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TASK 72-30-01-300-805
1 . Weld Repair of the Damaged Bolthole Threads on the Extension Case Pads of the High Pressure Compressor.
A.This procedure gives instructions to repair damage to boltholes on the high pressure compressor stator extension case (case) pads by welding and replacing the lock ring inserts. Refer to Figure 901.
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.
(4)Visual Inspection.
* * * PRE SB   72-0344
(g)Do an inspection of the threaded holes if the insert is removed for. Refer to TASK 72-30-01-300-801 (72-30-01, REPAIR 001).
1Damaged threads.
Maximum repairable limit:
Any amount.
2Do a No-go pin gauge inspection of the threaded holes.
Maximum repairable limit:
Any amount.
* * * END PRE SB   72-0344
C.The subsequent table gives a list of the part numbers that are applicable to this procedure. All part numbers are applicable to all paragraphs unless specified differently.
 
Part Number(s)
 
2302M69G03  
2302M69G06  
2644M02G01  
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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 Number
Description
 
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Inconel 718 Weld Wire AMS 5832
C.Referenced Procedures.
 
ATA Number
Description
 
70-00-03
Machining Data
 
70-21-22
Light Duty Aqueous Cleaning
 
70-24-00
Etching Procedures for Fluorescent Penetrant Inspection
 
70-24-01
Swab Etching Procedure
 
70-31-02
Acceptability Limits for Fluorescent-Penetrant Inspection
 
70-32-00
Indirect Inspection Methods
 
70-32-03
Spot-Fluorescent-Penetrant Inspection
 
70-32-05
Radiographic Inspection
 
70-41-00
Welding and Brazing Practices
 
70-42-00
Blending and Removal of High Metal Procedures
 
70-44-02
Localized Heat Treatment Procedures
 
72-30-01
Inspection 001
 
72-30-01
Repair 001
D.Expendable Parts. None.
E.SPD Information.
(1)Spares Supplied. None.
(2)Protected Spares. None.
(3)Locally Manufactured Spares. None.
F.Special Solutions. None.
G.Test Specimens. None.
3 . Dimensional Information.
Subtask 72-30-01-350-028
A.Refer to Figure 901 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.
4 . Setup Information.
Subtask 72-30-01-350-029
A.Set-up the case to machine the forward/aft air manifold pads. Refer to Figure 901, Figure 902, and as follows:
(1)Install the case with the aft surface on ground blocks.
(2)Make sure that the forward surface is 0.002 inch (0.05 mm) flat or better.
(3)Make sure that the air manifold pad surface is perpendicular to the machine head spindle to a maximum 0.005 inch (0.12 mm).
(4)Use the center of the oval section of the manifold pad as a repair datum to find the center of the damaged bolthole.
Subtask 72-30-01-350-030
B.Set-up the case to machine the eductor air tube pad. Refer to Figure 901, Figure 902, and as follows:
(1)Install the case with the aft surface on ground blocks.
(2)Make sure that the forward surface is 0.002 inch (0.05 mm) flat or better.
(3)Make sure that the surface of the eductor air tube pad is perpendicular to the machine head spindle to a maximum 0.005 inch (0.12 mm).
(4)Use the center of the eductor air tube pad as a repair datum to find the center of the damaged bolthole.
Subtask 72-30-01-350-031
C.Set-up the case to machine the bracket pad and the support bracket. Refer to Figure 901, Figure 902, and as follows:
(1)Install the case with the aft surface on ground blocks.
(2)Make sure that the forward surface is 0.002 inch (0.05 mm) flat or better.
(3)Make sure that the bracket support pad surface is perpendicular to the machine head spindle to a maximum 0.005 inch (0.12 mm).
(4)Use the repair datums defined in the figures to find the center of the damaged bolthole.
5 . Procedure.
Subtask 72-30-01-350-032
A.Identify the pad that has the damaged bolthole threads. Refer to Figure 901 and Figure 902.
Subtask 72-30-01-350-033
B.Remove inserts at the remaining locations on the same pad that has bolthole damage. Refer to TASK 72-30-01-300-801 (72-30-01, REPAIR 001).
Subtask 72-30-01-350-034
C.Set-up the case to machine the boltholes that you will repair. Refer to Figure 902 and Subtask 72-30-01-350-029 (paragraph 4).
Subtask 72-30-01-320-009
CAUTION:
