Original Date: 10/18/1999
Revision Date: 01/18/2007
Information : Advanced Repairs
In the past, Orenda Turbines performed all repairs in accordance with the Original Equipment Manufacturer’s specifications. This approach did not place any emphasis on improved durability and promoted only conventional repair techniques. As a result, Orenda Turbines developed a Failure Modes and Effects Criticality Analysis (FMECA)-based system for determining certification requirements, and a design-approval process for certification.
Millennium technologies are now being applied to engines which were designed 20 to 30 years ago. Parts are being re-manufactured to increase part strength in weak areas, such as using a laser alloy on turbine blade tips to prevent tip erosion. Orenda Turbines also employs state-of-the-art techniques (e.g., laser reverse machining; water jet cutting and coating stripping; chemical vapor deposition coating; electron beam physical vapor deposition coating) during the repair process. A sophisticated cost-benefit analysis is performed to obtain realistic cost-savings information and help the company make informed decisions regarding repair techniques. This approach enables the most cost- effective repair for the entire life cycle to be performed.
The repair cost-benefit analysis cannot be calculated by comparing the new part price to the repair cost. The certification procedures must be based on a rigorous FMECA. By applying advanced technologies, Orenda can double component life in the case of older technology engines. Canada’s Department of National Defence (DND) sponsored a National Durability Initiative to foster cooperation between industry and national laboratories, and to apply advanced technologies to products. All repair techniques must be approved by civil and/or military airworthiness authorities under design approval organization status. Orenda Turbines’ use of advanced repair techniques are projected to save the Canadian Forces (CF) F404 Engine Fleet approximately $60 million (U.S.) through the year 2012.
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Point of Contact for this survey.