AC 33-9

Advisory
U.S. Department
of Transportation
Federal Aviation
Circular
Administration
Subject: Developing Data for Major Date: 4/30/10 AC No: 33-9

Repairs of Turbine Engine Parts Initiated by: ANE-110
1. Purpose.
a. This advisory circular (AC) provides information and guidance on developing the
technical data needed for major repairs of critical and complex turbine engine parts. This
guidance will help persons developing major repair data meet the requirements of Title 14 of the
Code of Federal Regulations (14 CFR) part 43 to restore the engine to at least equal to its
original or properly altered condition. This does not mean that a repaired part must be returned
to a factory-new condition. However, the engine on which the repaired part is installed must
remain airworthy and in compliance with the applicable regulations. For repairs of turbine
engines and parts, the applicable requirements are Airworthiness Standards: Aircraft Engines (14
CFR part 33) and Fuel Venting and Exhaust Emissions Requirements for Turbine Engine
Powered Airplanes (14 CFR part 34).
b. Additionally, this AC provides guidance to assist persons developing major repairs with
developing a continued operational safety plan. It also helps them evaluate engine parts
recovered from accidents and incidents prior to making a repair.
2. Applicability.
a. This AC provides guidance to all persons developing the technical data to substantiate
major repairs for critical or complex turbine engine parts, including type certificate (TC) and
supplemental type certificate (STC) holders.
b. This guidance is neither mandatory nor regulatory in nature and does not constitute a
regulation. It describes acceptable means, but not the only means, for demonstrating compliance
with the applicable regulations. The FAA (“we”) will consider other methods of demonstrating
compliance that a person developing repair data may elect to present. Terms such as “should,”
“shall,” “may,” and “must” are used only in the sense of ensuring applicability of this particular
method of compliance when the acceptable method of compliance in this document is used.
While these guidelines are not mandatory, they are derived from extensive FAA and industry
experience in determining compliance with the applicable regulations. On the other hand, if we
become aware of circumstances that convince us that following this AC would not result in
4/30/10 AC 33-9
compliance with the applicable regulations, we will not be bound by the terms of this AC, and
we may require additional substantiation as the basis for finding compliance.
c. This document does not change, create any additional, authorize changes in, or permit
deviations from, existing regulatory requirements.
3. Related References. Please check the FAA’s website at

http://www.faa.gov/regulations_policies/ for the latest revision of the following documents.
a. AC 20-62D, Eligibility, Quality, and Identification of Aeronautical Replacement Parts;

May 24, 1996.
b. AC 33.75-1A, Guidance Material for 14 CFR 33.75, Safety Analysis; September 26,
2007.
c. AC 39-8, Continued Airworthiness Assessments of Powerplant and Auxiliary Power
Unit Installations of Transport Category Airplanes; September 8, 2003.
d. AC 43-18, Fabrication of Aircraft Parts by Maintenance Personnel; March 24, 2006.
e. AC 120-77, Maintenance and Alteration Data; October 7, 2002.
f. Order 8110.37D, Designated Engineering Representative (DER) Handbook; August 10,

2006.
g. Order 8110.4C, Type Certification; August 14, 2008.
h. Order 8110.54, Instructions for Continued Airworthiness Responsibilities,

Requirements, and Contents; July 1, 2005.
i. Order 8120.2F, Production Approval and Certificate Management Procedures; January

30, 2009.
j. FAA Order 8120.11, Disposition of Scrap or Salvageable Aircraft Parts and Materials;
February 12, 1996.
4. Background.
a. The designs of many critical and complex turbine engine parts, hereafter referred to as
“parts,” require the use of advanced design and test methodologies, comprehensive materials
data, and refined manufacturing techniques to achieve high levels of safety, reliability and
performance. A person developing a repair for a critical or complex part should have a thorough
understanding of the part’s design characteristics, operational environments, operating
requirements, and failure modes and effects. This knowledge is useful for determining if a repair
to a part is major and for developing the appropriate technical data for FAA approval.
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4/30/10 AC 33-9
b. Our previous evaluations of major repair data packages for critical and complex parts
have indicated that the data were not always adequate to support substantiation of the repair.
Data developed for major repairs of critical or complex parts may typically include rigorous
analyses and tests to show the engine on which the repaired part is installed will be at least equal
to its original or properly altered condition. An original or properly altered condition is an
airworthy condition that existed before the need for the proposed repair. An airworthy condition
means the aircraft conforms to its type certificate and is in a condition for safe operation.
c. This AC uses part categorization as an aid for persons to determine whether a part being
repaired is a critical or complex part. In addition, this AC recommends certain information be
included in major repair data packages to improve consistency and completeness. In Appendix 2
of this AC, we also provide templates for repairs related to various engine part families to assist
repair developers in identifying the technical elements and regulatory requirements when
developing and substantiating similar repairs, if determined major.
5. Part Categorization. This AC categorizes parts based on their most severe potential failure
effect using various methods for assessing malfunctions and failure modes. To assess
malfunctions and failure modes, repair developers may use the failure modes and effects
assessment described in Appendix 1 of this AC or other acceptable analytic techniques. Refer to
AC 33.75-1A for examples of other acceptable techniques.
a. Part Categories. The categories used in this AC are consistent with categories found in
Order 8120.2 and AC 39-8, and used in AC 43-18. The part categories are:
(1) Category 1. A product, i.e. engine, or part(s) thereof, whose failure could prevent
continued safe flight and landing; resulting consequences could reduce safety margins, degrade
performance, or cause loss of capability to conduct certain flight operations. A Category 1 part,
for the purpose of this AC and Orders 8110.37 and 8110.4, is a critical part.
(2) Category 2. An engine or part(s) thereof whose failure would not prevent
continued safe flight and landing; resulting consequences may reduce the capability of the
aircraft or the ability of the crew to cope with adverse operating conditions or subsequent
failures. For the purpose of this AC and Order 8110.4, a Category 2 part is typically a complex
part that may affect a critical part.
(3) Category 3. An engine or part(s) thereof whose failure would have no effect on
continued safe flight and landing of the aircraft. The only consequence would be partial or
complete loss of engine thrust or power (and associated engine services). For single engine
applications, consider changing part categorization to Category 1 or 2 if complete loss of thrust
could prevent continued safe flight and landing or reduce the ability of the crew to cope with
adverse operating conditions or subsequent failures.
b. Tables of Potential Failure Effects. The following tables provide some potential failure
effects for Categories 1 and 2. We also listed a few examples of parts whose malfunction or
failure could result in one or more of the listed potential failure effects.
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4/30/10 AC 33-9
Table 1. Category 1 Engine Parts
Potential Failure Effects Part Examples
(1) Non-containment of high- Life-limited parts

energy debris.
Main engine mounts, with no redundant load
(2) Concentration of toxic carrying features
products in the engine bleed air
intended for the cabin, and High pressure vessels (for example, casings
sufficient to incapacitate crew or subject to compressor discharge pressure and
passengers. combustor pressure)
(3) Significant thrust in the Containment structures

opposite direction to that
commanded by the pilot. Fan blades
(4) Uncontrolled fire. Fuel system shut-off
(5) Failure of the engine mount Primary structures (for example, structures that
system leading to inadvertent provide support and rigidity of the main engine
engine separation. backbone and for attachment of engine to
airframe)
(6) Release of the propeller by the
engine, if applicable. Thrust reverser control component if thrust
reverser control component is part of the engine
(7) Complete inability to shut the type certificate.
engine down.
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4/30/10 AC 33-9
Table 2. Category 2 Engine Parts
Potential Failure Effects Part Examples
(1) Controlled fires (that is, those brought under Rotating parts that are not life-limited
control by shutting down the engine or by onboard (for example, compressor and turbine
extinguishing systems). airfoils)
(2) Case burn-through where it can be shown there is Accessory gearbox and internal
no propagation to hazardous engine effects. components
(3) Release of low-energy parts where it can be shown Engine bearings

there is no propagation to hazardous engine effects.
Spinners
(4) Vibration levels that result in crew discomfort.
Main engine mounts with redundant load
(5) Concentration of toxic products in the engine bleed carrying features
air for the cabin sufficient to degrade crew
performance. Static gas path parts (for example, vanes
and seals)
(6) Thrust in the opposite direction to that commanded
by the pilot, below the level defined as hazardous. Control system actuators
(7) Loss of integrity of the load path of the engine Combustion liners
supporting system without actual engine separation.
Fuel nozzles
(8) Generation of thrust greater than maximum rated
thrust.
(9) Significant uncontrollable thrust oscillation.
(10) Loss of protection such as loss of overspeed

protection or loss of containment case capability.
(11) Effect or influence on a Category 1 part.
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4/30/10 AC 33-9
6. Developing Data for Major Repairs. To improve the quality and adequacy of data for
major repairs of critical (Category 1) and complex (Category 2) parts, we recommend persons
developing the major repair data include the following information in their repair data packages:
a. A description of:
(1) The part to be repaired, including the part number.
(2) The repair, including any associated limitations. For example:
• The extent of the damage the repair covers.

• How many times, if limited, the repair can be repeated on a single part.
b. The part categorization, if categorization is used.
c. The applicable sections of the regulatory requirements from the certification basis for
the engine(s) that the repaired part is eligible for installation on.
d. An applicability assessment of any related service difficulty reports and airworthiness

directives (ADs) to the part.
e. The complete step-by-step “how to” instructions for accomplishing the repair. This
should include drawings and specifications, new materials and fabrication details, if any.
f. Technical data. The regulations require that when performing a major repair, the work
be done in accordance with technical data approved by the Administrator. Technical data also
includes substantiation data to show compliance to applicable regulatory requirements.
(1) Category 1 parts. We recommend that persons developing data in support of a

major repair of a Category 1 part meet with the project aircraft certification office (PACO) to
develop a substantiation plan before submitting a data package. The plan should outline the
pertinent technical and regulatory requirements and testing, as needed to develop the data and
substantiate the repair. In addition, the plan should identify process controls, inspections or tests,
or both, required in the step-by-step procedures to mitigate the risks of improperly completing
the repair.
Note: For major repairs of Category 1 parts, Order 8110.37, Designated

Engineering Representative (DER) Handbook, requires DERs notify the PACO
prior to approval of the data. Order 8110.4, Type Certification, requires PACO
engineers notify the accountable directorate of a major repair of a Category 1 part
and coordinate data approval with the certificate management ACO.
(2) Category 2 parts. We recommend persons developing data in support of a major

repair of a Category 2 part use the templates in Appendix 2 of this AC or develop a new
template, if applicable.
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4/30/10 AC 33-9
(a) Together with industry we developed the sample templates in Appendix 2 for
typical repairs that were previously determined major. These templates may be used as aids to
identify technical elements and regulatory requirements to be considered when developing your
data and substantiating your repair for similar repairs to Category 2 parts, if determined major.
These templates are not all inclusive; rather, they are for a limited number of typical Category 2
parts.
(b) Persons using these templates should discuss any questions with the PACO. If
a template is not available for a proposed major repair, consider developing a new template.
Using a format consistent with the templates provided will help ensure that your template
identifies the applicable technical considerations and regulatory requirements. You should
review the new template with the PACO early in the project to determine if any additional data
will be needed.
g. An assessment of the applicability of the Instructions for Continued Airworthiness

