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TASK 72-31-41-300-801
1 . Airfoil Blend Repair.
A.This procedure gives instructions to repair the high pressure compressor rotor stage 1 blisk (blisk) airfoils by blending the damaged areas. 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.
(5)Visual Inspection.
(c)Do an inspection of area B (leading and trailing edges) on the blisk blade for:
1Nicks:
Maximum repairable limit:
Any amount, in the limits of Figure 902 and Figure 904 after you fully remove the damage by blending in this repair procedure.
2Dents and pits:
Maximum repairable limit:
Any amount, in the limits of Figure 902 and Figure 904 after you fully remove the damage by blending in this repair procedure.
3Scratches and gouges:
Maximum repairable limit:
Any amount, in the limits of Figure 902 and Figure 904 after you fully remove the damage by blending in this repair procedure.
4Deposits:
Maximum repairable limit:
Any amount. Blend but do not remove the parent material.
5Metal splatter deposits:
Maximum repairable limit:
Any amount. Blend but do not remove the parent material.
9Tears:
Maximum repairable limit:
Any amount, in the limits of Figure 902 and Figure 904 after you fully remove the damage by blending in this repair procedure.
(h)Do an inspection of the tip corners of the blisk for:
3All other damage:
Maximum repairable limit:
Any amount, in the limits of Figure 902 and Figure 904 after you fully remove the damage by blending in this repair procedure.
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)
 
2445M81P01  
2448M41P01  
Deleted
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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.
 
Description
Manufacturer
 
Surtronics 25+ Profilometer
Taylor Hobson Ltd.
 
P.O. Box 36
 
2 New Star Road
 
Leicester, LE4 9JQ, England
(3)Locally Manufactured Tools. None.
B.Consumable Materials.
 
Code No.
Description
 
C04-286
Shot, Peening, Cast Steel (AMS 2431/1 ASR), Cast Steel Shot, Regular Hardness (45-52 HRc) (S110 cast steel shot)
 
C10-010
Abrasive Cloth
 
C10-012
Tape, Masking (masking tape)
 
C10-021
Tape, Plastic
 
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Stone, Abrasive
C.Referenced Procedures.
 