REMOVE ONLY THE MINIMUM QUANTITY OF MATERIAL NECESSARY OR DAMAGE TO THE CASE CAN OCCUR.
D.Machine to remove damage from the bolthole. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 903, and as follows:
(1)Remove the damaged bolthole threads as follows:
(a)Put the machine head spindle on the center of the damaged bolthole.
(b)Increase the damaged bolthole diameter to fully remove the damage not to be more than 0.430 inch (10.92 mm).
(c)Remove the minimal parent material necessary when you remove the damage.
(d)Machine a 60 degree chamfer at the inner and outer locations of the repair area for welding access.
Subtask 72-30-01-110-010
E.Clean the case. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING), TASK 70-21-22-110-801 (CLEANING METHOD NO. 22 - LIGHT DUTY AQUEOUS CLEANING), and as follows:
(1)Use method 2.
Subtask 72-30-01-110-011
F.Etch the case repair areas. 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 C etchant.
Subtask 72-30-01-230-006
G.Do an inspection of the case repair areas. 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 D penetrant.
(2)For the acceptability limits, refer to TASK 70-31-02-220-003 (ACCEPTABILITY LIMITS FOR FLUORESCENT PENETRANT INSPECTION) and as follows:
(a)Use Class A limits.
Subtask 72-30-01-110-012
H.Clean the case. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING), TASK 70-21-22-110-801 (CLEANING METHOD NO. 22 - LIGHT DUTY AQUEOUS CLEANING), and as follows:
(1)Use method 2.
Subtask 72-30-01-350-035
I.Attach a restraining fixture to the forward flange and the aft flange to the welding turntable with clamps to prevent distortion during welding.
Subtask 72-30-01-310-001
CAUTION:
IF YOU WELD MORE THAN ONE AREA, LET SUFFICIENT TIME TO DECREASE THE TEMPERATURE BETWEEN EACH WELDING.
CAUTION:
DO NOT REMOVE MORE MATERIAL WITH HAND TOOLS FROM THE MACHINED WELD PREPARATION THAN YOU DID BEFORE.
J.Weld the case repair area. Refer to TASK 70-41-00-310-001 (WELDING AND BRAZING PRACTICES), Figure 904, and as follows:
(1)Weld-the case as follows:
(a)Use nickel-plated copper backup blocks (blocks) as follows:
1Align the blocks with the contour of the case inner diameter (ID).
2Attach the blocks on the two sides of the repair area.
(b)Weld the repair area with a perimeter style weld and as follows:
NOTE:
With the backup blocks and weld recommendations shown below, part distortion and the quantity of weld filler that is necessary to repair the bolthole will be kept to a minimum.
1Do not plug-weld the bolthole.
2You must keep an area in the center of the machined bolthole without weld build up.
3Use Inconel 718 Weld Wire AMS 5832.
4Use the low-heat input weld procedure.
5Make short weld passes and let the area become cool between the weld passes.
Subtask 72-30-01-350-036
WARNING:
DO NOT BREATHE THE PARTICLES FROM BLENDING. PARTICLES FROM BLENDING CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE APPROPRIATE PERSONAL PROTECTION EQUIPMENT, INCLUDING RESPIRATORY PROTECTION, SAFETY GLASSES, AND GLOVES.
K.Blend the weld smooth to the case ID until the welds are 0.0000-0.0015 inch (0.000-0.038 mm) above the adjacent parent metal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Subtask 72-30-01-110-013
L.Clean the case. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING), TASK 70-21-22-110-801 (CLEANING METHOD NO. 22 - LIGHT DUTY AQUEOUS CLEANING), and as follows:
(1)Use method 2.
Subtask 72-30-01-370-001
M.Local heat-treat the case weld repair area. Refer to TASK 70-44-00-800-010 (HEAT TREATING), TASK 70-44-02-370-003 (LOCALIZED HEAT TREATMENT PROCEDURES), and as follows:
(1)Use Cycle LH-1, short age cycle for Inconel 718 fabrications.
Subtask 72-30-01-260-001
N.Do a radiographic inspection of the case welded area. Refer to TASK 70-32-00-200-002 (INDIRECT INSPECTION METHODS), TASK 70-32-05-260-001 (RADIOGRAPHIC INSPECTION) , and as follows:
(1)Refer to TASK 70-31-02-220-003 (ACCEPTABILITY LIMITS FOR FLUORESCENT PENETRANT INSPECTION) and as follows:
(a)Use Class A limits.
Subtask 72-30-01-350-037
O.Set-up the case to machine the bolthole that you will repair. Refer to Figure 902 and Subtask 72-30-01-350-029 (paragraph 4).
Subtask 72-30-01-320-010