(ICAs). If ICAs are affected or needed, supplemental ICAs must be provided. Refer to FAA
Order 8110.54, Instruction for Continued Airworthiness Responsibilities, Requirements, and
Contents, for further information.
7. Developing a Continued Operational Safety (COS) Plan.
a. COS Management Plan. Repair approval holders and persons making a major repair
must perform their work in accordance with approved technical data and applicable performance
regulations. If service experience or FAA oversight audits show the repair data was inadequate,
in error, or the work was performed improperly, the FAA will evaluate the safety impact and
take appropriate action. That action may be to issue an AD, Special Airworthiness Information
Bulletin (SAIB), or other appropriate document. In such a case, the repair approval holder or the
person who performed the work, or both, may be requested to develop a corrective action
program or a design change to restore safety to an acceptable level. Therefore, the FAA
recommends that repair approval holders who develop data for major repairs and persons who
use that data to perform maintenance develop a COS management plan.
b. Part Identification. To facilitate part tracking as part of a COS management plan, we

recommend that persons proposing a repair provide supplementary part identification
procedures.
(1) Any original part markings, such as the part number and serial number, should be
maintained. Supplementary identification should be permanent and legible. It should include a
name, trademark, or other symbol of the person performing the repair. Supplementary
identification combined with adequate maintenance records ensures that if a problem occurs the
affected parts can be identified, tracked, and, if necessary, removed from service.
(2) Parts subject to an airworthiness limitation should retain their original markings in
accordance with § 45.14. When adding supplementary identification to the part, repair
developers must ensure that their repair identification does not adversely impact the part. For
example, do not apply repair identification on contact surfaces or near radii of parts because
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4/30/10 AC 33-9
these are typically areas of high stress concentrations. When impractical, i.e., the part is too
small or applying the repair identification would compromise part integrity, we recommend
entering part identification information in the part’s maintenance records.
c. Maintaining Records. Federal Aviation Regulations have specific minimum time

requirements for the retention of certain maintenance records. Experience has shown that the
maintenance records and the availability of repair data can be extremely valuable for accident
investigation and corrective action development. Therefore, we recommend that the data
approval holder and persons performing the major repairs, for example, repair stations,
owner/operators, or air carriers, keep records that include at least the following:
(1) A record keeping plan to:
(a) Identify where repaired parts are in service or who the customer
owners/operators of the parts are.
(b) Retain records of the work performed during the repair.
(c) Retain the technical data for the parts.
(2) Documentation of the quality control of the repair.
(3) A means to monitor the performance of repaired parts in service.
(4) A means to identify and isolate parts that do not conform to approved data or are
unairworthy.
(5) The capability to analyze failed parts and identify root causes of failures in order to
develop and implement corrective action(s) when needed.
8. Repair of Engine Parts Recovered from Accidents or Incidents.
a. We recommend persons repairing parts recovered from accidents or incidents inspect

these parts for hidden damage prior to beginning a repair. Repair stations are required to
perform this inspection per regulation, refer to § 145.211(c). This pre-repair inspection will
ensure the part does not have hidden damage or has not been overstressed or overheated, which
is not always obvious from visual or dimensional inspection.
b. The ICAs may be insufficient for this pre-repair inspection. Therefore, developing
special instructions for evaluating repairability of such parts may be appropriate. We suggest
repair developers review the part’s maintenance and operational records for relevant service
information and verify the history and origin of the parts when making that determination. Parts
that are determined to be unsuitable for repair should not be repaired and should be returned to
the owner with the appropriate entry in the part maintenance record. Refer to AC 20-62 and
Order 8120.11 for further information on the airworthiness and eligibility of such parts. Parts
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4/30/10 AC 33-9
otherwise eligible for repair which do not exhibit evidence of irreparable damage may be
repaired.
Francis A. Favara
Manager, Engine and Propeller Directorate
Aircraft Certification Service
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Appendix 1
APPENDIX 1. FAILURE MODES AND EFFECTS ASSESSMENT
1. A failure modes and effects assessment is a qualitative process, independent of failure rates
and probabilities, by which each failure mode of a part in the engine system is analyzed. Some
top-level functions typically considered in an engine failure modes and effects assessment are:
• Maintaining structural integrity, including allowed overspeed and overtemperature

exceedances;
• Providing thrust or power;
• Operating in inclement weather;
• Providing customer bleed, power extraction, or both; and
• Meeting fuel consumption, exhaust gas temperature, vibration, emission or noise limits.
2. Each system and subsystem of the engine is broken down into its basic functions using a
functional block diagram consistent with the Air Transport Association policy for identification
and definition of systems.
3. The functional block diagram defines each system and subsystem, and all their functions, in
the turbine engine. The experienced safety engineer performing the analysis determines the part-
to-part and part-to-system influences in both directions (input and output). The process flow is
shown in figure A1.1 below:
Figure A1.1. Process Flow Diagram
Determine input Identify parts Determine functions

functions from other within the system provided by the part
engine systems being analyzed being analyzed
Determine consequence of
failure to provide the desired
function by design intent
Categorize part by outcomes Determine outcome on part,

in Tables 1 and 2 of this AC engine system, and the engine
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Appendix 1
4. The part categorization process is built around the fundamental understanding of the part
function and its potential effects on physically or functionally mating parts or both. The
fundamental premise in the categorization process, and in the physical operation and function of
the turbine engine, is system interactions.
a. System interactions are influences a part, or a set of parts, can have on the turbine
engine, propulsion system, or aircraft through form, fit, or function, where
(1) Form is the shape, size, dimensions, and other physical measurable parameters that
uniquely characterize a part.
(2) Fit is the ability of a part to interface or interconnect, physically and functionally, at
the common boundaries with another part or system of the engine.
(3) Function is the action(s) the part is designed to perform in the engine.
b. These influences may extend beyond the component being classified, may be direct or
indirect, and may develop immediately or over time. Characteristics of these influences include:
(1) Direct influences, which are form and fit. These influences are based on physical
contact or interface clearances between adjacent parts.
(2) Indirect influences, which are functional in nature. These influences are not based
on physical contact, but may be aerodynamic, thermal, or vibratory.
5. The interactions where the consequence of failure is the furthest from the cause are the most
difficult to identify. Many fundamental relationships in part interactions and subsequent system
effects exist. Figure A1.2 below provides four examples.
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4/30/10 AC 33-9
Appendix 1
Figure A1.2. Part Interaction Considerations
Indirect Effect
1 Stage 1 HPT Effective HPC press. Stall margin Stall at limiting Part Interaction
Nozzle area/flow ratio consumption condition
Considerations
•Fluid interactions
• Air, fuel, oil
Indirect Effect
2 Fuel Pump Fuel flow Fuel to Starting Altitude re-light
•Direct interactions
Impeller schedule Combustor characteristic capability
• Mechanical
loading
• Aero loading
• Contact/wear
3 Time Relationship
Stage 2 HPT Cooling flow to Purge flow Hot gas
Critical part • Chemical
Nozzle rotor level ingestion temperature & •Indirect interactions
life
• Vibration
Direct Effect • Acoustical
4 Rotor Blade
Loads and
moments on
Local dovetail Dovetail or slot
LLP life impact • Primary air
loading bottom life
disk • Secondary air
• Control
system
• Structural
dynamics
• Sensor
systems
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Appendix 2
APPENDIX 2. SAMPLE TEMPLATES
1. Purpose. This appendix includes templates for major repairs related to 17 engine part
families, listed in Table A2-1 below. The FAA selected them based on typical repairs for
complex turbine engine parts submitted as major. These templates will aid repair developers in
identifying the technical elements and regulatory requirements they should consider when
developing and substantiating similar major repairs. Persons developing data must ensure that
any additional technical criteria or regulatory requirements are met for their specific proposed
major repair.
2. Template Instructions. Each template shows both shaded and un-shaded (clear) cells
corresponding to the sample repair and its specific engineering, technical and regulatory
considerations. Those cells that are generally applicable are un-shaded. However, the repair
developer must decide if the cells need to be completed or not. The templates identify the
current part 33 regulations, Amendments 1-20 inclusive, applicable to turbine engines as an
example. When reviewing the associated regulatory considerations, the repair developer should
determine applicability and identify the corresponding methods of compliance to be used to
provide the supporting data.
a. The certification basis of the engine(s) on which the repaired part is eligible for
installation identifies the regulatory requirements that should be reviewed for applicability.
Applicable regulations are those regulations that must be evaluated to determine that the engine
remains in compliance and airworthy with respect to the repair work performed. For critical and
complex parts, the repair developer should determine which of the original compliance findings
to those applicable regulations could be affected by their proposed major repair. To do this, you
must understand how the part to be repaired functions in the engine operating environment, and
the associated regulatory requirements. Repair developers substantiate their repair to these
requirements, using acceptable methods, to show that the condition of the engine on which the
repaired part is installed will be at least equal to its original or properly altered condition.
b. Acceptable methods are identified as follows:
(1) D - Documentation (for example, Instructions for Continued Airworthiness).
(2) A - Analysis of relevant data.
(3) I - Inspection (for example, metallurgical examination, hardness testing, Non-

destructive testing inspection).
(4) R - Rig testing.
(5) C - Component testing.
(6) E - Engine testing.
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4/30/10 AC 33-9
Appendix 2
(7) S - Similarity to previously FAA approved data. Repair developers will need to
show that the previously approved data is applicable to the new proposed repair, and to the
product type design if different than the type design for which the data was previously approved.
3. Sample Templates. If a template is not available for a particular major repair, the repair
developer can create or modify another as necessary.
Table A2-1. Sample Templates.

Template Number Title Page
1 Bearing Compartment and Carbon Seal 15
Parts Family
2 High Pressure Turbine (HPT) Blade Part 25
Family
3 Low Pressure Compressor (LPC) – High 36
Pressure Compressor (HPC) Blade Part
Family
4 Blades – Low Pressure Turbine (LPT) 46
5 Combustor Part Family 55
6 Externals Part Family (Tubes, Manifolds, 66
Ducts, Brackets)
7 Fuel Nozzle Part Family 75
8 Gearbox Housing Assembly Part Family 84
(Shafts, Gears, Housings)
Pressure Compressor (HPC) Stator Part
Family – Vane Sector (And Full Ring)
Type Stators
Presser Compressor (HPC) Stator Part
Family – Fixed Vane Type Stators
11 Major Engine Cases 112
12 Major Rotating (Non-Life Limited) Part 121
Family (Excluding Turbine Shaft
Coupling Part Family)
13 High Pressure Compressor (HPC)/High 130
Pressure Turbine (HPT)/Low Pressure
Turbine (LPT) Airseals (Non-Rotating)
And Shrouds (Stationary) Part Family
14 Static Structure Part Family (ducts, 138
bearing housings, etc.)
Pressure Compressor (HPC) Stator Part
Family – Variable Vane Type Stators
16 HPT Vane Part Family 157
17 Low Pressure Turbine (LPT) Vane Part 166
Family
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Appendix 2
Template 1
REPAIR SUBSTANTIATION CHECKLIST - BEARING COMPARTMENT AND

CARBON SEAL PART FAMILIES
Categories of Bearing Compartment & Carbon Seal Part Family Repair. Determine which repair
description best fits the repair proposal. If no repair description is appropriate, contact the FAA
Advisor for guidance.
CATEGORIES OF REPAIR DESCRIPTION