ATA No.
Description
 
70-24-00
Etching Procedures for Fluorescent-Penetrant Inspection
 
70-24-01
Swab Etching Procedure
 
70-32-00
Indirect Inspection Methods
 
70-32-02
Fluorescent Penetrant Inspection
 
70-42-00
Blending and Removal of High Metal Procedures
 
70-47-01
Shotpeening
 
72-31-41
Cleaning 001
 
72-31-41
Inspection 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 72-31-41-220-087
A.Refer to Figure 901 and Figure 902 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 reconvert from millimeters to inches.
NOTE:
Reference dimensions do not require inspection.
NOTE:
All dimensions were removed from the Dimensional Information table.
4 . Setup Information.
None.
5 . Procedure.
Subtask 72-31-41-160-009
CAUTION:
BE VERY CAREFUL DURING THE HANDLING AND STORAGE OF THE BLISK. AIRFOILS MUST ALWAYS HAVE PROTECTION BUT NOT DURING CLEANING, INSPECTION OR REPAIR.
A.If necessary, clean the blisk. Refer to TASK 72-31-41-100-801 (72-31-41, CLEANING 001).
Subtask 72-31-41-350-007
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.
CAUTION:
MAKE SURE THAT YOU KEEP THE MINIMUM CHORD LENGTH WHEN YOU DO THE BLENDING PROCEDURE. KEEP THE TIP CORNER RADIUS TO A MINIMUM. DO NOT BLEND THE TIP CORNER UNLESS IT IS NECESSARY TO AGREE WITH FIGURE 902.
CAUTION:
ONLY ONE BLEND IS PERMITTED PER BLISK AIRFOIL. BLENDING IS PERMITTED TO A MAXIMUM OF SEVEN AIRFOILS PER BLISK. A MAXIMUM OF FOUR ADJACENT AIRFOILS CAN BE BLENDED.
CAUTION:
MAKE SURE THAT YOU DO NOT INCREASE THE TEMPERATURE OF THE BLISK AIRFOIL TOO MUCH WHEN YOU POWER-BLEND THE LEADING AND TRAILING EDGES. TOO MUCH HEAT CAN CAUSE THERMAL STRESS TO THE BLISK.
CAUTION:
MAKE SURE YOU DO NOT REMOVE THE BLISK PARENT MATERIAL WHEN BLENDING TO REMOVE THE METAL SPLATTER OR DEPOSITS FROM THE BLISK AIRFOIL.
B.Blend the blisk damaged areas on the leading and trailing edges, area B. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), Figure 901, Figure 902, Figure 904 and as follows:
(1)Blending is not permitted on area A and area C of the blisk.
WARNING:
USE EYE PROTECTION WHEN YOU POLISH MATERIAL OR PARTS. THE PARTICLES CAN CAUSE AN INJURY TO YOUR EYES. USE IN A WELL-VENTILATED AREA.
(2)Use a fine C10-010  abrasive cloth or an abrasive stone as follows:
(a)Blend in longitudinal direction only (parallel to the blade length).
NOTE:
If a large blend is necessary, a power tool can be used, but only at a low speed.
(b)Make sure that the surface finish after the blending procedure is equivalent to or better than the initial surface finish.
(3)For the tears damage, blend 1.25 times the damage depth to fully remove the damage.
(4)The blend length must be a minimum of six times the depth of the damage and maximum eight times the depth.
(5)The blended contour of the blisk repair area must be the same as the contour of the adjacent non-blended areas.
(6)The trailing edge thickness in the blisk repair area must not be less than the thickness of the adjacent non-blended trailing edge.
(7)The chord length in the repaired section of the blisk airfoil must not be less than the minimum dimension G after the repair.
NOTE:
It is only necessary to measure the chord length on sections affected by the blend.
(8)If the blend location, measured from the airfoil tip, is equal to or less than dimension D, blend area D. Refer to Figure 902 and do as follows:
(a)Remove the unwanted material in area D.
(b)Keep blend depth to the same depth as the initial blend depth.
(9)The maximum number of permitted blends is dependent on blend depths and must be within requirements of Figure 904. These requirements must be read as follows:
(a)Count the total number of blends necessary between 0.025-0.040 inch (0.64-1.01 mm) in depth (if there are blends done before, include them) and find this number in column C, and as follows:
1For blends from previous repair only, it is permitted to have a blend ratio that is greater than 8 to 1. It is not permitted to create new blends greater than 8 to 1.
(b)Do a check of the same row in column D that agree with the maximum permitted number of blends less than 0.025 inch (0.63 mm) in depth.
NOTE:
For example, if it is necessary to do one blend of 0.040 inch (1.01 mm), then also a maximum of five blends of less than 0.025 inch (0.63 mm) can be done.
(c)The total blend count must include all blends done before and the number cannot be more than the given in column C and column D.
(d)You can blend one airfoil, if a minimum of one adjacent airfoil before and one adjacent airfoil after are not blended.
(e)You can blend a set of airfoils (it means two, three, or four consecutive airfoils) if a minimum of three adjacent airfoils before and three adjacent airfoils after are not blended.
(f)You cannot blend more than seven airfoils on the blisk. This includes the airfoils blended before.
Subtask 72-31-41-110-003
C.Etch the blisk 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 B etchant.
Subtask 72-31-41-230-007
D.Do an inspection of the blisk airfoil repair areas. Refer to TASK 70-32-00-200-002 (INDIRECT INSPECTION METHODS), TASK 70-32-02-230-001 (FLUORESCENT PENETRANT INSPECTION), and as follows:
(1)Use Class G penetrant.
(2)Indications are not permitted at edges, in fillets, or 0.100 inch (2.54 mm) of the edges of the airfoil.
(3)Deleted.
(4)Indications 0.015 inch (0.38 mm) or less are permitted.
(5)Linear indications are not permitted.
NOTE:
Linear indications are indications that are at least three times longer than they are wide.
Subtask 72-31-41-380-001
E.Alternative Procedure Available. Peen the blisk area CA. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 903 and as follows:
(1)It is necessary to peen at the same time on the two sides of the airfoil.
(2)Apply C10-021  plastic tape to the blisk areas that you will not peen.
(3)Use C04-286  S110 cast steel shot at an intensity of 0.006-0.012N.
(4)Make sure that you make the intensity verification in the blisk repair area with a scrap part or simulative fixture.
(5)A minimum coverage of 100 percent is necessary.
(6)Remove the plastic tape from the blisk.
Subtask 72-31-41-380-004
E.A.Alternative Procedure. Peen the blisk area CB. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 903, and as follows:
(1)It is permitted to peen one side of the airfoil at a time.
(2)Apply C10-012  masking tape to the areas that you will not peen.
(3)It is necessary to apply masking to all the airfoils that you will not peen.
(4)For the blended airfoils, area CB will not have masking, all other airfoil areas must be have masking.
(5)Use C04-286  S110 cast steel shot.
(6)Peen area to an intensity of 0.006-0.012N.
(7)Make sure that you make the intensity verification in the blisk repair area with a scrap part or simulative fixture.
(8)A minimum coverage of 100 percent is necessary and a maximum coverage of 125 percent is permitted.
(9)Remove the masking tape from the blisk.
Subtask 72-31-41-220-064
F.Do an inspection of the blisk airfoil surface finish as follows:
(1)Use a Surtronics 25+ Profilometer or equivalent GE approved tool. Refer to paragraph 2.A.(2).
(2)Use a 0.010 inch (0.25 mm) cutoff length.
(3)The surface finish of the airfoil must be 20 microinches (0.5 micrometer) or better.
Subtask 72-31-41-140-002
WARNING:
USE EYE PROTECTION WHEN YOU POLISH MATERIAL OR PARTS. THE PARTICLES CAN CAUSE AN INJURY TO YOUR EYES. USE IN A WELL-VENTILATED AREA.
(4)If necessary, polish the with your hands the blisk repaired area with C10-010  abrasive cloth or equivalent to do a surface finish.
Subtask 72-31-41-220-065
G.Do a final visual inspection of the blisk. Refer to TASK 72-31-41-200-801 (72-31-41, INSPECTION 001).
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Figure 901   High Pressure Compressor Stage 1 Blisk
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Figure 902   (Sheet 1 ) High Pressure Compressor Stage 1 Blisk - Dimensional Information
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Figure 902   (Sheet 2 ) High Pressure Compressor Stage 1 Blisk - Dimensional Information
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Figure 902   (Sheet 3 ) High Pressure Compressor Stage 1 Blisk - Dimensional Information
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Figure 902   (Sheet 4 ) High Pressure Compressor Stage 1 Blisk - Dimensional Information
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Figure 902   (Sheet 5 ) High Pressure Compressor Stage 1 Blisk - Dimensional Information
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Figure 903   (Sheet 1 ) Shotpeening Information
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Figure 903   (Sheet 2 ) Shotpeening Information
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Figure 904   High Pressure Compressor Stage 1 Blisk - Blend Repair Areas and Limits