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TASK 72-31-44-300-801
1 . Airfoil Blend Repair.
A.This procedure gives instructions to repair the high pressure compressor rotor stage 5 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 airfoils for:
1Nicks:
Maximum repairable limit:
Any amount in the limits of Figure 902 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 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 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 after you fully remove the damage by blending in this repair procedure.
(h)Do an inspection of the tip corners of the blisk airfoils for:
1Damage:
Maximum repairable limit:
Any amount, maximum depth of 0.040 inch (1.01 mm) 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 repair. All part numbers are applicable to all paragraphs unless specified differently.
 
Part Number(s)
 
2357M35P01  
2357M35P02  
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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
 
C10-021
Tape, Plastic
 
C10-037
Deleted
 
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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
 
72-31-44
Cleaning 001
 
72-31-44
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 72-31-44-220-052
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.
 
Description
Minimum In-Process Dimension
Maximum In-Process Dimension
Minimum Finish Dimension
Maximum Finish Dimension
Reference Dimension
 
Dim. B
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0.040 in. (1.01 mm)
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Dim. D
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0.067 in. (1.70 mm)
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4 . Setup Information.
None.
5 . Procedure.
Subtask 72-31-44-100-001
CAUTION:
BE VERY CAREFUL WHEN YOU MOVE AND PUT THE BLISK INTO STORAGE. BLISK AIRFOILS MUST ALWAYS HAVE A PROTECTION BUT NOT DURING CLEANING, INSPECTION, OR REPAIR.
A.If necessary, clean the blisk. Refer to TASK 72-31-44-100-801 (72-31-44, CLEANING 001).
Subtask 72-31-44-220-079
B.Do a visual inspection of the blisk airfoils area B (leading and trailing edges) and area A (leading edge). Refer to Figure 901, Figure 902, Figure 904, and as follows:
(1)The blisk is repairable if it agrees with the conditions that follow:
(a)A maximum of one blend is permitted for each airfoil, regardless if the blend is in area A or area B.
(b)Refer to Figure 902, Table 1, for the maximum permitted blend depth and the maximum number of airfoils that can be repaired with this repair procedure, and as follows:
1The maximum number of permitted blended airfoils of Table 1 must include the blends repaired before, regardless if the blend is in area A or area B.
2The total number of blends permitted for each blisk is specified as a combination of the row values of the two columns in Table 1.
(c)You cannot repair the damage in the airfoil area A with this repair procedure.
(d)A blend set is specified as two or more blended airfoils in a row.
(e)A blend set of four airfoils maximum in a row can be repaired with this repair procedure, and as follows:
1For a number of more than six blended airfoils, a minimum of six non-blended airfoils in a row is necessary on the two sides of a set. Refer to Figure 904.
2For a number of six blended airfoils maximum, a minimum of six non-blended airfoils in a row is not necessary on the two sides of a set. Refer to Figure 904.
(f)One blend airfoil is not interpreted as a blend set and does not apply the minimum number of six non-blended airfoil in a row on the two sides.
Subtask 72-31-44-350-002
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 THE CHORD LENGTH AGREES WITH THE MINIMUM CHORD LENGTH LIMIT WHEN YOU DO THE BLENDING PROCEDURE. IF YOU BLEND MORE THAN THE MINIMUM CHORD LIMIT, DAMAGE TO THE BLISK CAN OCCUR. BLEND THE RADIUS TIP CORNERS ONLY IF NECESSARY TO REMOVE DAMAGE. KEEP THE TIP CORNER RADIUS TO A MINIMUM OR DAMAGE TO THE BLISK CAN OCCUR.
CAUTION:
ONLY ONE BLEND IS PERMITTED FOR EACH BLISK AIRFOIL.
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 AIRFOIL.
CAUTION:
DELETED.
C.Blend the damaged area on the blisk airfoil leading and trailing edges, area B. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), Figure 902, and as follows:
(1)Make sure that you do not remove the airfoil parent material when you blend to remove the metal splatter or deposits.
(2)You cannot blend area A and area C with this repair procedure.