REPAIRS
1. Restoration of Protective Coating
• This repair includes touch-up coating
2. Weld or Braze Repair
• This repair excludes detail part replacement
• This repair includes detail part replacement
4. Assembly and/or Disassembly
• This repair assembles, disassembles, removes and replaces detail parts, or sub-
assemblies without use of permanent attachment techniques (i.e.; welding or
brazing). Assembly is either bolted or riveted.
5. Blend Repair
6. Dimensional Restoration by Coating or Plating
7. Bushing/Helicoil Repair
8. Straightening, Re-twist, or Reforming Repair
• This repair includes straightening of bent knife edges
9. Surface Treatment Repair
• This repair includes peening, vibratory tumble (e.g.; restoration of surface
finish/texture)
10. Machining Repair
• This repair includes lapping, skim cut, non-conventional machining.
11. Restoration of Adhesives, Bonding Agents, Potting Compound
When the cell under a category of repair is not shaded, the items listed under that requirement
should be reviewed for applicability, based on the repair design, and only the items pertinent to
this category of repair should be selected and addressed appropriately. Items not selected need
not be addressed.
An FAA-approved configuration means a new part (produced under a PC, TSO, or PMA) or a
previously approved repaired part.
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Appendix 2
CATEGORIES OF REPAIR
Req Repair Design Requirements to be 1 2 3 4 5 6 7 8 9 10 11
No. Identified and Substantiated.
1. Applicable Degradation Modes:
Select all that apply based on the
function of the part and its operating
environment in the engine. This section
provides the background for
establishing the substantiation
requirements.
a. Thermo-Mechanical Fatigue
b. Oxidation
c. Corrosion
d. Elevated Temperature-Induced
Changes (Creep, Diffusion,
Ageing, Temperature
Gradients)
e. Wear due to: Adhesion,
Abrasion, Corrosion, Erosion,
Cavitation, Fretting, Oxidation
f. High Cycle Fatigue
g. Rubbing, foreign object impact
damage, O3 chemical attack, etc.
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Appendix 2
2. Select all mechanical, metallurgical,
and physical properties of the part
affected by the repair design, and
assess their impact on the part’s
airworthiness:
Mechanical Properties:
a. Stress-Strain
b. Fracture Toughness
c. Fatigue Strength (S-N,
Goodman, Dwell Time)
d. Creep
e. Tensile Properties (Yield,
Strength, Elongation)
f. Hardness
g. Young’s Modulus
h. Natural Frequencies
Metallurgical Properties:
i. Chemical Composition (Alloy

constituents)
j. Microstructure (grain size –
shape - boundary precipitates,
gamma prime size and volume
fraction, etc.)
k. Melting Point
l. Corrosion Resistance
m. Oxidation Resistance
n. Wear Resistance (Consider
wear types in (1)(e))
o. Crack Propagation Rate
Physical Properties:
p. Density (weight)
q. Coefficient of Thermal
Expansion
r. Refractive Index (X-Rays)
s. Center of Gravity
t. Polar Moment of Inertia
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Appendix 2
3. Select all Material
Properties/Characteristics for
weldments or brazed joints that apply
and evaluate them and their interface
with the parent metal. The effect of any
changes to the part’s metallurgy, as a
result of welds or braze, should be
evaluated for airworthiness.
a. Microstructure (grain size, grain

shape, grain boundary precipitates,
gamma prime size, and volume fraction,
etc.)
b. Porosity (weldment)
c. Diffusion Zone (brazing)
d. Heat Affected Zone (welding)
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Appendix 2
4. Select all Coating
Properties/Characteristics that apply
and evaluate them and their interface
changes to the part’s physical and
operational capability, as a result of the
coating, should be evaluated for
airworthiness.
a. Coating Material Composition

b. Thickness, Coverage & Uniformity
c. Coating and Diffusion Zone
Microstructure
d. Coating Hardness
e. Sintering
f. Strip Requirements/Process
g. Residual Stress
h. Resistance to Spalling
i. Thermal Resistance (coefficient of
thermal expansion for the coating)
j. Erosion Resistance
k. Bonding (Interface Contamination)
l. Hydrogen Embrittlement (Plating)
m. Compatibility With Base
Material/Other Coatings
5. Select surface treatment that applies
(without material removal) and evaluate
effect(s), if any, on airworthiness:
a. Burnishing
b. Peening
c. Butterfly Polish
d. Mass Media Finishing
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Appendix 2
6. Evaluate any degradation in the part’s
function or durability due to the
following processes, when applicable,
and assess its impact, if any, on existing
ICAs.
a. Machining, Milling, Broaching, or

Grinding
b. Non-traditional Machining
c. Welding, Brazing or Coating
d. Straightening, re-twisting, re-
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
j. Cleaning (chemical, power flash,
ultrasonic)
k. Residual Plating, Stripping, or
Cleaning Agents
l. Stress Intensity Factor (Kt)
m. Heat Treatment (time, temp,
atmosphere, etc.)
n. Plating
o. Dimensional Short-falls
p. Repetitive or Conflicting Repairs
q. Contamination
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Appendix 2
7. Establish the Applicability of the
Repair and the Repair Processing
Sequence or evaluate any changes to an
existing repair sequence for potential
impact on the airworthiness of the part.
8. Select all that may be potentially affected
by the repair design, and evaluate system
effect(s):
a. Structural Strength, including
major load paths
b. Heat Transfer
c. Secondary Airflow
d. Aerodynamics
e. Weight
f. Center of Gravity
g. Moment of Weight
9. Establish Measurable Characteristics
and the allowable tolerances for the
repaired part features and for any
replacement detail(s) and give due
consideration to mating part(s):
• Surface finish/texture
• Shotpeen Intensity/Coverage
• Bearing bore dimensions and
location characteristics
• Pressure Strength Test
• Flow Capacity test
• Dimensions, including heat
distortion effects
1) Roundness
2) Flatness
3) Parallelism
4) Concentricity
5) True Position Tolerances
6) Edge Distance Requirements
7) Finish Dimensions Requirements
10. Significant Operations Identified for
Validation that would include parameter
variability limits.
21
4/30/10 AC 33-9
Appendix 2
11. Manufacturing requirements for
fabrication of repair details or
replacement sections used to
accomplish repair:
• Drawings/Specs
• Quality Requirements
• Critical Process Validation needs
Applicable 14 CFR Part 33

Requirements
Subpart A – General
12. 33.4 Instructions for Continuous
Airworthiness (ICA's)
13. 33.5 Instruction manual for installing
and operating the engine
14. 33.7 Engine ratings and operating
limitations
15. 33.8 Selection of engine power and
thrust ratings
Subpart B – Design and
Construction; General
16. 33.14 Start-stop cyclic stress (low cycle
fatigue)
17. 33.15 Materials
18. 33.17 Fire prevention
19. 33.19 Durability (Note that 33.19 is
associated with 33.27; 33.63; 33.83;
33.87; 33.88; and 33.90)
22
4/30/10 AC 33-9
Appendix 2
20. 33.21 Engine cooling
21. 33.23 Engine mounting attachments and
structure
22. 33.25 Accessory attachments
23. 33.27 Turbine, compressor, fan, and
turbo-supercharger rotors
24. 33.28 Electrical and electronic control
systems
25. 33.29 Instrument connection
Repair Process Capability Technical
Substantiation Requirements
Subpart E – Design and
Construction; Turbine Aircraft
Engines
26. 33.62 Stress analysis
27. 33.63 Vibration
28. 33.65 Surge and stall characteristics
(Note 2)
29. 33.66 Bleed air system
30. 33.67 Fuel system
31. 33.68 Induction system icing
(operability aspects) (Note 2)
32. 33.69 Ignitions system
33. 33.71 Lubrication system
34. 33.72 Hydraulic actuating systems
35. 33.73 Power or thrust response
36. 33.74 Continued rotation
23
4/30/10 AC 33-9
Appendix 2
Req Airworthiness Standards to be 1 2 3 4 5 6 7 8 9 10 11
No. Substantiated
Engines (continued)
37. 33.75 Safety analysis
38. 33.76 Bird ingestion (operability aspects
of ingestion)
39. 33.77 Foreign object ingestion—ice
(operability aspects of ingestion)
40. 33.78 Rain and hail ingestion
41. 33.79 Fuel burning thrust augmentor
Subpart F – Block Tests; Turbine
Aircraft Engines
42. 33.83 Vibration test
43. 33.85 Calibration tests
44. 33.87 Endurance test
45. 33.88 Engine overtemperature test
46. 33.89 Operation test (Note 2)
47. 33.90 Initial maintenance inspection
48. 33.91 Engine component tests
(HCF/LCF bench testing)
49. 33.92 Rotor locking tests
50. 33.93 Teardown inspection
51. 33.94 Blade containment and rotor
unbalance tests (weight changes)
52. 33.95 Engine-propeller system tests
53. 33.96 Engine tests in auxiliary power
unit (APU) mode
54. 33.97 Thrust reversers
55. 33.99 General conduct of block tests
Part 33 -Appendix A – Instructions
for Continued Airworthiness
Part 33 -Appendix B- Certification
Standard Atmospheric
Concentrations of Rain and Hail
Part 34 – Exhaust Emissions
24
4/30/10 AC 33-9
Appendix 2
Template 2
REPAIR SUBSTANTIATION CHECKLIST – HIGH PRESSURE TURBINE (HPT)

BLADE PART FAMILY
Categories of HPT Blade Part Family Repair. Determine which repair description best fits the
repair proposal. If no repair description is appropriate, contact the FAA Advisor for guidance.
CATEGORIES REPAIR DESCRIPTION

OF REPAIRS
1. Overcoat Repair (without stripping)
2. Strip and Re-coat Repair
• This repair removes and replaces all types of coatings.
3. Weld or Braze Repair (excludes detail parts replacement)
• Includes restoration of airfoil tip and chord length
• Includes detail parts replacement
Including shot-peen, glass bead peen, and vibratory tumble (e.g.; restoration of surface
finish/texture).
6. Blend Repair
7. Blade Internal Cavity Cleaning Repair
8. Sulfidation or Corrosion Repair
9. Assembly and/or Disassembly. This repair removes and replaces details parts without the use of
permanent attachment techniques (i.e., welding or brazing), but assembly is either bolted or
riveted.
25
4/30/10 AC 33-9
Appendix 2
Req Repair Design Requirements to be Identified 1 2 3 4 5 6 7 8 9

No. and Substantiated. Repair Properties and
Requirements to be Identified and
Substantiated.
1. Applicable Degradation Modes: Select all
that apply based on the function of the part
and its operating environment in the engine.
This section provides the background for
establishing the substantiation requirements.
a. Thermo-mechanical fatigue
b. Oxidation
c. Corrosion
d. Elevated temperature-induced
changes (creep, diffusion, ageing,
temperature gradients)
e. Wear due to: adhesion, abrasion,
corrosion, erosion, cavitation,
fretting, oxidation
f. High-cycle fatigue
2. Select all mechanical, metallurgical, and

physical properties of the part affected by
the repair design, and assess their impact on
the part’s airworthiness:
26
4/30/10 AC 33-9
Appendix 2
Req Repair Design Requirements to be 1 2 3 4 5 6 7 8 9

No. Identified and Substantiated. Repair
Properties and Requirements to be
Identified and Substantiated.
a. Stress-Strain
c. Fatigue Strength (S-N, Goodman,
Dwell Time)
d. Creep
e. Tensile Properties (Yield, Strength,
Elongation)
f. Hardness

constituents)
j. Microstructure (grain size – shape -
boundary precipitates, gamma
prime size and volume fraction,
etc.)
k. Melting Point
n. Wear Resistance (consider wear
types in (1)(e))
p. Density (weight)
q. Coefficient of Thermal Expansion
27
4/30/10 AC 33-9
Appendix 2

Properties/Characteristics for weldments
or brazed joints that apply and evaluate
them and their interface with the parent
metal. The effect of any changes to the
part’s metallurgy as a result of welds or
braze should be evaluated for airworthiness.

fraction, etc.)
28
4/30/10 AC 33-9
Appendix 2

Properties/Characteristics that apply and
evaluate them and their interface with the
parent metal. The effect of any changes to
the part’s physical and operational capability
as a result of the coating should be evaluated
for airworthiness.

Microstructure
d. Coating Hardness
e. Sintering
g. Residual Stress
l. Hydrogen Embrittlement (Plating)
m. Compatibility With Base
29
4/30/10 AC 33-9
Appendix 2
Req Repair Properties and Requirements to be 1 2 3 4 5 6 7 8 9
5. Select Surface Treatment that applies
(Without Material Removal) and evaluate
a. Burnishing
b. Peening
c. Butterfly Polish

function or durability due to the following
processes, when applicable, and assess its
impact, if any, on existing ICAs.

