* * * FOR ALL
TASK 72-24-40-300-804
1 . Thermal Spray Repair of Pilot Diameter FC/Diameter CF.
A.This procedure gives instructions to repair the forward fan shaft (shaft) by thermal spraying the pilot diameter FC/diameter CF. Refer to Figure 901.
NOTE:
This repair can be done at pilot diameter FC, pilot diameter CF, or at the two pilot diameters, if it applies to the defect area.
B.The following maximum repairable limits apply to this repair:
NOTE:
The information below gives maximum repairable limits for the applicable Inspection sections. The paragraphs are numbered the same as the manual Inspection sections.
NOTE:
For 72-24-40, Inspection 001, refer to TASK 72-24-40-200-801 (72-24-40, INSPECTION 001) .
(4)Visual Inspection.
(k)Do an inspection of the shaft aft pilot diameter (diameter FC) for:
1Wear, fretting, and galling on the fan mid shaft contact area of the pilot:
Maximum repairable limit:
Any amount that can be fully removed in the limits of 5.6520 inches (143.560 mm).
(l)Do an inspection of the shaft forward pilot (diameter CF) for:
1Galling on pilot:
Maximum repairable limit:
Any amount that can be fully removed in the limits of 5.2936 inches (134.457 mm).
(5)Dimensional Inspection.
(a)Do an inspection of the shaft for:
4Shaft forward pilot diameter (diameter CF):
Maximum repairable limit:
5.2936 inches (134.457 mm).
5Shaft aft pilot diameter (diameter FC):
Maximum repairable limit:
5.6520 inches (143.560 mm).
C.The subsequent table gives a list of the part numbers that are applicable to this repair. All part numbers are applicable to all paragraphs unless specified differently.
 
Part Number(s)
 
2117M43P01  
2321M44P01  
2321M44P02  
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D.Proprietary/Complex Process Statement.
(1)None.
2 . Tools, Equipment, and Materials.
NOTE:
Repair sources can use equivalent alternatives for tools, equipment, and consumable materials, however, the repair source must demonstrate and document equivalency.
A.Tools and Equipment.
(1)Special Tools. None.
(2)Standard Tools and Equipment. None.
(3)Locally Manufactured Tools. None.
B.Consumable Materials.
 
Code No.
Description
 
C02-088
Lubricant, Solid Dry Film, Everlube 9002 (dry film lubricant)
 
C04-035
Solvent, General (isopropyl alcohol)
 
C04-271
Shot, Peening, Cast Steel (AMS 2431/2 ASH), Cast Steel Shot, High Hardness (55-62 HRc) (S110 cast steel shot)
 
C10-012
Tape, Masking, High Temperature (masking tape)
 
C10-021
Tape, Plastic
 
C10-182
Cloth, Cleaning For Aircraft Structural (SAE-AMS 3819, BMS 15-5) (cleaning cloth)
 
C10-205
Almen Test Strips
C.Referenced Procedures.
 
ATA No.
Description
 
70-00-03
Machining Data
 
70-21-00
Chemical Cleaning
 
70-21-03
Cleaning Method No. 3 - Steam Cleaning
 
70-22-00
Special Cleaning Precautions
 
70-22-80
Special Cleaning Procedure No. 80 - Cleanliness Inspection
 
70-23-00
Stripping Procedures
 
70-23-23
Removal of Coating by High Pressure Water Stripping
 
70-24-00
Etching Procedures for Fluorescent-Penetrant Inspection
 
70-24-01
Swab Etching Procedure
 
70-32-00
Indirect Inspection Methods
 
70-32-03
Spot-Fluorescent-Penetrant Inspection
 
70-42-00
Blending and Removal of High Metal Procedures
 
70-47-01
Shotpeening
 
70-49-00
Thermal Spraying
 
70-49-21
Thermal Spraying Nickel-Chromium/Aluminum Composite (Powder)
 
70-49-28
Thermal Spraying Tungsten Carbide (Powder)
 
72-24-40
Cleaning 001
 
72-24-40
Inspection 001
D.Expendable Parts. None.
E.SPD Information.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. Refer to TASK 70-49-21-340-022 (THERMAL SPRAYING NICKEL-CHROMIUM/ALUMINUM COMPOSITE (POWDER)) and TASK 70-49-28-340-029 (THERMAL SPRAYING TUNGSTEN CARBIDE (POWDER)) .
3 . Dimensional Information.
Subtask 72-24-40-220-094
A.Refer to Figure 901 and Figure 904 for specified dimensions and locations.
NOTE:
The dimensional data identified within this procedure was designed using inches as the base unit of measurement for dimensional values. The conversion to millimeters is rounded to one less decimal digit than inches. For minimum dimensions, converted values are rounded up. For maximum dimensions, converted values are rounded down. To avoid conversion errors, do not re-convert from millimeters to inches.
NOTE:
Reference dimensions do not require inspection.
 