(3)Use a fine C10-010  abrasive cloth or an abrasive stone as follows:
(a)Blend in longitudinal direction only, parallel to the length of the blisk airfoil.
NOTE:
A power tool can be used, but only at a low speed, if a blend larger in length or in depth is necessary.
(b)Make sure that the surface finish after the blending procedure is equivalent to or better than the initial surface finish.
(4)For tear damage, blend 1.25 times the damage depth to fully remove the damage.
(5)The blend length must be a minimum of six times the depth of the finished blend, and a maximum of eight times the depth of the finished blend.
(6)The blended contour of the repair area must be the same as the contour of the adjacent non-blended areas.
(7)The leading and trailing edge thickness after blending must not be less than the initial thickness of the adjacent non-blended leading and trailing edge.
(8)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.
(9)If the blend location, measured from the airfoil tip, is equal to or less than dimension D, blend area D as follows:
(a)Remove the unwanted material in area D.
(b)Keep the blend depth to the same depth as the initial blend depth.
Subtask 72-31-44-110-008
D.Etch the blisk airfoil 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 C etchant.
Subtask 72-31-44-230-003
E.Do an inspection of the blisk airfoil repair area. 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.
Subtask 72-31-44-380-049
F.Peen the blisk airfoil repair area. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 903, and as follows:
(1)Apply C10-021  plastic tape to the blisk areas that you will not peen.
(2)Use C04-286  S110 cast steel shot.
(3)Peen to an intensity of 0.006-0.012N.
(4)The parameters can be set to peen the airfoils to a coverage of 100 percent and the necessary intensity.
NOTE:
It is recommended to put the nozzle to 0.500 inch (12.70 mm) outboard of the airfoil tips with a stand-off distance of approximately 12.0 inches (304 mm) at 45 degrees to get a sufficient peening of the airfoils.
NOTE:
It is permitted to peen the two sides of the airfoil at the same time with split flow equipment, but it is not necessary.
(5)Intensity verification is necessary in the blisk repaired area. Use a scrap part or simulative fixture.
(6)Overspray is permitted on the concave, convex, leading, and trailing edge areas of the blisk airfoil.
(7)Remove the plastic tape from the blisk.
(8)Remove the plastic tape from the blisk.
(9)Remove the blisk from the holding fixture.
Subtask 72-31-44-220-053
G.Do an inspection of the blisk airfoil surface finish repair area as follows:
NOTE:
It is necessary that the surface finish inspection and the polish are done only to the areas that were shot peened and oversprayed.
(1)Use a Surtronics 25+ profilometer or equivalent GE approved tool.
(2)Use a 0.010 inch (0.25 mm) cutoff length.
(3)The surface finish of the airfoil must be 32 microinches (0.8 micrometer) or better.
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, manually polish to do a surface finish improvement of the repaired area and as follows:
(a)Use an C10-010  abrasive cloth or equivalent.
Subtask 72-31-44-220-054
H.Do a final inspection of the blisk airfoil. Refer to TASK 72-31-44-200-801 (72-31-44, INSPECTION 001).
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Figure 901   High Pressure Compressor Stage 5 Blisk Nomenclature
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Figure 902   (Sheet 1 ) High Pressure Compressor Stage 5 Blisk Blend Requirements and Dimensional Information
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Figure 902   (Sheet 2 ) High Pressure Compressor Stage 5 Blisk Blend Requirements and Dimensional Information
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Figure 902   (Sheet 3 ) High Pressure Compressor Stage 5 Blisk Blend Requirements and Dimensional Information
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Figure 902   (Sheet 4 ) High Pressure Compressor Stage 5 Blisk Blend Requirements and Dimensional Information
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Figure 903   High Pressure Compressor Stage 5 Blisk Shotpeening Information
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Figure 904   (Sheet 1 ) High Pressure Compressor Stage 5 Blisk Examples
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Figure 904   (Sheet 2 ) High Pressure Compressor Stage 5 Blisk Examples
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Figure 904   (Sheet 3 ) High Pressure Compressor Stage 5 Blisk Examples