Grinding
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
j. Cleaning (Chemical, power flash,
Ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
q. Contamination
30
4/30/10 AC 33-9
Appendix 2

7. Establish the Applicability of the Repair and
the Repair Processing Sequence or evaluate
any changes to an existing repair sequence for
potential impact on the airworthiness of the
part.
8. Select all that may be potentially affected by
the repair design, and evaluate system
effect(s):
a. Structural Strength, including major

load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight
31
4/30/10 AC 33-9
Appendix 2
Critical Measurable Characteristics
9. Establish Measurable Characteristics and
the allowable tolerances for the repaired
part features and for any replacement
detail(s) and give due consideration to
mating part(s):
a. Surface finish/texture
b. Shotpeen Intensity/Coverage
c. Bearing bore dimensions and
d. Pressure Strength Test
e. Flow Capacity test
f. Dimensions, including heat
distortion effects
• Roundness
• Flatness
• Parallelism
• Concentricity
• True Position Tolerances
• Edge Distance
• Requirements
• Finish Dimensions
Requirements
g. Airfoil Profile
• Leading & Trailing Edge
Contour
• Concave & convex contours
• Thickness
• Chord & Airfoil Length
• Twist/Lean/Bow
h. Tip Length
i. Airfoil wall thickness
10. Part Weight:
a. Mass
b. Moment
32
4/30/10 AC 33-9
Appendix 2
11. Platform width & (angel wing) Cross
Notch/Cross Shroud geometry
12. Cooling (Total flow, flow split, back flow
margin, hole exit geometry/angle/location,
cross-over hole size, metering plate)
13. Verification Plan with Significant Operations
Identified for Repair Source Qualification
14. Process Demonstration (including variability
requirements)
15. Part Demonstration/Inspection
16. Manufacturing requirements for fabrication

of repair details or replacement sections used
to accomplish repair:
• Drawings/Specifications
• Source Substantiation Requirements
Applicable 14 CFR Part 33 Requirements
18. 33.5 Instruction manual for installing and
operating the engine
19. 33.7 Engine ratings and operating limitations
20. 33.8 Selection of engine power and thrust
ratings
Subpart B – Design and Construction;
General
fatigue)
33
4/30/10 AC 33-9
Appendix 2
22. 33.15 Materials
associated with 33.27; 33.63; 33.83; 33.87;
33.88; and 33.90)
structure
28. 33.27 Turbine, compressor, fan, and turbo-
supercharger rotors
systems
Subpart E – Design and Construction;
Turbine Aircraft Engines
32. 33.63 Vibration
(Note 2)
36. 33.68 Induction system icing (operability
aspects) (Note 2)
43. 33.76 Bird ingestion (operability aspects of
ingestion)
34
4/30/10 AC 33-9
Appendix 2
Req Repair Properties and Requirements to 1 2 3 4 5 6 7 8 9
No. be Identified and Substantiated.
Aircraft Engines
53. 33.91 Engine component tests (HCF/LCF
bench testing)
58. 33.96 Engine tests in auxiliary power unit
(APU) mode
Part 33 -Appendix A – Instructions for
Continued Airworthiness
Standard Atmospheric Concentrations of
Rain and Hail
35
4/30/10 AC 33-9
Appendix 2
Template 3
REPAIR SUBSTANTIATION CHECKLIST – LOW PRESSURE COMPRESSOR (LPC)

– HIGH PRESSURE COMPRESSOR (HPC) BLADE PART FAMILY
Categories of LPC/HPC Blade Part Family Repair. Determine which repair description best fits
the repair proposal. If no repair description is appropriate, contact the FAA Advisor for
guidance.

OF REPAIRS
• This repair removes and replaces any and all types of coatings
• This repair includes restoration of airfoil tip and chord length
• This repair includes detail parts replacement
4. Assembly or Disassembly
• This repair removes and replaces detail parts without the use of permanent
attachment techniques (i.e., welding or brazing) but assembly is either bolted or
riveted.
5. Blend Repair
6. Remove and Restore Anti-gallant Coating
8. Straightening, Re-twist or Re-forming Repair
• This repair includes dent repair
• This repair includes shot-peen, glass bead peen, vibratory tumble (e.g., restoration of
surface finish/texture)
36
4/30/10 AC 33-9
Appendix 2
1. Applicable Degradation Modes: Select
all that apply based on the function of the
part and its operating environment in the
engine. This section provides the
background for establishing the
substantiation requirements.
b. Oxidation
c. Corrosion
Ageing, Temperature Gradients)
e. Wear due to: Adhesion, Abrasion,
Corrosion, Erosion, Cavitation,
Fretting, Oxidation
37
4/30/10 AC 33-9
Appendix 2
the repair design, and assess their impact
on the part’s airworthiness:
a. Stress-Strain
Dwell Time)
d. Creep
f. Hardness

constituents)
j. Microstructure (grain size – shape
- boundary precipitates, gamma
etc.)
k. Melting Point
n. Wear Resistance (Consider wear
types in (1)(e))
p. Density (weight)
38
4/30/10 AC 33-9
Appendix 2
and evaluate them and their interface with
the parent metal. The effect of any
changes to the part’s metallurgy as a result
of welds or braze should be evaluated for
airworthiness.

shape, grain boundary
precipitates, gamma prime size
and volume fraction, etc.)
39
4/30/10 AC 33-9
Appendix 2
the part’s physical and operational
capability as a result of the coating should
be evaluated for airworthiness.

b. Thickness, Coverage &
Uniformity
Microstructure
d. Coating Hardness
e. Sintering
g. Residual Stress
i. Thermal Resistance (coefficient
of thermal expansion for the
coating)
k. Bonding (interface
contamination)
l. Hydrogen Embrittlement (plating)
m. Compatibility with Base

a. Burnishing
b. Peening
c. Butterfly Polish
40
4/30/10 AC 33-9
Appendix 2
Req Repair Properties & Requirements to be
No. Identified and Substantiated. 1 2 3 4 5 6 7 8 9
following processes, when applicable, and
assess its impact, if any, on existing ICAs.
a. Machining, Milling, Broaching,

or Grinding
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
Ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
q. Contamination
7. Establish the Applicability of the Repair

and the Repair Processing Sequence or
evaluate any changes to an existing repair
sequence for potential impact on the
airworthiness of the part.
41
4/30/10 AC 33-9
Appendix 2
the repair design and evaluate system
effect(s):
Stress
a. Heat Transfer
b. Secondary Airflow
c. Aerodynamics
mating part(s):
d. Pressure Strength test
distortion effects
• Roundness
• Flatness
• Parallelism
• Concentricity
• Edge Distance Requirements
Requirements
g. Airfoil Profile
Contour
• Thickness
• Twist/Lean/Bow
h. Tip Length
42
4/30/10 AC 33-9
Appendix 2
10. Dovetail functional fit test
11. Part weight test:
a. Mass Weight
b. Moment Weight
12. Technical Plan with Significant Operations
Identified
requirements)
ratings
General
fatigue)
21. 33.15 Materials
associated with 33.27; 33.63; 33.83; 33.87;
33.88; and 33.90)
structure
43
4/30/10 AC 33-9
Appendix 2
supercharger rotors
systems
31. 33.63 Vibration
32. 33.65 Surge and stall characteristics (Note 2)
aspects) (Note 2)
ingestion)
Subpart F – Block Tests; Turbine Aircraft
Engines
bench testing)
44
4/30/10 AC 33-9
Appendix 2
55. 33.94 Blade containment and rotor unbalance
tests (Weight changes)
(APU) mode
Rain and Hail
45
4/30/10 AC 33-9
Appendix 2
Template 4
REPAIR SUBSTANTIATION CHECKLIST - LOW PRESSURE TURBINE (LPT)

BLADE PART FAMILIES
Categories of LPT Blade Part Family Repair. Determine which repair description best fits the
OF REPAIRS
3. Weld or Braze Repair (excludes detail part replacement)
• Includes detail part replacement
6. Blend Repair
• This repair includes shot peen, glass bead peen, vibratory tumble (e.g., restoration of
surface finish/texture)
46
4/30/10 AC 33-9
Appendix 2
Req Repair Design Requirements to be
No. Identified and Substantiated. Repair 1 2 3 4 5 6 7 8
b. Oxidation
c. Corrosion
Ageing, Temperature Gradients)
e. Wear due to: Adhesion, Abrasion,
Corrosion, Erosion, Cavitation,
Fretting, Oxidation
47
4/30/10 AC 33-9
Appendix 2
a. Stress-Strain
Dwell Time)
d. Creep
f. Hardness

constituents)
etc.)
k. Melting Point
types in (1)(e))
p. Density (weight)
48
4/30/10 AC 33-9
Appendix 2
weldments or brazed joints that apply and
the part’s metallurgy as a result of welds or
braze should be evaluated for
airworthiness.

4. Coating Material Properties, Characteristics

& Processes:
a. Deposited Material Composition

Uniformity
c. Microstructure
d. Hardness
e. Sintering
f. Strip Process
g. Residual Stress
h. Lubricant Properties
i. Spalling Resistance
j. Thermal Resistance
k. Erosion Resistance
l. Bonding (Interface
Contamination)
m. Environmental Resistance
n. Diffusion Zone
o. Hydrogen Embrittlement Free
p. (Plating)
q. Compatibility With Base Material
49
4/30/10 AC 33-9
Appendix 2
a. Burnishing
b. Peening
c. Butterfly Polish

Grinding
d. Straightening, Re-twisting, Re-
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
Ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
q. Contamination

50
4/30/10 AC 33-9
Appendix 2
No. Identified and Substantiated. 1 2 3 4 5 6 7 8
effect(s):
major load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight

mating part(s):
distortion effects
• Roundness
• Flatness
• Parallelism
• Concentricity
• Edge Distance Requirements
Requirements
g. Airfoils Profile
Contour
• Thickness
• Twist/Lean/Bow
h. Tip Length
j. Throat Area
51
4/30/10 AC 33-9
Appendix 2
Req Repair Properties and Requirements to
No. be Identified and Substantiated. 1 2 3 4 5 6 7 8
10. Part Weight:
a. Moment
b. Mass
11. Platform width & (angel wing) Cross
Notch/Cross Shroud geometry
MPE Repair Process Capability
Technical Substantiation Requirements
12. Verification Plan with Significant
Operations Identified for Repair Source
Qualification
13. Process Demonstration (including
variability requirements)
of repair details or replacement sections
used to accomplish repair:
• Source Substantiation
Requirements
52
4/30/10 AC 33-9
Appendix 2
limitations
ratings
General
fatigue)
21. 33.15 Materials
associated with 33.27; 33.63; 33.83; 33.87;
33.88; and 33.90)
structure
supercharger rotors
systems
31. 33.63 Vibration
(Note 2)
aspects) (Note 2)
53
4/30/10 AC 33-9
Appendix 2
Turbine Aircraft Engines (continued)
ingestion)
Aircraft Engines
47 33.85 Calibration tests
bench testing)
(APU) mode
Rain and Hail
54
4/30/10 AC 33-9
Appendix 2
Template 5
REPAIR SUBSTANTIATION CHECKLIST - COMBUSTOR PART FAMILY
Categories of Combustor Part Family Repairs. Determine which repair description best fits the

OF REPAIRS
1. Strip & Recoat Repair
• This repair removes and replaces any and all types of coatings.
2. Blend Repair
• This repair includes straightening of bent flanges
4. Weld/Braze Repair
• Excludes Detail Part Replacement
5. Weld/Braze Repair
• Includes Detail Part Replacement
• This repair removes and replaces detail parts without use of permanent attachment
technique, (i.e. weld or braze); assembly is either bolted or riveted.
8. Dimensional Restoration by Coating or Plating.
55
4/30/10 AC 33-9
Appendix 2
Repair Properties and
Substantiated.
environment in the engine. This
section provides the background for
requirements.
a. Thermo-Mechanical
Fatigue
b. Oxidation
c. Corrosion
d. Elevated Temperature-
Induced Changes (Creep,
Diffusion, Ageing,
Temperature Gradients)
e. Wear due to: Adhesion,
Abrasion, Corrosion,
Erosion, Cavitation, Fretting,
Oxidation
g. Rubbing, foreign object
impact damage, O3 chemical
attack, etc.
56
4/30/10 AC 33-9
Appendix 2
Substantiated.