Description
Minimum In-Process Dimension
Maximum In-Process Dimension
Minimum Finish Dimension
Maximum Finish Dimension
Reference Dimension
 
Dia B
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--
--
--
15.9252 in. (404.500 mm)
 
Dia CF
5.2856 in. (134.255 mm)
5.2936 in. (134.457 mm)
5.2768 in. (134.031 mm)
5.2776 in. (134.051 mm)
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Dia FC
(for bond and top coating application)
5.6480 in. (143.460 mm)
5.6520 in. (143.560 mm)
5.6160 in. (142.647 mm)
5.6170 in. (142.671 mm)
--
 
Dia FC
(for top coating application only)
5.6360 in. (143.155 mm)
5.6397 in. (143.248 mm)
5.6160 in. (142.647 mm)
5.6170 in. (142.671 mm)
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Dim. AE
--
--
0.757 in. (19.23 mm)
0.777 in. (19.73 mm)
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4 . Setup Information.
Subtask 72-24-40-350-011
A.Set-up the shaft for machining. Refer to Figure 903 and as follows:
(1)Set-up the shaft to machine the pilot diameter FC and as follows:
(a)Install the shaft mounting flange on the machining fixture/machine table as follows:
Subtask 72-24-40-350-012
1The flatness of surface A must be 0.001 inch (0.02 mm) or less.
2The runout of diameter B must be 0.001 inch (0.02 mm) or less.
(b)Use bolts to attach the shaft to the machining fixture/machine table as follows:
Subtask 72-24-40-350-013
1Install the bolts in each second flange bolt hole.
(c)If necessary, do Subtask 72-24-40-350-012 (paragraph 4.A.(1)(a)1) and Subtask 72-24-40-350-013 (paragraph 4.A.(1)(b)1) again to get the runout of diameter B.
(2)Set-up the shaft to machine the pilot diameter CF and as follows:
(a)Install the shaft mounting flange on the machining fixture/machine table as follows:
Subtask 72-24-40-350-014
1The flatness of surface A must be 0.001 inch (0.02 mm) or less.
2The runout of diameter B must be 0.001 inch (0.02 mm) or less.
3The total runout of diameter FC must be 0.0005 inch (0.012 mm) or less.
(b)Use bolts to attach the shaft to the machining fixture/machine table as follows:
Subtask 72-24-40-350-015
1Install the bolts in each second flange bolt hole.
(c)If necessary, do Subtask 72-24-40-350-014 (paragraph 4.A.(2)(a)1) thru Subtask 72-24-40-350-015 (paragraph 4.A.(2)(b)1) again to get the flatness of surface A, runout of diameter B, and runout of diameter FC.
5 . Procedure.
Subtask 72-24-40-160-010
A.If necessary, remove the dry film lubricant from the spline teeth and threads of the shaft. Refer to TASK 72-24-40-200-801 (72-24-40, INSPECTION 001) and Figure 901.
Subtask 72-24-40-160-011
B.If necessary, clean the shaft. Refer to TASK 72-24-40-100-801 (72-24-40, CLEANING 001).
Subtask 72-24-40-220-095
C.Do a visual inspection of the shaft pilot diameter FC/diameter CF. Refer to Figure 901 and as follows:
(1)If there is thermal spray coating, do Subtask 72-24-40-330-002 (paragraph 5.D.).
(2)If there is no thermal spray coating, do Subtask 72-24-40-160-012 (paragraph 5.E.).
Subtask 72-24-40-330-002
D.Alternative Procedure Available. Remove the thermal spray coating from the shaft pilot diameter FC/diameter CF. Refer to TASK 70-23-00-100-001 (STRIPPING PROCEDURES), TASK 70-23-23-330-008 (REMOVAL OF COATINGS BY HIGH PRESSURE WATER STRIPPING), Figure 901, and Figure 902.
Subtask 72-24-40-320-004
CAUTION:
REMOVE ONLY THE MINIMUM QUANTITY OF MATERIAL NECESSARY OR DAMAGE TO THE SHAFT CAN OCCUR.
D.A.Alternative Procedure. Machine the shaft pilot diameter FC/diameter CF to remove the thermal spray coating. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-24-40-220-094 (paragraph 3.A.), Figure 901, and Figure 902.
(1)Set-up the shaft to machine diameter FC/diameter CF. Refer to Subtask 72-24-40-350-011 (paragraph 4.A.).
Subtask 72-24-40-160-012
E.If necessary, clean the shaft. Refer to TASK 72-24-40-100-801 (72-24-40, CLEANING 001).
Subtask 72-24-40-220-096
