* * * FOR ALL
TASK 72-31-43-300-801
1 . Repair for the High Pressure Compressor Rotor Stage 3-4 Spool.
A.This procedure gives instructions to repair the high pressure compressor rotor stage 3-4 spool (spool) seal teeth by removing the existing coating and recoating. 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.
(h)Do an inspection of the seal teeth for:
1Chipped or missing coating on lateral faces of diameter SS and diameter TT after recoat:
Maximum repairable limit:
Any amount, if the in-process diameter agrees with the limits in paragraph 6.E.
2Missing coating on the seal tip of diameter SS and diameter TT:
Maximum repairable limit:
Any amount, if the in-process diameter agrees with the limits in paragraph 6.E.
(6)Special Dimensional Inspection.
(e)Measure the interstage air seal teeth diameters for:
4Diameter SS:
Maximum repairable limit:
20.023 inches (508.59 mm).
5Diameter TT:
Maximum repairable limit:
21.197 inches (538.41 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)
 
2357M34G01  
2439M37G01  
2439M37G02  
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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.
 
Description
Figure
 
Holding Fixture
905
B.Consumable Materials.
 
Code No.
Description
 
C04-113
Abrasive, Grit, Aluminum Oxide 220 Mesh (aluminum oxide)
 
C04-271
Shot, Peening, Cast Steel (AMS 2431/2 ASH), Cast Steel Shot, High Hardness (55-62 HRc) (S110 steel shot)
 
C10-012
Tape, Masking, High Temperature (tape)
C.Referenced Procedures.
 
ATA No.
Description
 
70-00-03
Machining Data
 
70-21-00
Chemical Cleaning
 
70-21-01
Cleaning Method No. 1 - Solvent Degreasing
 
70-21-03
Cleaning Method No. 3 - Steam Cleaning
 
70-21-04
Cleaning Method No. 4 - Dry Abrasive Blast Cleaning
 
70-21-09
Cleaning Method No. 9 - Light-Duty Alkaline Cleaning of Titanium Alloys
 
70-23-00
Stripping Procedures
 
70-23-12
Stripping Thermal Sprayed Coatings
 
70-23-23
Removal of Coatings 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
 
70-49-02
Thermal Spraying Aluminum Oxide - Alumina (Powder)
 
70-49-10
Thermal Spraying Nickel-Aluminum (Powder)
 
72-31-43
Inspection 001
D.Expendable Parts. None.
E.SPD Information. None.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. Refer to TASK 70-49-02-340-003 (THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER)) and TASK 70-49-10-340-011 (THERMAL SPRAYING NICKEL-ALUMINUM (POWDER)) .
3 . Dimensional Information.
Subtask 72-31-43-220-048
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.
 
Description
Minimum In-Process Dimension
Maximum In-Process Dimension
Minimum Finish Dimension
Maximum Finish Dimension
Reference Dimension
 
Dia SS
20.023 in. (508.59 mm)
20.045 in. (509.14 mm)
20.055 in. (509.40 mm)
20.065 in. (509.65 mm)
--
 
Dia TT
21.197 in. (538.41 mm)
21.219 in. (538.96 mm)
21.229 in. (539.22 mm)
21.239 in. (539.47 mm)
--
 