affected by the repair design and
airworthiness:
a. Stress-Strain
d. Creep
f. Hardness
i. Chemical Composition
(Alloy constituents)
j. Microstructure (grain size
– shape - boundary
precipitates, gamma prime
size and volume fraction,
etc.)
k. Melting Point
n. Wear Resistance (Consider
p. Density (weight)
Expansion
57
4/30/10 AC 33-9
Appendix 2
Substantiated.
weldments or brazed joints that
apply and evaluate them and their
interface with the parent metal. The
effect of any changes to the part’s
metallurgy as a result of welds or
airworthiness.
a. Microstructure (grain size,

grain shape, grain
boundary precipitates,
gamma prime size and
volume fraction, etc.)
d. Heat Affected Zone
(welding)
Material Properties/Degradation
Modes/Product Qualities/etc.
Technical Substantiation
Requirements
4. Coating & Plating Material Properties
Characteristics & Processes:
a. Deposit material
composition
b. Thickness, Coverage,
and Uniformity
c. Microstructure
d. Hardness
e. Sintering
f. Strip process
g. Residual stress
h. Lubricant properties
m. Contamination)
n. Environmental
Resistance
o. Diffusion Zone
p. Hydrogen Embrittlement
Free Plating
q. Compatibility with base
material
58
4/30/10 AC 33-9
Appendix 2
Substantiated.
b. Shotpeen
intensity/coverage
c. Bearing bore dimensions
and location
characteristics
d. Pressure strength test
e. Flow capacity test
f. Dimensions, including
heat distortion effects
• Roundness
• Flatness
• Parallelism
• Concentricity
• True position
tolerances
• Edge distance
requirements
• Finish dimensions
requirements
59
4/30/10 AC 33-9
Appendix 2
Substantiated.
6. Evaluate any degradation in the
part’s function or durability due
to the following processes, when
applicable, and assess its impact, if
any, on existing ICAs.
a. Machining, Milling,
Broaching, or Grinding
c. Welding, Brazing or
Coating
d. Straightening, Re-twisting,
Re-forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
j. Cleaning (Chemical, power
flash, Ultrasonic)
k. Residual Plating, Stripping,
or Cleaning Agents
m. Heat Treatment (time,
temp, atmosphere, etc.)
n. Plating
p. Repetitive or Conflicting
Repairs
q. Contamination
7. Establish the Applicability of the

Repair and the Repair Processing
Sequence or evaluate any changes to
an existing repair sequence for
potential impact on the airworthiness
of the part.
60
4/30/10 AC 33-9
Appendix 2
Req Repair Properties and Requirements
No. to be Identified and Substantiated. 1 2 3 4 5 6 7 8
8. Select all that may be potentially
evaluate system effect(s):
major load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight
distortion effects
g. Roundness
h. Flatness
i. Parallelism
j. Concentricity
k. True Position Tolerances
l. Edge Distance Requirements
m. Finish Dimensions
Requirements
n. Diameter/Locating
o. Air Swirler Features
p. Mixing Air (dilution)
Features
q. Datum Location Features
r. Air Cooling Hole Diameter
s. Flowpath Exit Features
t. Sealing Features
u. Aft Seal
v. Fuel Nozzles
w. Igniter interfaces
x. Flanges
61
4/30/10 AC 33-9
Appendix 2
10. Cooling Feature Characteristics:
a. Airflow
b. Hole Diameter
c. Blocked Hole
Quantity/Location
d. Cooling Slot
Height/Length/Location
e. Quantity of Holes/Slots
11. Thermal Barrier Coating:
a. Thickness
b. Coverage
c. Type
Qualification
62
4/30/10 AC 33-9
Appendix 2
13. Process Demonstration Including:
a. Variability Requirements
15. Manufacturing Requirements for
replacement sections to accomplish
repair:
a. Drawings/Specifications
b. Quality Requirements
c. Source Substantiation
Requirements
Requirements
17. 33.5 Instruction Manual for Installing
and Operating the Engine
18. 33.7 Engine Ratings and Operating
Limitations
19. 33.8 Selection of Engine Power and
Thrust Ratings
20. 33.14 Start-stop cyclic stress
(low cycle fatigue)
21. 33.15 Materials
associated with 33.27; 33.63; 33.83;
33.87; 33.88; and 33.90)
24. 33.21 Engine
25. 33.23 Engine mounting attachments
and structure
63
4/30/10 AC 33-9
Appendix 2
turbo supercharger rotors
systems
Engines
31. 33.63 Vibration
32. 33.65 Surge and stall characteristics,
(Note 2)
35. 33.68 Induction system icing,
(operability aspects) (Note 2)
42. 33.76 Bird ingestion (operability
aspects of ingestion)
Aircraft Engines
48. 33.87 Endurance tests
52. 33.91 Engine component tests
(HCF/LCF Bench Testing)
64
4/30/10 AC 33-9
Appendix 2
57. 33.96 Engine tests in auxiliary power
unit (APU) mode
Part 33-Appendix A – Instructions
Part 33-Appendix B- Certification
Standard Atmospheric
Concentrations of Rain and Hail
65
4/30/10 AC 33-9
Appendix 2
Template 6
REPAIR SUBSTANTIATION CHECKLIST - EXTERNALS PART FAMILY

(Tubes, Manifolds, Ducts, Brackets)
Categories of Externals (Tubes, Manifolds, Ducts, Brackets) Part Family. Determine which
repair description best fits the repair proposal. If no repair description is appropriate, contact the
FAA Advisor for guidance.

OF REPAIRS
assemblies without use of permanent attachment techniques (i.e.; welding or brazing).
Assembly is either bolted or riveted.
4. Blend Repair
8. Straightening, Re-twist or Reforming Repair
9. Repairs to Restore Adhesives, Bonding Agents, Potting Compounds.
• This repair includes lapping, skim cut, non-conventional machining
66
4/30/10 AC 33-9
Appendix 2
No. Identified and Substantiated. Repair 1 2 3 4 5 6 7 8 9 10
b. Oxidation
c. Corrosion
fretting, oxidation
67
4/30/10 AC 33-9
Appendix 2
the repair design and assess their impact on
a. Stress-Strain
Dwell Time)
d. Creep
f. Hardness

constituents)
fraction, etc.)
k. Melting Point
types in (1)(e))
p. Density (weight)
Expansion
68
4/30/10 AC 33-9
Appendix 2
airworthiness.



Uniformity
c. Microstructure
d. Hardness
e. Sintering
f. Strip Process
g. Residual Stress
Contamination)
n. Diffusion Zone
(Plating)
p. Compatibility With Base
Material
a. Burnishing
b. Peening
c. Butterfly Polish
69
4/30/10 AC 33-9
Appendix 2

or Grinding
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
Ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
q. Contamination
70
4/30/10 AC 33-9
Appendix 2
No. be Identified and Substantiated. 1 2 3 4 5 6 7 8 9 10
effect(s):

major load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight

mating part(s):
b. Shotpeen intensity/coverage
distortion effects
• Roundness
• Flatness
• Parallelism
• Concentricity
• True position tolerances
• Edge distance requirements
requirements
10. Coating Coverage Definition

11. Blend Area Proximity Limits Defined
71
4/30/10 AC 33-9
Appendix 2
Qualification
Requirements
limitations
ratings
General
fatigue)
21. 33.15 Materials
associated with 33.27; 33.63; 33.83; 33.87;
33.88; and 33.90)
structure
supercharger rotors
72
4/30/10 AC 33-9
Appendix 2
General
systems
31. 33.63 Vibration
aspects) (Note 2)
ingestion)
Aircraft Engines
73
4/30/10 AC 33-9
Appendix 2
Req Repair Properties and Requirements to be
No. Identified and Substantiated. 1 2 3 4 5 6 7 8 9 10
Engines
50. 33.89 Operation test
bench testing)
tests (weight changes)
(APU) mode
Rain and Hail
74
4/30/10 AC 33-9
Appendix 2
Template 7
REPAIR SUBSTANTIATION CHECKLIST - FUEL NOZZLE PART FAMILY
Categories of Fuel Nozzle Part Family Repair. Determine which repair description best fits
the repair proposal based. If no repair description is appropriate, contact the FAA Advisor for
guidance.

OF REPAIRS
1. Blend Repair
2. Thread Restoration and Functional Testing.
• Repair removes and replaces detail parts without use of permanent attachment
techniques, (i.e. welding or brazing) but assembly is either bolted or riveted.
4. Machining Repair
• Includes lapping, skim cut, non-conventional machining.
7. Dimensional Restoration By Coating or Plating
75
4/30/10 AC 33-9
Appendix 2
Req Repair Design Requirements to be Identified
No. and Substantiated. Repair Properties and 1 2 3 4 5 6 7
Substantiated.
b. Oxidation
c. Corrosion
corrosion, erosion, cavitation, fretting,
oxidation
76
4/30/10 AC 33-9
Appendix 2
Substantiated.
physical properties of the part affected by the
repair design and assess their impact on the
part’s airworthiness:
a. Stress-Strain
dwell time)
d. Creep
e. Tensile Properties (yield, strength,
elongation)
f. Hardness
i. Chemical Composition (alloy
constituents)
boundary precipitates, gamma prime
size and volume fraction, etc.)
k. Melting Point
types in (1)(e))
p. Density (weight)
77
4/30/10 AC 33-9
Appendix 2
Substantiated.
3. Select all Material Properties/Characteristics
for weldments or brazed joints that apply and
parent metal. The effect of any changes to the
part’s metallurgy as a result of welds or braze
should be evaluated for airworthiness.

fraction, etc.)
4. Select all Coating Properties/Characteristics

that apply and evaluate them and their interface
changes to the part’s physical and operational
capability as a result of the coating should be

Microstructure
d. Coating Hardness
e. Sintering
g. Residual Stress
m. Compatibility With Base Material/Other
Coatings
78
4/30/10 AC 33-9
Appendix 2
Substantiated.
5. Select Surface Treatment that applies (without
material removal) and evaluate effect(s), if any,
on airworthiness:
a. Burnishing
b. Peening
c. Butterfly Polish


Grinding
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
Ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
q. Contamination

potential impact on the airworthiness of the part.
79
4/30/10 AC 33-9
Appendix 2
Substantiated.
8. Select all that may be potentially affected by the
repair design and evaluate system effect(s):

load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight

9. Establish Measurable Characteristics and the
allowable tolerances for the repaired part
features and for any replacement detail(s) and
give due consideration to mating part(s):
c. Bearing bore dimensions and location
characteristics
f. Dimensions, including heat distortion
effects
• Roundness
• Flatness
• Parallelism
• Concentricity
• Finish dimensions requirements
g. Diameter/locating
h. Air swirler features
i. Mixing air (dilution) features
j. Datum location features
k. Air cooling hole diameter
l. Flowpath exit features
m. Aft seal
n. Flanges
o. Igniter interfaces
80
4/30/10 AC 33-9
Appendix 2
No. Identified and Substantiated, Cont’d. 1 2 3 4 5 6 7
10. Material Debit Due To:
a. Heat Treat
b. Weld, Braze, Coat or Plate Processes
c. Machine Process
d. Blend
e. Hone
f. Lap
g. Grit Blast
h. Strip
11. Flow Volume
12. Flow Pattern
13. Pressure/Leak Test
requirements)
17. Manufacturing requirements for fabrication of
repair details or replacement sections used to
accomplish repair:

18. 33.4 Instructions for Continuous Airworthiness
(ICA's)
ratings
81
4/30/10 AC 33-9
Appendix 2
No. Identified and Substantiated. 1 2 3 4 5 6 7
Subpart B – Design and Construction; General
22. 33.14 Start-stop cyclic stress (Low cycle fatigue)
23. 33.15 Materials
25. 33.19 Durability (Note that 33.19 is associated
with 33.27; 33.63; 33.83; 33.87; 33.88; and 33.90)
27. 33.23 Engine mounting attachments and structure
29. 33.27 Turbine, compressor, fan, and turbo
supercharger rotors
30. 33.28 Electrical and electronic control systems
Subpart E – Design and Construction; Turbine
Aircraft Engines
33. 33.63 Vibration
37. 33.68 Induction system icing (operability aspects)
(Note 2)
ingestion)
45. 33.77 Foreign object ingestion—ice (operability
82
4/30/10 AC 33-9
Appendix 2
Modes/Product Qualities/etc. Technical
Engines
54. 33.91 Engine component tests (HCF/LCF bench
testing)
57. 33.94 Blade containment and rotor unbalance tests
(weight changes)
59. 33.96 Engine tests in auxiliary power unit (APU)
mode
Part 33 Appendix A – Instructions for
Part 33 Appendix B- Certification Standard
Atmospheric Concentrations of Rain and Hail
83
4/30/10 AC 33-9
Appendix 2
Template 8
REPAIR SUBSTANTIATION CHECKLIST - GEARBOX HOUSING ASSEMBLY

PART FAMILY (SHAFTS, GEARS, HOUSINGS)
Categories of Gearbox Housing Assembly Part Family (shafts, gears, housings). Determine
which repair description best fits the repair proposal. If no repair description is appropriate,
contact the FAA Advisor for guidance.
OF REPAIRS
• Includes Touch Up Coating
Assembly is either bolted or riveted.
6. Blend Repair
• This repair includes straightening of bent knife edges
finish/texture)
12. Restoration of Adhesives, Bonding Agents, Potting Compounds.
84
4/30/10 AC 33-9
Appendix 2
No. Identified and Substantiated. Repair 1 2 3 4 5 6 7 8 9 10 11 12
b. Oxidation
c. Corrosion
fretting, oxidation
85
4/30/10 AC 33-9
Appendix 2
No. Identified and Substantiated. Repair 1 2 3 4 5 6 7 8 9 10 11 12
a. Stress-Strain
Dwell Time)
d. Creep
f. Hardness

constituents)
etc.)
k. Melting Point
types in (1)(e))
p. Density (weight)
86
4/30/10 AC 33-9
Appendix 2
No. Identified and Substantiated. 1 2 3 4 5 6 7 8 9 10 11 12
airworthiness.

fraction, etc.)


c. Microstructure
d. Hardness
e. Sintering
f. Strip Process
g. Residual Stress
l. Bonding (Interface Contamination)
n. Diffusion Zone
(Plating)
p. Compatibility With Base Material
87
4/30/10 AC 33-9
Appendix 2
a. Burnishing
b. Peening
c. Butterfly Polish


or Grinding
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
Ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
q. Contamination
88
4/30/10 AC 33-9
Appendix 2
effect(s):

major load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight
89
4/30/10 AC 33-9
Appendix 2
9. Bearing Bore:
a. Dimension
b. Location
mating part(s):
g. distortion effects
• Roundness
• Flatness
• Parallelism
• Concentricity
requirements
90
4/30/10 AC 33-9
Appendix 2
No. be Identified and Substantiated. 1 2 3 4 5 6 7 8 9 10 11 12
continued
11 Oil Nozzle Flow Test
Qualification
requirements)
Requirements
limitations
ratings
91
4/30/10 AC 33-9
Appendix 2
General
fatigue)
21. 33.15 Materials
associated with 33.27; 33.63; 33.83; 33.87;
33.88; and 33.90)
structure
27. 33.27 Turbine, compressor, fan, and turbo
supercharger rotors
systems
31. 33.63 Vibration
(Note 2)
aspects) (Note 2)
ingestion)
92
4/30/10 AC 33-9
Appendix 2
Aircraft Engines
bench testing)
Aircraft Engines
(APU) mode
Rain and Hail
. Part 34 – Exhaust Emissions
93
4/30/10 AC 33-9
Appendix 2
Template 9

– HIGH PRESSURE COMPRESSOR (HPC) STATOR PART FAMILY – VANE
SECTOR (AND FULL RING) TYPE STATORS
Categories of LPC-HPC Stator Repair. Determine which repair description best fits the repair
proposal. If no repair description is appropriate, contact the FAA Advisor for guidance.

OF REPAIRS
1. Restoration of Protective Coating (Paint, Aluminizing, Oil, etc.)
• This repair includes touch-up coating
Assembly is either bolted or riveted
5. Blend Repair
finish/texture)
• This repair includes straightening of bent flanges
9. Restoration of Adhesives, Bonding Agents & Potting Compounds
94
4/30/10 AC 33-9
Appendix 2
No. Identified and Substantiated. Repair 1 2 3 4 5 6 7 8 9
b. Oxidation
c. Corrosion
fretting, oxidation
95
4/30/10 AC 33-9
Appendix 2
a. Stress-Strain
dwell time)
d. Creep
e. Tensile Properties (yield,
strength, elongation)
f. Hardness
constituents)
fraction, etc.)
k. Melting Point
types in (1)(e))
p. Density (weight)
Expansion
96
4/30/10 AC 33-9
Appendix 2
airworthiness.



Uniformity
c. Microstructure
d. Hardness
e. Sintering
f. Strip Process
g. Residual Stress
Contamination)
n. Diffusion Zone
(Plating)
p. Compatibility With Base
Material
97
4/30/10 AC 33-9
Appendix 2
a. Burnishing
b. Peening
c. Butterfly Polish


or Grinding
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
Ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
q. Contamination

98
4/30/10 AC 33-9
Appendix 2
Req. Repair Design Requirements to be 1 2 3 4 5 6 7 8 9
No. Identified and Substantiated, Repair
by the repair design and evaluate system
effect(s):
major load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight
mating part(s):
distortion effects
• Roundness
• Flatness
• Parallelism
• Concentricity
• True Position
Tolerances
• Edge Distance
• Requirements
Requirements
g. Airfoil Profile
h. Leading & Trailing Edge
Contours
i. Concave & Convex Contours
j. Thickness
k. Chord & Tip Length
l. Twist/Lean/Bow
10. Outer Band Rail Functional Fit
11. Inner Band Arc Length
12. Outer Band to Inner Band Dim
Relationship
13. Assembled Honeycomb Inner Radius
99
4/30/10 AC 33-9
Appendix 2
No. be Identified and Substantiated. 1 2 3 4 5 6 7 8 9
Qualification
Requirements
limitations
ratings
General
fatigue)
23. 33.15 Materials
associated with 33.27; 33.63; 33.83; 33.87;
33.88; and 33.90)
structure
100
4/30/10 AC 33-9
Appendix 2
General
turbosupercharger
systems
33. 33.63 Vibration
(Note 2)
aspects) (Note 2)
ingestion)
45. 33.77 Foreign object ingestion (operability
Aircraft Engines
101
4/30/10 AC 33-9
Appendix 2
bench testing)
(APU) mode
Rain and Hail
102
4/30/10 AC 33-9
Appendix 2
Template 10
REPAIR SUBSTANTIATION CHECKLIST –LOW PRESSURE COMPRESSOR (LPC)

– HIGH PRESSER COMPRESSOR (HPC) STATOR PART FAMILY – FIXED VANE
TYPE STATORS (CANTILEVERED AT O.D.)
proposal based. If no repair description is appropriate, contact the FAA Advisor for guidance.

OF REPAIRS
3. Blend Repair
finish/texture)
103
4/30/10 AC 33-9
Appendix 2
No. and Substantiated. Repair Properties and 1 2 3 4
Substantiated.
b. Oxidation
c. Corrosion
oxidation
104
4/30/10 AC 33-9
Appendix 2
Substantiated.
repair design and assess their impact on the
a. Stress-Strain
Dwell Time)
d. Creep
Elongation)
f. Hardness

constituents)
k. Melting Point
types in (1)(e))
p. Density (weight)
105
4/30/10 AC 33-9
Appendix 2
Substantiated.
Properties/Characteristics for weldments or
brazed joints that apply and evaluate them
and their interface with the parent metal. The
effect of any changes to the part’s metallurgy
as a result of welds or braze should be

fraction, etc.)

part’s physical and operational capability as a
result of the coating should be evaluated for
airworthiness.

Microstructure
d. Coating Hardness
e. Sintering
g. Residual Stress
k. Bonding (interface contamination)
106
4/30/10 AC 33-9
Appendix 2
Req Repair Properties & Requirement to be
No. Identified and Substantiated. 1 2 3 4
a. Burnishing
b. Peening
c. Butterfly Polish

Grinding
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
Ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
Contamination
107
4/30/10 AC 33-9
Appendix 2
load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight

d. location characteristics
e. Pressure strength test
f. Flow capacity test
g. Dimensions, including heat distortion
effects:
• Roundness
• Flatness
• Parallelism
• Concentricity
• Finish dimensions requirements
Airfoil Profile
• Leading & Trailing Edge Contours

• Concave & Convex Contours
• Thickness
• Chord & Tip Length Twist/Lean/Bow
108
4/30/10 AC 33-9
Appendix 2
Repair Properties & Requirement to be 1 2 3 4
10. Outer Band Rail Functional Fit
11. Inner Band Arc Length
12. Outer Band to Inner Band Dim Relationship
13. Assembled Honeycomb Inner Radius
Identified
requirements)
accomplish repair:
109
4/30/10 AC 33-9
Appendix 2
(ICA's)
ratings
General
22. 33.14 Start-stop cyclic stress (low cycle fatigue)
23. 33.15 Materials
25. 33.19 Durability(Note that 33.19 is associated
with 33.27; 33.63; 33.83; 33.87; 33.88; and
33.90)
structure
28 33.25 Accessory attachments
turbosupercharger rotors
33. 33.63 Vibration
aspects) (Note 2)
110
4/30/10 AC 33-9
Appendix 2
Turbine Aircraft Engines (continued)
ingestion)
Engines
48. 33.83 Vibration tests
testing)
(APU) mode
Part 33 -Appendix B- Certification Standard
Atmospheric Concentrations of Rain and
Hail
111
4/30/10 AC 33-9
Appendix 2
Template 11
REPAIR SUBSTANTIATION CHECKLIST -- MAJOR ENGINE CASES
Categories of Major Cases Part Family. Determine which repair description best fits the repair

OF REPAIRS
5. Restoration of Adhesives, Bonding Agents, Potting Compound.
6. Bushing or Helicoil Repair
• Includes touch-up coating
• This repair assembles, disassembles, removes and replaces detail parts, or sub-assemblies
without the use of permanent attachment techniques (i.e.; welding or brazing). Assembly is
either bolted or riveted.
9. Remove and Restore Anti-gallant
10. Blend Repair
112
4/30/10 AC 33-9
Appendix 2
CATEGORIES OF REPAIRS
Req Repair Design Requirements to be Identified 1 2 3 4 5 6 7 8 9 10
Substantiated.
that apply based on the function of the part and
its operating environment in the engine. This
b. Oxidation
c. Corrosion
d. Elevated temperature-induced changes
(creep, diffusion, ageing, temperature
gradients)
oxidation
g. Rubbing, foreign object impact damage,
O3 chemical attack, etc.
113
4/30/10 AC 33-9
Appendix 2
Req. Repair Design Requirements to be Identified 1 2 3 4 5 6 7 8 9 10
Substantiated
a. Stress-Strain
Dwell Time)
d. Creep
Elongation)
f. Hardness

constituents)
k. Melting Point
types in (1)(e))
p. Density (weight)
114
4/30/10 AC 33-9
Appendix 2
Substantiated.
part’s metallurgy as a result of welds or braze
4 Select all Coating Properties/Characteristics

changes to the part’s physical and operational
capability as a result of the coating should be

Microstructure
d. Coating Hardness
e. Sintering
g. Residual Stress
m. Compatibility With Base Material/Other
Coatings
5. Select Surface Treatment that applies (Without

Material Removal) and evaluate effect(s), if any,
on airworthiness:
a. Burnishing
b. Peening
c. Butterfly Polish
115
4/30/10 AC 33-9
Appendix 2
Substantiated.