F.Do a visual inspection of the shaft pilot diameter FC/diameter CF for parent metal wear as follows:
(1)Use 10X magnification.
(2)If the pilot diameter FC/diameter CF has parent metal wear, do Subtask 72-24-40-320-005 (paragraph 5.G.).
(3)If the pilot diameter FC or diameter CF do not have parent material wear, measure to make sure it is within the in-process limits. Refer to Subtask 72-24-40-220-094 (paragraph 3.A.) and as follows:
(a)If the pilot diameter FC or diameter CF are more than the maximum in-process limits then the shaft cannot be repaired by this procedure.
Subtask 72-24-40-320-005
CAUTION:
MAKE SURE TO REMOVE THE MINIMUM QUANTITY OF PARENT MATERIAL NECESSARY TO REMOVE DEFECTS.
G.Machine the shaft pilot diameter FC/diameter CF. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-24-40-220-094 (paragraph 3.A.), Figure 904, and as follows:
(1)Set-up the shaft to machine diameter FC/diameter CF. Refer to Subtask 72-24-40-350-011 (paragraph 4.A.).
(2)Machine the shaft pilot diameter FC/diameter CF to the in-process dimensions and as follows:
(a)If necessary, remove all parent metal wear from the shaft.
NOTE:
If the damage is not removed in the maximum in-process dimension, the shaft cannot be repaired by this procedure.
(b)The final surface finish must be 90 microinches (2.3 micrometers).
(c)Break all sharp edges to 0.015-0.030 inch (0.39-0.76 mm).
(3)Remove the shaft from the machining fixture/machine table.
Subtask 72-24-40-110-010
H.Etch the shaft pilot diameter FC/diameter CF. Refer to TASK 70-24-00-110-033 (ETCHING PROCEDURES FOR FLUORESCENT-PENETRANT INSPECTION), TASK 70-24-01-110-034 (SWAB ETCHING PROCEDURE), and as follows:
(1)Use Class B etchant.
Subtask 72-24-40-230-005
I.Do an inspection of the shaft pilot diameter FC/diameter CF. Refer to TASK 70-32-00-200-002 (INDIRECT INSPECTION METHODS), TASK 70-32-03-230-002 (SPOT-FLUORESCENT-PENETRANT INSPECTION), and as follows:
(1)Use Class G penetrant.
(2)Linear indications are not permitted.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
(3)Indications that are 0.015 inch (0.38 mm) or less are permitted.
Subtask 72-24-40-110-011
J.Clean the shaft pilot diameter FC/diameter CF as follows:
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
(1)Clean the shaft pilot diameter FC/diameter CF with a C10-182   cleaning cloth moist with C04-035  isopropyl alcohol and do as follows:
(a)Replace the dirty clothes with a C10-182  cleaning cloth until the last moist cloth stays clean.
Subtask 72-24-40-380-004
K.Peen the shaft pilot diameter FC/diameter CF. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 902, and as follows:
(1)Apply C10-021  plastic tape to the shaft that you will not peen.
(2)Use C04-271  S110 cast steel shot.
(3)Peen the shaft to an intensity of 6-12N and as follows:
(a)Make sure that you do the intensity verification in a simulative fixture.
(4)Use C10-205  Almen test strips and an Almen strip holder to measure the intensity at pilot diameter FC/diameter CF.
(5)Overspray is permitted on all areas, but not on threads and on thermal spray coated areas.
(6)Use a minimum impingement angle of 35 degrees.
(7)Remove the plastic tape from the shaft pilot diameter FC/diameter CF.
Subtask 72-24-40-160-013
WARNING:
USE EYE PROTECTION WHEN YOU USE COMPRESSED AIR TO CLEAN, COOL, OR DRY PARTS OR TOOLS. PARTICLES CAN CAUSE AN INJURY TO YOUR EYES. ENSURE COMPRESSED AIR PRESSURE IS LESS THAN 30 PSIG (207 KPA). DO NOT POINT COMPRESSED AIR AT YOURSELF OR OTHER PERSONS.
(8)Use clean, dry shop air to remove the remaining dust and particles from the shaft.
Subtask 72-24-40-220-098
L.Do a dimensional inspection of the in-process limits of diameter FC for the application of a bond coat and top coat or the application of only a top coat to restore diameter FC to the finish limits, use the table below as follows:
 
