
Typical distress occurs on inner liners first
• TBC spall due to CMAS attack
• Typical of hot and sandy regions (can occur in any environment however)
Recommended for hot and sandy regions:
1. Thin TBC
• Less prone to spallation
• 2256M23G04 (inner liner) and 2256M22G02/G04 (outer liner)
2. Improved Durability Combustor Assembly P/N 2480M46G01
• Additional multi hole patches and preferential cooling to reduce TBC / metal
temperatures
• Thin TBC
• Material change from Hast X to HS188 for additional metal temperature capability

Note: Thick TBC recommended for customers operating in neutral (low risk
of CMAS) environments

11 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
Data Request
CFM requests photos of combustor assemblies during
routine BSI interval:

 TI: 2480M46G01
(HS188/hot and sandy config)

 PreTI: 1317M56G14
(Advanced TBC coating config)
Example Photographs
Thank you to customers that already provided photos

Send combustor assembly\photos to CFM Combustor Module Leader:

Scott Yeager: scott.yeager@ge.com
12 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
 Pre-Tech Insertion
Inner/Outer Liner
Support Cracking

13 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
Event Description
IFSD event April 2016
• Stall and high core vibration during climb
• Crew reported uncommanded shut down
• Metal found in tailpipe, engine replaced

Disassembly findings:
• Combustor: aft support rings separated 100%
• HPT Nozzles: distress and missing material especially near 12:00
• Rotating FOS: missing ~115 degree sector of catenary arm to tip
• Significant downstream damage

Relevant Engine history

• CSN: 36K, CSSV: 17K
• Previous SV – Combustor Support Legs weld repaired (Inner and
Outer Liner)
14 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
Event Progression
Inner Liner Support
1 Legs - cracking and
100% separation (LCF)
2 3
Outer Liner Support Legs -
2 cracking and 100% separation
(HCF/mixed mode)
1

4 Combustion Chamber Drops

3 Thermal distress occurs at

12:00 location on HPT Nozzles
(LE and Inner Band)

AINS, Nut Cover, Static FOS: Thermal Distress Near 12:00

4 Rotating FOS: catenary arm creep
HPT/LPT flowpath: downstream airfoil distress
15 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
Improved Liner Support Configurations
Current Configuration
Old Configuration: New Configuration:
Inner Liner HS188, lower stress shape
Hast-X
Rework Available All Tech Insertion
All Pre-Tech Insertion
2008 Release
• 72-0694 = 7B
• 72-0782 = 5A
• 72-0692 = 5B Rework
• 72-0649 =5C

New Configuration:
Old Configuration:
Outer Liner Hast-X
Hast-X, lower stress shape
No Rework Available
2012 Release
• 72-0888 = 7B
• 72-1004 = 5B

16 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
Proposed Maintenance Action: Inner Liner
Outer support rework SBs from cat 7 to cat 5 (part exposure)
• Complete – SBs 72-0694 (7B) / 72-0692 (5B)

New cat 3 SB to inspect inner support legs for cracking

• Pre-TI inner liners over 25K cycles
• Target issuance July 2017

Cancel ESM 72-42-03 Repair 011: aft support leg weld repair
• Target incremental changes release July 2017
Old Configuration: New Configuration:
Hast-X HS188, lower stress shape

17 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
Proposed Maintenance Action : Outer Liner
Cancel ESM 72-42-04 aft support leg weld repairs (old
configuration only)
• Target incremental changes release July 2017
• SPAD repair available (repair #018)

Old Configuration: New Configuration:

Hast-X Hast-X, lower stress shape

18 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
 AMM Limit Updates

19 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
 AMM Changes and Clarifications

Outer/Inner Liners Connected Cracks

• AMM limits extension for connected cracks published both 5B/7B AMM
• Old limits for connected cracks still applicable
• Cracks not connected when each one ends in burn through hole

Continuing support to AMM / ESM clarification to improve

inspections and maintainability
20 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
Combustion Chamber Inspection
 BSI guide for Combustor Chamber updated for 2016
 Update included more examples of common conditions
Inner Liner
Outer Liner

Deflector Plate Dome Area

Can Download from myCFM Portal

21 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
Summary
Combustor demonstrating high on-wing reliability and
repairability