Grinding
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
Contamination
116
4/30/10 AC 33-9
Appendix 2
Req Repair Properties and Requirements to be 1 2 3 4 5 6 7 8 9 10
the repair design, and evaluate system effect(s):
9. Hole dimensions and location characteristics
10. Flange & Case Wall thickness & configuration
effects
• Roundness
• Flatness
• Parallelism
• Concentricity
requirements

requirements)
117
4/30/10 AC 33-9
Appendix 2
accomplish repair:
(ICA's)
118
4/30/10 AC 33-9
Appendix 2
ratings
General
fatigue)
21. 33.15 Materials
with 33.27; 33.63; 33.83; 33.87; 33.88; and
33.90)
structure
supercharger rotors
31. 33.63 Vibration
aspects) (Note 2)
119
4/30/10 AC 33-9
Appendix 2
Engines
ingestion)
45 33.79 Fuel burning thrust augmentor
Engines
testing)
tests (weight changes)
(APU) mode
Hail
120
4/30/10 AC 33-9
Appendix 2
Template 12
REPAIR SUBSTANTIATION CHECKLIST - MAJOR ROTATING (NON-LIFE

LIMITED) PART FAMILY (EXCLUDING TURBINE SHAFT COUPLING PART
FAMILY)
Categories of Major Rotating (Non-Life Limited) Part Repairs. Determine which repair
description best fits the repair proposal. If no repair description is appropriate, contact the FAA
Advisor for guidance.

OF REPAIRS
1. Restoration of Protective Coating (Paint, Aluminizing, Oil, etc.)
• Includes touch-up coating
• This repair assembles, disassembles, removes and replaces detail parts, or sub-assemblies
without use of permanent attachment techniques (i.e.; welding or brazing). Assembly is either
bolted or riveted
4. Blend Repair
5. Remove and Restore Anti-gallant
8. Honing Repair
9. Machining Repair
121
4/30/10 AC 33-9
Appendix 2
b. Oxidation
c. Corrosion
fretting, oxidation
122
4/30/10 AC 33-9
Appendix 2
a. Stress-Strain
dwell time)
d. Creep
f. Hardness
constituents)
fraction, etc.)
k. Melting Point
types in (1)(e))
p. Density (weight)
Expansion
123
4/30/10 AC 33-9
Appendix 2
airworthiness.



c. Microstructure
d. Hardness
e. Sintering
f. Strip Process
g. Residual Stress
l. Bonding (interface contamination)
n. Diffusion Zone
(plating)
p. Compatibility with Base Material
124
4/30/10 AC 33-9
Appendix 2
a. Burnishing
b. Peening
c. Butterfly Polish

or Grinding
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
Contamination
125
4/30/10 AC 33-9
Appendix 2
effect(s):

major load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight

mating part(s):
g. Distortion effects
• Roundness
• Flatness
• Parallelism
• Concentricity
• Edge Distance
Requirements
Requirements
10. Coating Coverage Definition

12. No Grit Blast/Coating in Fillet Radii
126
4/30/10 AC 33-9
Appendix 2
Qualification
Requirements
limitations
ratings
General
fatigue)
22. 33.15 Materials
associated with 33.27; 33.63; 33.83; 33.87;
33.88; and 33.90)
127
4/30/10 AC 33-9
Appendix 2
General
structure
supercharger
systems
32. 33.63 Vibration
(Note 2)
aspects) (Note 2)
ingestion)
128
4/30/10 AC 33-9
Appendix 2
Aircraft Engines
bench testing)
(APU) mode
Part 33 -Appendix B -– Certification
Rain and Hail
129
4/30/10 AC 33-9
Appendix 2
Template 13
REPAIR SUBSTANTIATION CHECKLIST – HIGH PRESSURE COMPRESSOR

(HPC)/HIGH PRESSURE TURBINE (HPT)/LOW PRESSURE TURBINE (LPT)
AIRSEALS (NON-ROTATING) AND SHROUDS (STATIONARY) PART FAMILY
Categories of HPC/HPT/LPT Airseals (non-rotating) and Shrouds (stationary) Part Family

Repair. Determine which repair description best fit the repair proposal. If no repair description
is appropriate, contact the FAA Advisor for guidance.

OF REPAIRS
Assembly is either bolted or riveted
2. Blend Repair
• This repair excludes detail part replacement)
• This repair includes part detail replacement
8. Machining Repair
130
4/30/10 AC 33-9
Appendix 2
No. and Substantiated. Repair Properties and 1 2 3 4 5 6 7 8
Substantiated.
b. Oxidation
c. Corrosion
oxidation
131
4/30/10 AC 33-9
Appendix 2
Substantiated.
repair design, and assess their impact on the
a. Stress-Strain
dwell time)
d. Creep
e. Tensile Properties (yield, strength,
elongation)
f. Hardness

constituents)
k. Melting Point
types in (1)(e))
p. Density (weight)
132
4/30/10 AC 33-9
Appendix 2
Substantiated.
Properties/Characteristics for weldments or
brazed joints that apply and evaluate them
and their interface with the parent metal. The
effect of any changes to the part’s metallurgy
as a result of welds or braze, should be

fraction, etc.)

part’s physical and operational capability as a
result of the coating should be evaluated for
airworthiness.

Microstructure
d. Coating Hardness
e. Sintering
g. Residual Stress
133
4/30/10 AC 33-9
Appendix 2
a. Burnishing
b. Peening
c. Butterfly Polish

Grinding
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
Contamination


load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight
134
4/30/10 AC 33-9
Appendix 2
characteristics
effects
1) Roundness
2) Flatness
3) Parallelism
4) Concentricity
5) True Position Tolerances
6) Edge Distance
7) Requirements
8) Finish Dimensions
Requirements

10. Coating Coverage Definition:
a. No Grit Blast
b. No coating in Filet Radii
Identified
requirements)
accomplish repair:
135
4/30/10 AC 33-9
Appendix 2
(ICA's)
ratings
General
21. 33.15 Materials
with 33.27; 33.63; 33.83; 33.87; 33.88; and
33.90)
structure
supercharger rotors
31. 33.63 Vibration
aspects) (Note 2)
136
4/30/10 AC 33-9
Appendix 2
ingestion)
Engines
46. 33.83 Vibration tests
testing)
(APU) mode
Hail
137
4/30/10 AC 33-9
Appendix 2
Template 14
REPAIR SUBSTANTIATION CHECKLIST - STATIC STRUCTURE PART FAMILY

(Ducts, Bearing Housings, Etc.)
Categories of Static Structure Parts Family Repairs. Determine which repair description best fits the
repair proposal based. If no repair description is appropriate, contact the FAA Advisor for guidance.
CATEGORIES OF REPAIR DESCRIPTION

REPAIRS
1. Blend Repair
2. Weld/Braze Repairs
3. Weld/Braze Repairs
• This repair removes and replaces detail parts without the use of permanent attachment.
Techniques, i.e., welded or brazed, assembly is either bolted or riveted.
5. Dimensional Restoration Coating or Plating
• This repair includes dent repair.
138
4/30/10 AC 33-9
Appendix 2
No. Identified and Substantiated. Repair 1 2 3 4 5 6
environment in the engine. This
requirements.
b. Oxidation
c. Corrosion
changes (creep, diffusion,
ageing, temperature gradients)
e. Wear due to: adhesion,
abrasion, corrosion, erosion,
cavitation, fretting, oxidation
damage, O3 chemical attack,
etc.
139
4/30/10 AC 33-9
Appendix 2
airworthiness:
a. Stress-Strain
d. Creep
f. Hardness

constituents)
gamma prime size and
volume fraction, etc.)
k. Melting Point
n. Wear Resistance (consider
p. Density (weight)
Expansion
140
4/30/10 AC 33-9
Appendix 2
changes to the part’s metallurgy as a
result of welds or braze should be

141
4/30/10 AC 33-9
Appendix 2
Properties/Characteristics that apply
changes to the part’s physical and
operational capability, as a result of the
coating, should be evaluated for
airworthiness.

Uniformity
Microstructure
d. Coating Hardness
e. Sintering
g. Residual Stress
coating)
contamination)
l. Hydrogen Embrittlement
(Plating)
Modes/Product Qualities/etc. Technical
a. Burnishing
b. Peening
c. Butterfly Polish
142
4/30/10 AC 33-9
Appendix 2
No Identified and Substantiated. 1 2 3 4 5 6
following processes, when applicable,
and assess its impact, if any, on existing
ICAs.

or Grinding
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
j. Cleaning (Chemical, power
flash, Ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
p. Repetitive or Conflicting
Repairs Contamination
7. Cleaning Properties, Characteristics &

Material Property Debits:
a. Chemical (solutions, etc.)

b. Grit Blast (,pressure media etc.)
c. Power Flush (pressure, solution
time, temp, etc.)
d. Ultrasonic (solution frequency,
time, etc.)
e. Furnace (time, temp, atmosphere,
etc.)
143
4/30/10 AC 33-9
Appendix 2
No Identified and Substantiated. 1 2 3 4 5 6
by the repair design and evaluate system
effect(s):

major load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight
mating part(s):
distortion effects
• Roundness
• Flatness
• Parallelism
• Concentricity
• True Position
Tolerances
• Edge Distance
• Requirements
Requirements
10. Parent material thickness reduction

assessment
11. Dimensional & Tolerance
Reverse engineered parts
Qualification
144
4/30/10 AC 33-9
Appendix 2
Req Repair Properties & Requirement to
No be Identified and Substantiated. 1 2 3 4 5 6
13. Process Demonstration:
• Including variability
requirements
15. Manufacturing requirements for
replacement sections used to
accomplish repair:
Requirements
Requirements
17. 33.5 Instruction manual for installing
and operating the engine
limitations
19. 33.8 Selection of engine power and
thrust ratings
fatigue) (weight and CG location
changes effects on disks)
21. 33.15 Materials
associated with 33.27; 33.63; 33.83;
33.87; 33.88; and 33.90)
25. 33.23 Engine mounting attachments
and structure
turbo supercharger rotors
145
4/30/10 AC 33-9
Appendix 2
Req Repair Properties & Requirement to
General; continued
systems
29. 33.29 Instrument Control
31. 33.63 Vibration
32. 33.65 Surge and stall characteristics (Note
2)
146
4/30/10 AC 33-9
Appendix 2
35. 33.68 Induction system icing
42. 33.76 Bird ingestion (operability aspects
of ingestion)
Aircraft Engines
48. 33.87 Endurance test(see Note 2)
50 33.89 Operation test (operability aspects)
bench testing)
(APU) mode
Part 33 —Appendix A – Instructions DER
Part 33— Appendix B- Certification
Standard Atmospheric Concentrations
of Rain and Hail
147
4/30/10 AC 33-9
Appendix 2
Template 15

– HIGH PRESSURE COMPRESSOR (HPC) STATOR PART FAMILY – VARIABLE
VANE TYPE STATORS
proposal based. If no repair description is appropriate, contact the FAA Advisor for guidance.

OF REPAIRS
2. Blend Repair
finish/texture)
148
4/30/10 AC 33-9
Appendix 2
Substantiated.
1. Applicable Degradation Modes: Select all that
apply based on the function of the part and its
operating environment in the engine. This
section provides the background for establishing
the substantiation requirements.
b. Oxidation
c. Corrosion
d. Elevated temperature-induced changes
(creep, diffusion, ageing, temperature
gradients)
oxidation
g. Rubbing, foreign object impact damage,
O3 chemical attack, etc.
149
4/30/10 AC 33-9
Appendix 2
Substantiated.
repair design, and assess their impact on the
a. Stress-Strain
Dwell Time)
d. Creep
Elongation)
f. Hardness

constituents)
k. Melting Point
n. Wear Resistance (Consider wear types
in (1)(e))
p. Density (weight)
150
4/30/10 AC 33-9
Appendix 2
Substantiated.
evaluate them and their interface with the parent
metal. The effect of any changes to the part’s
metallurgy as a result of welds or braze should
a. Microstructure (grain size, grain shape,

grain boundary precipitates, gamma
prime size and volume fraction, etc.)
4. Select all Coating Properties/Characteristics

with the parent metal. The effect of any changes
to the part’s physical and operational capability
as a result of the coating should be evaluated for
airworthiness.