P.Machine the locking ring slot and threaded hole to the finish dimensions. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 901, Figure 902, and Figure 905.
Subtask 72-30-01-110-014
Q.Clean the case. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING), TASK 70-21-22-110-801 (CLEANING METHOD NO. 22 - LIGHT DUTY AQUEOUS CLEANING), and as follows:
(1)Use method 2.
Subtask 72-30-01-260-002
R.Do a radiographic inspection of the case welded area. Refer to TASK 70-32-00-200-002 (INDIRECT INSPECTION METHODS), TASK 70-32-05-260-001 (RADIOGRAPHIC INSPECTION) , and as follows:
(1)Refer to TASK 70-31-02-220-003 (ACCEPTABILITY LIMITS FOR FLUORESCENT PENETRANT INSPECTION) and as follows:
(a)Use Class A limits.
Subtask 72-30-01-110-015
S.Clean the case. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING), TASK 70-21-22-110-801 (CLEANING METHOD NO. 22 - LIGHT DUTY AQUEOUS CLEANING), and as follows:
(1)Use method 2.
Subtask 72-30-01-110-016
T.Etch the case repaired areas. 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 C etchant.
Subtask 72-30-01-230-007
U.Do an inspection of the case repaired areas. 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 D penetrant.
(2)For the acceptability limits, refer to TASK 70-31-02-220-003 (ACCEPTABILITY LIMITS FOR FLUORESCENT PENETRANT INSPECTION) and as follows:
(a)Use Class A limits.
Subtask 72-30-01-110-017
V.Clean the case. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING), TASK 70-21-22-110-801 (CLEANING METHOD NO. 22 - LIGHT DUTY AQUEOUS CLEANING), and as follows:
(1)Use method 2.
Subtask 72-30-01-220-083
W.Do a dimensional inspection of the case. Refer to TASK 72-30-01-200-801 (72-30-01, INSPECTION 001).
Subtask 72-30-01-350-038
X.Install threaded inserts at all locations where you removed the inserts. Refer to TASK 72-30-01-300-801 (72-30-01, REPAIR 001).
Subtask 72-30-01-110-018
Y.Clean the case. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING), TASK 70-21-22-110-801 (CLEANING METHOD NO. 22 - LIGHT DUTY AQUEOUS CLEANING), and as follows:
(1)Use method 2.
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Figure 901   (Sheet 1 ) High Pressure Compressor Stator Extension Case Pads
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Figure 901   (Sheet 2 ) High Pressure Compressor Stator Extension Case Pads
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Figure 901   (Sheet 3 ) High Pressure Compressor Stator Extension Case Pads
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Figure 901   (Sheet 4 ) High Pressure Compressor Stator Extension Case Pads
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Figure 902   Weld Repair Setup and Figure Requirements
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Figure 903   Pre-Weld Machine Dimensions at Damaged Bolthole
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Figure 904   Perimeter Welding at Damaged Bolthole
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Figure 905   (Sheet 1 ) Pad and Bolthole Definitions
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Figure 905   (Sheet 2 ) Pad and Bolthole Definitions
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Figure 905   (Sheet 3 ) Pad and Bolthole Definitions
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Figure 905   (Sheet 4 ) Pad and Bolthole Definitions
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Figure 905   (Sheet 5 ) Pad and Bolthole Definitions
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Figure 905   (Sheet 6 ) Pad and Bolthole Definitions
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Figure 905   (Sheet 7 ) Pad and Bolthole Definitions
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Figure 905   (Sheet 8 ) Pad and Bolthole Definitions
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Figure 905   (Sheet 9 ) Pad and Bolthole Definitions
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Figure 905   (Sheet 10 ) Pad and Bolthole Definitions
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Figure 905   (Sheet 11 ) Pad and Bolthole Definitions
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Figure 905   (Sheet 12 ) Pad and Bolthole Definitions
* * * FOR ALL
Figure 905   (Sheet 13 ) Pad and Bolthole Definitions