“Hot and sandy” upgrades available to increase durability in

CMAS environments

Service Bulletins and ESM changes being released to address

support leg cracking

AMM / ESM updates implemented to improve inspection

clarity/limits

22 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
 Thank you

Grazie

23 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
 Additional Information

24 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
 5B/7B Configurations Overview
Pre-TI Combustor

Assembly P/N 1968M41G01 1968M41G02 1968M41G03 1968M41G04 Assembly P/N 1968M41G04 1968M41G03 1968M68G41 1968M41G03

Outer Liner P/N Outer Liner P/N 1317M56G14 1317M56G13 1968M63G19 1968M63G19
1317M56G08 1317M56G13 1317M56G13 1317M56G14
(last part list revision)

Inner Liner P/N

1317M57G05 1317M57G05 1317M57G05 1317M57G05 Inner Liner P/N 1317M57G05 2257M42G01 1968M64G04 2257M42G02
(last part list revision)

Intro Date
(first part list revision / last 1997 / 2006 1997 / 2011 1999 / 2011 2010 Intro Date 2007 2008 2011 2011
part revision)
Outer Liner Multi-Hole Y Y N Y
Outer Liner Multi-Hole N Y Y Y
Inner Liner Multi-Hole N Y N N
Inner Liner Multi-Hole N N N N
TBC Thickness Thin Thick Thick Thin
TBC Thickness Thin Thin Thin Thin (HiY)

Improved Outer Liner Lug Improved Outer Liner Lug Y Y Y Y

Y Y Y Y Ring Geometry
Ring Geometry

Improved Inner Liner Improved Inner Liner Support Y Y Y Y

N Y Y Y
Support Ring Geometry Ring Geometry

Liner Material Hast-X Hast-X Hast-X Hast-X

Liner Material Hast-X Hast-X Hast-X Hast-X
SB’s 72-0638_7B 72-0888_7B 72-0607_7B 72-0889_7B
72-0647_5B 72-1004_5B 72-0616_5B 72-1004_5B SB’s 72-0889_7B 72-0694_7B 72-0229_7B 72-0694_7B
72-1004_5B 72-0692_7B 72-0336_5B 72-0692_7B

New Make Spares

25 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan
 5B/7B Configurations Overview
TI Combustor

Assembly P/N 2256M26G01 2256M26G02 2256M26G03 2256M26G04 Assembly P/N 2256M26G02 2256M26G03 2256M26G04 2480M46G01

Outer Liner P/N

2256M22G01 2256M22G01 2256M22G03 2256M22G04 Outer Liner P/N 2256M22G01 2256M22G01 2256M22G02 2480M42G01
(last part list revision)
2256M22G03 2256M22G03 2256M22G04
Inner Liner P/N
2256M23G01 2256M23G02 2256M23G03 2256M23G04 Inner Liner P/N 2256M23G02 2256M23G03 2256M23G04 2480M43G01
(last part list revision)

Intro Date Intro Date 2006 2007-04 2010-10 ~2Q-2012

2006 2006 2006 2009
(first part list revision)
Outer Liner Multi-Hole N N N Y
Outer Liner Multi-Hole N N N N
Inner Liner Multi-Hole N Y Y Y
Inner Liner Multi-Hole N N Y Y
TBC Thickness Thick Thick Thin Thin
TBC Thickness Thick Thick Thick Thin
Improved Outer Liner Lug N N N Y
Improved Outer Liner Lug Ring Geometry Y Y Y
Y Y Y Y
Ring Geometry
Improved Inner Liner Y Y Y Y
Improved Inner Liner Support Ring Geometry
N N Y Y
Support Ring Geometry

Liner Material Hast-X Hast-X Hast-X HS188

Liner Material Hast-X Hast-X Hast-X Hast-X

SB’s Orginal Orginal 72-0644_7B 72-0795_7B SB’s Original 72-0644_7B 72-0795_7B 72-0890_7B
72-0658_5B 72-0782_5B 72-0888_7B 72-0658_5B 72-0782_5B 72-0852_5B
72-1004_5B

New Make Spares

26 / CFM Proprietary Information subject to restrictions on the cover CFM56 Symposium – June 2017 – Milan