A visual inspection of an engine identified a loose bent fan blade; what is the correct repair procedure?

• A. Replacement of the fan assembly
• B. Straighten and bend blade
• C. Re-rivet and straighten the bent blade
• D. Weld and straighten the bent blade

Answer: (D)

A damaged, loose, and bent fan blade creates an unsafe condition because the blade must rotate at high speed with precise balance. Straightening or welding introduces heat, alters the blade’s metallurgy and geometry, and can leave hidden cracks or residual stresses that rapidly propagate under operation. This compromises strength and balance, increasing the risk of blade failure. Replacing the entire fan assembly ensures a new, properly balanced unit with no cracks or fatigue, which is the safe and reliable repair. After replacement, the system should be balanced and checked for proper run-out to confirm safe operation.