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TASK 72-31-45-300-801
1 . Repair for the High Pressure Compressor Rotor Stage 6-10 Spool.
A.This procedure gives instructions to repair the forward rabbet of the high pressure compressor rotor stage 6-10 spool (spool) with a thermal spray repair. 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.
NOTE:
For 72-31-45, Inspection 001. Refer to TASK 72-31-45-200-807 (72-31-45, INSPECTION 001) .
(4)Visual Inspection.
(c)Do an inspection of the forward rabbet for:
1Nicks, dents, and scratches on parent metal:
Maximum repairable limit:
Any amount in depth and quantity provided the rabbet can be machined to two mils below the deepest point of any nick, dent, or scratch and the in-process dimension agrees with 21.074 inches (535.28 mm).
2Fretting, galling, or wear on parent metal:
Maximum repairable limit:
Any amount in depth and quantity provided the rabbet can be machined to two mils below the deepest point of all fretting, galling, or wear and in-process dimension agrees with 21.074 inches (535.28 mm).
3Corrosion pits on parent metal:
Maximum repairable limit:
Any amount in depth and quantity provided the rabbet can be machined to two mils below the bottom of the deepest pit and the in-process dimension agrees with 21.074 inches (535.28 mm).
4Chipped or missing HVOF or APS coating:
Maximum repairable limit:
Any amount in depth and quantity provided the in-process dimension agrees with 21.074 inches (535.28 mm).
(6)Dimensional Inspection:
(b)Do an inspection of the diameters as follows:
3Diameter M:
Maximum repairable limit:
21.074 inches (535.28 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)
 
2357M30G02  
2439M35G01  
2439M35G02  
2445M40G02  
 
2610M90G01  
2628M56G01  
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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
 
C10-012
Tape, Masking, High Temperature (masking tape)
 
C04-166
Shot, Peening, Conditioned Cut Wire (CCW14 steel shot)
 
C04-178
Deleted
 
C07-038
Inconel 718 Powder
 
C10-021
Tape, Plastic
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
 
70-24-00
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
 
70-49-32
Thermal Spraying Inconel 718 (powder)
 
72-31-45
Cleaning 001
 
72-31-45
Inspection 001
D.Expendable Parts. None.
E.SPD Information. None.
F.Special Solutions. None.
G.Test Specimens. Refer to TASK 70-49-32-340-033 (THERMAL SPRAYING INCONEL 718 (POWDER)) .
3 . Dimensional Information.
Subtask 72-31-45-220-102
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 reconvert from millimeters to inches.
 
Minimum
Maximum
Minimum
Maximum
 
In-Process
In-Process
Finish
Finish
Reference
 
Description
Dimension
Dimension
Dimension
Dimension
Dimension
 
Dim. B
--
--
0.180 in.
0.200 in.
--
 
(4.58 mm)
(5.08 mm)
 