Diameter FC In-Process Limits
Coating Method and Steps
 
If diameter FC is more than 5.637 inches (143.248 mm).
Apply a bond coat and top coat to diameter FC, do Subtask 72-24-40-340-003 (paragraph 5.M.) and Subtask 72-24-40-340-002(paragraph 5.N.).
 
If diameter FC is 5.637 inches (143.248 mm) or less.
Apply only a top coat to diameter FC, do Subtask 72-24-40-340-002 (paragraph 5.N.).
Subtask 72-24-40-340-003
WARNING:
DO NOT THERMAL SPRAY IF YOU ARE NOT APPROVED (TRAINED AND QUALIFIED). USE PERSONAL PROTECTION EQUIPMENT AND APPROVED SAFETY PROCEDURES. USE EITHER A CONTINUOUS-FLOW EXHAUST SYSTEM OR A WATER-CURTAIN EXHAUST SYSTEM. WATER-CURTAIN EXHAUST SYSTEMS MAY COLLECT OVERSPRAY PARTICLES OF SOME METALS (MAGNESIUM, ALUMINUM AND IRON) AND CAN FORM HYDROGEN. WHEN MIXED WITH AIR, HYDROGEN CAN BURN AND IS EXPLOSIVE.
M.Thermal-spray the shaft (diameter FC) and the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-21-340-022 (THERMAL SPRAYING NICKEL-CHROMIUM/ALUMINUM COMPOSITE (POWDER)), Figure 901, and as follows:
(1)Apply C10-012  masking tape to the areas adjacent to diameter FC. Refer to Figure 902.
(2)Do the preliminary operations specified in TASK 70-49-00-340-001 (THERMAL SPRAYING), use the surface roughness limits for the titanium base material.
(3)Overspray is not permitted.
(4)Apply the bond coat to the shaft (diameter FC) and the test specimens at the same time, same distance, same angle, and to the same as-sprayed thickness of 0.004-0.008 inch (0.11-0.20 mm) and do as follows:
(a)Apply a sufficient quantity of bond coat to make a final top coat thickness of 0.0095-0.0120 inch (0.242-0.304 mm) after machining. Refer to Subtask 72-24-40-220-094 (paragraph 3.A.).
(5)Do all quality assurance testing specified in TASK 70-49-21-340-022 (THERMAL SPRAYING NICKEL-CHROMIUM/ALUMINUM COMPOSITE (POWDER)).
(a)Do the metallography test to make sure that the bond coat meets the quality requirements.
(b)Deleted.
(6)Remove the C10-012  masking tape from the areas adjacent to diameter FC.
Subtask 72-24-40-340-002
WARNING:
DO NOT THERMAL SPRAY IF YOU ARE NOT APPROVED (TRAINED AND QUALIFIED). USE PERSONAL PROTECTION EQUIPMENT AND APPROVED SAFETY PROCEDURES. USE EITHER A CONTINUOUS-FLOW EXHAUST SYSTEM OR A WATER-CURTAIN EXHAUST SYSTEM. WATER-CURTAIN EXHAUST SYSTEMS MAY COLLECT OVERSPRAY PARTICLES OF SOME METALS (MAGNESIUM, ALUMINUM AND IRON) AND CAN FORM HYDROGEN. WHEN MIXED WITH AIR, HYDROGEN CAN BURN AND IS EXPLOSIVE.
N.Thermal-spray the shaft and the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-28-340-029 (THERMAL SPRAYING TUNGSTEN CARBIDE (POWDER)), Figure 901, and as follows:
(1)Apply C10-012  masking tape to the areas adjacent to diameter FC/diameter CF. Refer to Figure 902.
(2)Do the preliminary operations specified in TASK 70-49-00-340-001 (THERMAL SPRAYING), use the surface roughness limits for the titanium base material and as follows:
(a)If a bond coat is applied to the shaft (diameter FC), it is not permitted to grit blast the shaft (diameter FC).
(3)Overspray is permitted on diameter CF to the tangency point. Refer to Figure 902. Overspray is not permitted in diameter FC.
(4)Apply the thermal spray coating as follows:
(a)Make sure that you apply thermal spray coating to the test specimens at the same time, same distance, same angle, and to the same thickness as the shaft, and as follows:
1For diameter CF. Thermal-spray coating thickness must be 0.004-0.008 inch (0.11-0.20 mm) after final machining. Make sure that you apply the thermal-spray coating to a maximum as-spray thickness of 0.008 inch (0.20 mm).
2For diameter FC. Thermal-spray coating thickness must be 0.0095-0.0120 inch (0.242-0.304 mm) after final machining. Make sure that you apply the thermal-spray coating to a maximum as-spray thickness of 0.0120 inch (0.304 mm).
(5)Do all quality assurance testing specified in TASK 70-49-28-340-029 (THERMAL SPRAYING TUNGSTEN CARBIDE (POWDER)).
(6)Remove the masking tape from the areas adjacent to diameter FC/diameter CF.
Subtask 72-24-40-320-006
O.Machine the shaft pilot diameter FC/diameter CF. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-24-40-220-094 (paragraph 3.A.), Figure 904, and as follows:
(1)Set-up the shaft to machine diameter FC/diameter CF. Refer to Subtask 72-24-40-350-011 (paragraph 4.A.).
(2)Machine the shaft pilot diameter FC/diameter CF to the finish dimension as follows:
(a)Make sure that there is a 0.000-0.003 inch (0.00-0.07 mm) step between the thermal spray coating and the base material.
(3)The surface finish must be 32 microinches (0.81 micrometers) or better.
(4)If necessary, blend the shaft pilot diameter FC/diameter CF. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
(a)Blend the shaft to remove all high metal or rolled edges.
(b)Break all the sharp edges to 0.005-0.015 inch (0.13-0.38 mm).
(5)Remove the shaft from the machining fixture/machine table.
Subtask 72-24-40-220-097
P.Do a visual inspection of the shaft thermal spray coating as follows:
(1)Chipping, flaking, and spalling are not permitted.
(2)The thermal spray coating must have a full, constant coverage in the thermal spray coating areas.
(3)If the thermal spray coating is more than the limits, do Subtask 72-24-40-330-002 (paragraph 5.D.) thru Subtask 72-24-40-220-097 (paragraph 5.P.) again.
Subtask 72-24-40-640-005
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
Q.If necessary, apply C02-088  dry film lubricant to the threads and splines of the shaft. Refer to TASK 72-24-40-200-801 (72-24-40, INSPECTION 001).
Subtask 72-24-40-110-012
R.Clean the shaft. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-24-40-160-014
CAUTION:
MAKE SURE THAT ALL NECESSARY REPAIRS AND DRY FILM LUBRICANT APPLICATION ARE COMPLETED BEFORE YOU DO THE CLEANLINESS INSPECTION OR DAMAGE TO THE SHAFT AND THE ENGINE ASSEMBLY CAN OCCUR.
S.Do a cleanliness inspection of the shaft. Refer to TASK 70-22-00-100-001 (SPECIAL CLEANING PRECAUTIONS), TASK 70-22-80-160-801 (SPECIAL CLEANING PROCEDURE NO. 80 - CLEANLINESS INSPECTION), and as follows:
(1)Use Class C cleanliness.
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Figure 901   (Sheet 1 ) Forward Fan Shaft
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Figure 901   (Sheet 2 ) Forward Fan Shaft
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Figure 901   (Sheet 3 ) Forward Fan Shaft
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Figure 902   (Sheet 1 ) Forward Fan Shaft - Masking Areas
* * * FOR ALL
Figure 902   (Sheet 2 ) Forward Fan Shaft - Masking Areas
* * * FOR ALL
Figure 903   Forward Fan Shaft - Setup information
* * * FOR ALL
Figure 904   (Sheet 1 ) Forward Fan Shaft - Final Machining Dimensions
* * * FOR ALL
Figure 904   (Sheet 2 ) Forward Fan Shaft - Final Machining Dimensions