Dim M
--
--
Deleted
Deleted
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4 . Setup Information.
Subtask 72-31-43-350-003
A.Set-up the spool for thermal spraying/shotpeening/water jet as follows:
Subtask 72-31-43-930-001
(1)If necessary, make a holding fixture.
Subtask 72-31-43-350-004
(2)Install the spool on a holding fixture or on the machine table. Refer to Figure 902, Figure 904, and as follows:
(a)Surface L must be flat to 0.050 inch (1.27 mm) or less.
(b)Diameter M must have a runout of 0.050 inch (1.27 mm) or less.
Subtask 72-31-43-350-005
B.Set-up the spool for machining as follows:
Subtask 72-31-43-930-002
(1)If necessary, make the machining fixture. Refer to Figure 905.
Subtask 72-31-43-350-006
(2)Install the spool on the fixture aft end down. Refer to Figure 902, Figure 904, and as follows:
(a)Surface L must be flat to 0.002 inch (0.05 mm) or less.
(b)Diameter M must have a runout of 0.002 inch (0.05 mm) or less.
5 . Procedure.
Subtask 72-31-43-100-002
A.Alternative Procedure Available. Remove the coating from the spool seal teeth as follows:
(1)Set-up the spool for coating removal. Refer to Figure 904, Subtask 72-31-43-350-003 (paragraph 4.A.), Setup Information, and Subtask 72-31-43-350-005 (paragraph 4.B.), Setup Information.
(2)Remove the thermal coating from the spool seal teeth. Refer to TASK 70-23-00-100-001 (STRIPPING PROCEDURES) and TASK 70-23-23-330-008 (REMOVAL OF COATINGS BY HIGH PRESSURE WATER STRIPPING).
Subtask 72-31-43-100-003
A.A.Alternative Procedure. Remove the coatings from the seal teeth as follows:
(1)Remove the top coating and bond coating from the seal teeth. Refer to TASK 70-21-04-120-001 (CLEANING METHOD NO. 4 - DRY ABRASIVE BLAST CLEANING), TASK 70-23-00-100-001 (STRIPPING PROCEDURES), and TASK 70-23-12-110-027 (STRIPPING THERMAL SPRAYED COATINGS) and as follows:
(a)If necessary, grit-blast thermal spray coating to remove top coat. Refer to TASK 70-21-04-120-A01 (DRY ABRASIVE BLAST CLEANING METHOD 4A) and as follows:
1Apply C10-012  tape to areas that you will not grit blast.
2Use C04-113  aluminum oxide at 75-90 psia (517-621 kPa).
(b)If necessary, apply C10-012  tape again.
(c)Remove the bond coating. Refer to TASK 70-23-00-100-001 (STRIPPING PROCEDURES).
(d)Remove the tape.
(e)If necessary, remove the remaining coating residue with a plastic media blast. Refer to TASK 70-21-04-120-E01 (DRY ABRASIVE BLAST CLEANING METHOD 4E).
(f)If you used plastic media blast, clean to remove the plastic media residue. Refer to TASK 70-21-09-110-007 (CLEANING METHOD NO. 9 - LIGHT-DUTY ALKALINE CLEANING OF TITANIUM ALLOYS).
Subtask 72-31-43-220-049
B.Do a dimensional inspection of the repair diameters. Refer to Subtask 72-31-43-220-048 (paragraph 3.A.), Dimensional Information, and as follows:
(1)Measure each diameter at eight equally-spaced locations and calculate the average diameter dimension.
(2)If the repair diameter is within in-process dimensions and there is no damage on the surface, refer to Subtask 72-31-43-200-002 (paragraph 5.G.).
(3)If the repair diameter is within in-process dimensions but there are damages or remaining coating on the diameter surface or if the diameter is more than the maximum in-process dimension, machine the diameter. Refer to Subtask 72-31-43-320-001 (paragraph 5.C.).
(4)If the repair diameter is less than the minimum in-process dimension, the spool is not repairable with this repair procedure.
Subtask 72-31-43-320-001
C.If necessary, machine the seal tooth tip diameters. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-31-43-220-048 (paragraph 3.A.), Dimensional Information, Figure 902, and as follows:
(1)Set-up the seal for machining. Refer to Subtask 72-31-43-350-003 (paragraph 4.A.), Setup Information, and Subtask 72-31-43-350-005 (paragraph 4.B.), Setup Information.
(2)Machine the seal teeth to the in-process dimensions.
Subtask 72-31-43-350-007
D.If you machined the seal teeth, blend the burrs and rolled edges from the seal teeth. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
(1)Break all edges to 0.000-0.004 inch (0.00-0.10 mm).
Subtask 72-31-43-100-004
E.Clean the spool. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-31-43-110-006
F.Etch the repair area. 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 72-31-43-200-002
G.Do an inspection of the repair diameters. 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)Indications more than 0.015 inch (0.38 mm) are not permitted.
(3)Linear indications are not permitted.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
Subtask 72-31-43-380-001
H.Peen the repair diameters. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 903, and as follows:
(1)Use C04-271  S110 steel shot.
(2)Intensity must be 0.006-0.012N.
(3)Overspray is permitted.
(4)Intensity verification is necessary in the seal teeth.
Subtask 72-31-43-340-001
WARNING:
DO NOT BREATHE THE PARTICLES FROM BLASTING OR LET THE PARTICLES TOUCH YOU. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
I.Thermal-spray the spool and the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), Figure 902, and as follows:
Subtask 72-31-43-350-008
(1)Set-up the seal for thermal spraying. Refer to Subtask 72-31-43-350-003 (paragraph 4.A.), Setup Information, and Subtask 72-31-43-350-005 (paragraph 4.B.), Setup Information.
(2)Apply a mask to the part. Refer to Figure 902 and as follows:
(a)Use C10-012  tape.
Subtask 72-31-43-140-001
(3)Grit blast area EA, area EB and the test specimens. Refer to Figure 902 and as follows:
(a)The final surface finish must agree with titanium-base material.
Subtask 72-31-43-100-005
(4)Clean area EA, area EB and the test specimens. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-01-110-001 (CLEANING METHOD NO. 1 - SOLVENT DEGREASING).
Subtask 72-31-43-340-002
(5)Apply bond coat to areas EA and EB on each seal tooth, and to the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-10-340-011 (THERMAL SPRAYING NICKEL-ALUMINUM (POWDER)), Figure 902, and as follows:
NOTE:
Spray coat must be applied within 2 hours after grit blasting.
(a)Apply a mask to the part. Refer to Figure 902 and as follows:
1Use C10-012  tape.
(b)Overspray is permitted only in area GH.
(c)The bond coating thickness in area EA must be 0.002-0.005 inch (0.06-0.12 mm).
(d)The bond coating thickness in area EB must be 0.002-0.008 inch (0.06-0.20 mm).
(e)Do all the quality assurance tests specified in TASK 70-49-10-340-011 (THERMAL SPRAYING NICKEL-ALUMINUM (POWDER)).
(6)Apply top coat to areas EA and EB on each seal tooth, and to the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-02-340-003 (THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER)), Figure 902, and as follows:
(a)If necessary, apply a mask to the part again. Refer to Figure 902 and as follows:
1Use C10-012  tape.
(b)Overspray is permitted only in area GH.
(c)The final machined top coating thickness in area EA must be 0.003-0.013 inch (0.08-0.33 mm).
(d)The final top coating thickness in area EB must be 0.003-0.013 inch (0.08-0.33 mm).
(e)Do all the quality assurance tests specified in TASK 70-49-02-340-003 (THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER)).
1The porosity for the top coat may be less than or equal to V-4.
Subtask 72-31-43-320-002
J.Machine the spool. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-31-43-220-048 (paragraph 3.A.), Dimensional Information, Figure 902, and as follows:
(1)Set-up the seal for machining. Refer to Subtask 72-31-43-350-003 (paragraph 4.A.), Setup Information, and Subtask 72-31-43-350-005 (paragraph 4.B.), Setup Information.
(2)Machine the repair diameters to the finish dimensions.
Subtask 72-31-43-100-006
K.Clean the spool. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-31-43-200-003
L.Do a visual inspection of the machined coating on the seal teeth. Refer to TASK 72-31-43-200-801 (72-31-43, INSPECTION 001).
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Figure 901   High Pressure Compressor Rotor Stage 3-4 Spool
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Figure 902   (Sheet 1 ) High Pressure Compressor Rotor Stage 3-4 Spool - Dimensional Information
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Figure 902   (Sheet 2 ) High Pressure Compressor Rotor Stage 3-4 Spool - Dimensional Information
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Figure 902   (Sheet 3 ) High Pressure Compressor Rotor Stage 3-4 Spool - Dimensional Information
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Figure 902   (Sheet 4 ) High Pressure Compressor Rotor Stage 3-4 Spool - Dimensional Information
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Figure 903   High Pressure Compressor Rotor Stage 3-4 Spool - Shot Peen Intensity Verification Locations
* * * FOR ALL
Figure 904   (Sheet 1 ) Holding Fixture - Setup Information
* * * FOR ALL
Figure 904   (Sheet 2 ) Holding Fixture - Setup Information
* * * FOR ALL
Figure 905   (Sheet 1 ) Holding Fixture
* * * FOR ALL
Figure 905   (Sheet 2 ) Holding Fixture
* * * FOR ALL
Figure 905   (Sheet 3 ) Holding Fixture
* * * FOR ALL
Figure 905   (Sheet 4 ) Holding Fixture
* * * FOR ALL
Figure 905   (Sheet 5 ) Holding Fixture
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Figure 905   (Sheet 6 ) Holding Fixture