Dia M
21.072 in.
21.076 in.
21.088 in.
21.092 in.
--
 
(535.23 mm)
(535.33 mm)
(535.64 mm)
(535.73 mm)
4 . Setup Information.
Subtask 72-31-45-350-007
A.Set up the spool for machining/shotpeening/thermal spraying as follows:
(1)Install the spool in the holding fixture.
(2)Surface A must be flat to 0.001 inch (0.02 mm) or less.
(3)Diameter B must have a runout of 0.001 inch (0.02 mm) or less.
5 . Procedure.
Subtask 72-31-45-100-001
A.If necessary, clean the spool. Refer to TASK 72-31-45-100-801 (72-31-45, CLEANING 001).
Subtask 72-31-45-320-001
B.Machine the spool. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-31-45-220-102 (paragraph 3.A.), Dimensional Information, Figure 901, and as follows:
(1)Set up the spool for machining. Refer to Subtask 72-31-45-350-007 (paragraph 4.A.), Setup Information.
(2)Machine diameter M to the in-process dimensions.
(3)If there is HVOF thermal spray or plasma thermal spray on this diameter, remove all thermal spray from the repair diameter.
NOTE:
HVOF thermal spray coating will come off in small chips when machined and base material will come off in a continuous curl when machined.
Subtask 72-31-45-350-008
(4)If necessary, blend the spool. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
(a)Remove burrs and rolled edges.
(b)Break edges to 0.010 inch (0.25 mm) maximum.
Subtask 72-31-45-100-002
C.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 72-31-45-110-006
D.Etch diameter M. 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 72-31-45-200-001
E.Do an inspection of diameter M. 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)Refer to TASK 72-31-45-200-807 (72-31-45, INSPECTION 001) for the fluorescent penetrant inspection limits.
Subtask 72-31-45-380-001
F.Peen the spool repair area. Refer to TASK 70-47-01-380-016 (SHOTPEENING) and do as follows:
(1)Set up the spool for shotpeening. Refer to Subtask 72-31-45-350-007 (paragraph 4.A.), Setup Information, except as follows:
(a)Surface A and diameter B may have a runout of up to 0.050 inch (1.27 mm).
(2)Apply C10-021  plastic tape to all areas that you will not peen. Refer to Figure 902.
(3)Use C04-166  CCW14 steel shot.
(4)Peen to an intensity of 6-12N.
(5)Coverage must be a minimum of 125 percent.
(6)Intensity verification is required in repaired area. Refer to Figure 903.
(7)Remove the C10-021  plastic tape.
Subtask 72-31-45-340-002
G.Thermal-spray the spool and test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-32-340-033 (THERMAL SPRAYING INCONEL 718 (POWDER)), Subtask 72-31-45-220-102 (paragraph 3.A.), Dimensional Information, Figure 901, and do as follows:
(1)Apply C10-012  masking tape to all areas that will not be thermal sprayed. Refer to Figure 902.
(2)Set up the spool for grit blasting and thermal spraying. Refer to Subtask 72-31-45-350-007 (paragraph 4.A.), Setup Information, except as follows:
(a)Surface A and diameter B may have a runout of up to 0.050 inch (1.27 mm).
(3)Perform the preliminary operations specified in TASK 70-49-00-340-001 (THERMAL SPRAYING).
(a)Use the surface roughness limits for the nickel base material.
(4)Apply C07-038  Inconel 718 powder to diameter M and the test specimens. Apply thermal spray coating to the test specimens and to diameter M at the same time and to the same thickness, and do as follows:
(a)Overspray is not permitted.
(b)Apply a sufficient quantity of thermal spray coating to machine to the finished dimension.
(c)The final thermal spray thickness must be 0.006-0.011 inch (0.16-0.27 mm).
(d)The thermal spray coating applied to the test specimens must simulate the part geometry, the spray angle, and the as-sprayed deposit thickness on the spool.
(5)Do all the quality assurance testing specified in TASK 70-49-32-340-033 (THERMAL SPRAYING INCONEL 718 (POWDER)).
(6)Remove the masking tape.
Subtask 72-31-45-220-100
H.Do a dimensional inspection of diameter M. Refer to Subtask 72-31-45-220-102 (paragraph 3.A.), Dimensional Information, Figure 901, and as follows:
(1)If the thermal spray coating thickness is less than the requirement, and/or diameter M is less than the minimum finished dimension, remove and re-apply thermal spray coating. Refer to Subtask 72-31-45-320-001 (paragraph 5.B.).
Subtask 72-31-45-320-002
I.Machine the spool. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-31-45-220-102 (paragraph 3.A.), Dimensional Information, Figure 901, and as follows:
(1)Set up the spool for machining. Refer to Subtask 72-31-45-350-007 (paragraph 4.A.), Setup Information.
(2)Machine diameter M to the finish dimensions.
(3)The surface finish of diameter M must be 90 microinches (2.3 micrometers) or less.
Subtask 72-31-45-100-003
J.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 72-31-45-220-101
K.Do a visual inspection of the thermal spray as follows:
(1)Spalling, chipping, cracking, or separation of the thermal spray coating is not permitted.
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Figure NaN01   (Sheet 1 ) Compressor Rotor Spool Stages 6-10 - Dimensional Information
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Figure NaN01   (Sheet 2 ) Compressor Rotor Spool Stages 6-10 - Dimensional Information
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Figure NaN01   (Sheet 3 ) Compressor Rotor Spool Stages 6-10 - Dimensional Information
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Figure NaN02   Compressor Rotor Spool Stages 6-10 - Masking
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Figure NaN03   Compressor Rotor Spool Stages 6-10 - Peening Intensity Verification