Microstructure
d. Coating Hardness
e. Sintering
g. Residual Stress
m. Compatibility with Base Material/Other
Coatings
5. Select Surface Treatment that applies (without

material removal) and evaluate effect(s), if any, on
airworthiness:
a. Burnishing
b. Peening
c. Butterfly Polish
151
4/30/10 AC 33-9
Appendix 2

Grinding
d. Straightening, Re-twisting, Re-forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
Contamination
152
4/30/10 AC 33-9
Appendix 2
7. Establish the Applicability of the Repair and the
Repair Processing Sequence or evaluate any
changes to an existing repair sequence for
repair design, and evaluate system effect(s):
load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight
characteristics
effects
• roundness
• flatness
• parallelism
• concentricity
• true position tolerances
• edge distance
• requirements
• finish dimensions requirements
g. Airfoil profile
• leading & trailing edge contours
• concave & convex contours
• thickness
• chord & tip length
• twist/lean/bow

10. Spindle (Trunnion) Diameter
11. Outer Spindle (Trunnion) to Lever Seating Flat
12. Outer Spindle (Trunnion) to Inner Spindle
(Trunnion)
13. Outer Spindle (Trunnion) to Inner Spindle (Trunnion)
Concentricity
153
4/30/10 AC 33-9
Appendix 2
No. Identified and Substantiated, Cont’d. 1 2 3 4

Identified
requirements)
accomplish repair:
(ICA's)
21. 33.8 Selection of engine power and thrust ratings
Subpart B – Design and Construction; General
23. 33.15 Materials
25. 33.19 Durability(Note that 33.19 is associated
with 33.27; 33.63; 33.83; 33.87; 33.88; and 33.90)
27. 33.23 Engine mounting attachments and structure
supercharger rotors
Aircraft Engines
32. 33.62 Stress Analysis
33. 33.63 Vibration
154
4/30/10 AC 33-9
Appendix 2
Aircraft Engines
37. 33.68 Induction system icing (operability aspects)
(Note 2)
ingestion)
45. 33.77 Foreign object ingestion (operability aspects
of ingestion)
Engines
testing)
155
4/30/10 AC 33-9
Appendix 2
Engines
57. 33.94 Blade containment and rotor unbalance tests
(weight changes)
59. 33.96 Engine tests in auxiliary power unit (APU)
mode
Part33 -Appendix A – Instructions for
Atmospheric Concentrations of Rain and Hail
156
4/30/10 AC 33-9
Appendix 2
Template 16
REPAIR SUBSTANTIATION CHECKLIST - HPT VANE PART FAMILY
Categories of HPT Vane Repair. Determine which repair description best fits the repair

OF REPAIRS
• This repair removes and replaces any and all types of coatings.
• Includes detail parts replacement
4. Assembly and/or disassembly
• This repair removes and replaces details parts without the use of permanent
attachment techniques (i.e., welding or brazing) but assembly is either bolted or
riveted.
5. Blend Repair
157
4/30/10 AC 33-9
Appendix 2

No. Identified and Substantiated. Repair 1 2 3 4 5 6 7
b. Oxidation
c. Corrosion
fretting, oxidation
f. High cycle fatigue
158
4/30/10 AC 33-9
Appendix 2

the repair design, and assess their impact
on the part’s airworthiness:
a. Stress-Strain
Dwell Time)
d. Creep
f. Hardness

constituents)
etc.)
k. Melting Point
types in (1)(e))
p. Density (weight)
Expansion
159
4/30/10 AC 33-9
Appendix 2

airworthiness.


capability, as a result of the coating,

Uniformity
Microstructure
d. Coating Hardness
e. Sintering
g. Residual Stress
coating)
contamination)
l. Hydrogen Embrittlement
(plating)
160
4/30/10 AC 33-9
Appendix 2
No, Identified and Substantiated. Repair 1 2 3 4 5 6 7
a. Burnishing
b. Peening
c. Butterfly Polish
161
4/30/10 AC 33-9
Appendix 2

or Grinding
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
Contamination
effect(s):
major load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight
162
4/30/10 AC 33-9
Appendix 2
No. be Identified and Substantiated. 1 2 3 4 5 6 7
9. Dimension of sealing features (leakage,
secondary circuits)
mating part(s):
distortion effects
• Roundness
• Flatness
• Parallelism
• Concentricity
• Edge distance
• Requirements
• Requirements
g. Airfoils Profile
• Leading & trailing edge
contour
• Thickness
• Chord & airfoil length
• Twist/lean/bow
h. Tip length
j. Throat area

margin, hole exit geometry, allowable
plugged holes)
Identified
requirements)
163
4/30/10 AC 33-9
Appendix 2
Requirements
17 33.5 Instruction manual for installing and
limitations
ratings
General
fatigue)
21. 33.15 Materials
associated with 33.27; 33.63; 33.83; 33.87;
33.88; and 33.90)
structure
General
supercharger rotors
systems
Subpart E – Design and construction;
Turbine aircraft Engines
30. 33.62 Stress Analysis
31. 33.63 Vibration
164
4/30/10 AC 33-9
Appendix 2
(Note 2)
aspects) (Note 2)
ingestion)
43. 33.77 Foreign object ingestion (operability
Aircraft Engines
bench testing)
57 33.96 Engine tests in auxiliary power unit
(APU) mode
Part 33 -Appendix B – Certification
Rain and Hail
165
4/30/10 AC 33-9
Appendix 2
Template 17
REPAIR SUBSTANTIATION CHECKLIST - LOW PRESSURE TURBINE (LPT) VANE

PART FAMILY
Categories of LPT Vane Part Family Repair. Determine which repair description best fit the
repair proposal based. If no repair description is appropriate, contact the FAA Advisor for
guidance.

OF REPAIRS
3. Weld or Braze Repair (excludes detail part replacement)
5. Disassembly and/or Assembly
• This repair removes and replaces detail parts without the use of permanent attachment
(i.e.; welding or brazing) but assembly is either bolted or riveted.
6. Blend Repair
7. Dimensional Restoration Repair (by coating of plating)
166
4/30/10 AC 33-9
Appendix 2
b. Oxidation
c. Corrosion
fretting, oxidation
f. High cycle fatigue
167
4/30/10 AC 33-9
Appendix 2
a. Stress-Strain
Dwell Time)
d. Creep
f. Hardness

constituents)
etc.)
k. Melting Point
types in (1)(e))
p. Density (weight)
168
4/30/10 AC 33-9
Appendix 2
Properties/Characteristics for weldments
or brazed joints that apply and evaluate
them and their interface with the parent
metal. The effect of any changes to the
part’s metallurgy as a result of welds or
airworthiness.

169
4/30/10 AC 33-9
Appendix 2
capability as a result of the coating should

Uniformity
Microstructure
d. Coating Hardness
e. Sintering
g. Residual Stress
k. Bonding (Interface
Contamination)

a. Burnishing
b. Peening
c. Butterfly Polish
170
4/30/10 AC 33-9
Appendix 2

Grinding
forming
e. Blending
f. Honing
g. Lapping
h. Grit Blast
i. Stripping
ultrasonic)
Cleaning Agents
atmosphere, etc.)
n. Plating
Contamination
potential impact on the airworthiness of the
part.
effect(s):

major load paths
b. Heat Transfer
d. Aerodynamics
e. Weight
g. Moment of Weight
171
4/30/10 AC 33-9
Appendix 2
margin, hole exit geometry/angle/location,
cross over hole size, metering plate)
10. Dimension of sealing features (leakage,
secondary circuits)
mating part(s):
distortion effects
• Roundness
• Flatness
• Parallelism
• Concentricity
• True Position
• Tolerances
• Edge Distance
• Requirements
• Requirements
g. Airfoils Profile
• Leading and Trailing Edge
Contour
• Concave and convex contours
• Thickness
• Chord and Airfoil Length
• Twist/Lean/Bow
h. Tip Length
j. Throat Area

Qualification
172
4/30/10 AC 33-9
Appendix 2
ratings
General
fatigue)
21. 33.15 Materials
associated with 33.27; 33.63; 33.83; 33.87;
33.88; and 33.90)
structure
173
4/30/10 AC 33-9
Appendix 2
General
supercharger rotors
systems
Subpart E – Design and construction;
31. 33.63 Vibration
33. 33.66 Bleed air systems
aspects) (Note 2)
ingestion)
174
4/30/10 AC 33-9
Appendix 2
Aircraft Engines
bench testing)
(APU) mode
Part 33 - Appendix A – Instructions for
Part 33 - Appendix B- Certification
Rain and Hail
175

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Advisory

Subject: Developing Data for Major Date: 4/30/10 AC No: 33-9

3. Related References. Please check the FAA’s website at

a. AC 20-62D, Eligibility, Quality, and Identification of Aeronautical Replacement Parts;

d. AC 43-18, Fabrication of Aircraft Parts by Maintenance Personnel; March 24, 2006.

e. AC 120-77, Maintenance and Alteration Data; October 7, 2002.

f. Order 8110.37D, Designated Engineering Representative (DER) Handbook; August 10,

g. Order 8110.4C, Type Certification; August 14, 2008.

h. Order 8110.54, Instructions for Continued Airworthiness Responsibilities,

i. Order 8120.2F, Production Approval and Certificate Management Procedures; January

Table 1. Category 1 Engine Parts

Potential Failure Effects Part Examples

(1) Non-containment of high- Life-limited parts

(3) Significant thrust in the Containment structures

(4) Uncontrolled fire. Fuel system shut-off

Table 2. Category 2 Engine Parts

Potential Failure Effects Part Examples

(3) Release of low-energy parts where it can be shown Engine bearings

(9) Significant uncontrollable thrust oscillation.

(10) Loss of protection such as loss of overspeed

(11) Effect or influence on a Category 1 part.

(1) The part to be repaired, including the part number.

(2) The repair, including any associated limitations. For example:

• The extent of the damage the repair covers.

b. The part categorization, if categorization is used.

d. An applicability assessment of any related service difficulty reports and airworthiness

(1) Category 1 parts. We recommend that persons developing data in support of a

Note: For major repairs of Category 1 parts, Order 8110.37, Designated

(2) Category 2 parts. We recommend persons developing data in support of a major

g. An assessment of the applicability of the Instructions for Continued Airworthiness

7. Developing a Continued Operational Safety (COS) Plan.

b. Part Identification. To facilitate part tracking as part of a COS management plan, we

c. Maintaining Records. Federal Aviation Regulations have specific minimum time

(1) A record keeping plan to:

(b) Retain records of the work performed during the repair.

(c) Retain the technical data for the parts.

(2) Documentation of the quality control of the repair.

(3) A means to monitor the performance of repaired parts in service.

8. Repair of Engine Parts Recovered from Accidents or Incidents.

a. We recommend persons repairing parts recovered from accidents or incidents inspect

APPENDIX 1. FAILURE MODES AND EFFECTS ASSESSMENT

• Maintaining structural integrity, including allowed overspeed and overtemperature

Figure A1.1. Process Flow Diagram

Determine input Identify parts Determine functions

Categorize part by outcomes Determine outcome on part,

Figure A1.2. Part Interaction Considerations

APPENDIX 2. SAMPLE TEMPLATES

b. Acceptable methods are identified as follows:

(1) D - Documentation (for example, Instructions for Continued Airworthiness).

(2) A - Analysis of relevant data.

(3) I - Inspection (for example, metallurgical examination, hardness testing, Non-

(4) R - Rig testing.

(5) C - Component testing.

(6) E - Engine testing.

Table A2-1. Sample Templates.

REPAIR SUBSTANTIATION CHECKLIST - BEARING COMPARTMENT AND

CATEGORIES OF REPAIR DESCRIPTION

i. Chemical Composition (Alloy

a. Microstructure (grain size, grain

a. Coating Material Composition