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TASK 72-31-45-300-803
1 . Thermal Spray Repair of The Aft Rabbet.
A.This procedure gives instructions to repair the high pressure compressor rotor stage 6-10 spool (spool) by thermal spraying the aft rabbet. 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.
(d)Do an inspection of the aft rabbet for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount in depth and quantity if the rabbet can be machined to 0.002 inch (0.05 mm) below the deepest point of a nick, dent, or scratch and the in-process dimension agrees with 15.182 inches (385.63 mm) minimum.
2Fretting, galling, or wear:
Maximum repairable limit:
Any amount in depth and quantity if the rabbet can be machined to 0.002 inch (0.05 mm) below the deepest point of all fretting, galling, or wear and in-process dimension agrees with 15.182 inches (385.63 mm) minimum.
3Corrosion pits:
Maximum repairable limit:
Any amount in depth and quantity if the rabbet can be machined to 0.002 inch (0.05 mm) below the bottom of the deepest pit and the in-process dimension agrees with 15.182 inches (385.63 mm) minimum.
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)
 
2357M30G02  
2439M35G01  
2439M35G02  
2445M40G02  
 
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
 
C04-003
Solvent, General (acetone)
 
C04-035
Solvent, General (isopropyl alcohol)
 
C04-166
Shot Peening, Conditioned Cut Wire (CCW14 steel shot)
 
C10-012
Tape, Masking, High Temperature (masking tape)
 
C10-021
Tape (plastic tape)
 
C10-182
Cloth, Cleaning for Aircraft Structural (SAE-AMS 3819, BMS 15-5) (cleaning cloth)
 
C10-205
Almen Test Strips (Almen N test strips)
C.Referenced Procedures.
 
ATA No.
Description
 
70-00-03
Machining Data
 
70-16-00
Marking Practices
 
70-16-08
Dot Peen Marking for Optical Character Recognition
 
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
 
70-49-36
High Density Inconel 718 Coating Applied by HVOF Thermal Spray
 
72-31-45
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 72-31-45-220-134
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.
 
Minimum
Maximum
Minimum
Maximum
 
In-Process
In-Process
Finish
Finish
Reference
 
Description
Dimension
Dimension
Dimension
Dimension
Dimension
 
Dia B
15.182 in.
15.198 in.
15.204 in.
15.208 in.
--
 
(385.63 mm)
(386.02 mm)
(386.19 mm)
(386.28 mm)
 
Dia M
--
--
--
--
21.0900 in.
 
(353.686 mm)
 
Dim. RA
--
--
0.165 in.
0.185 in.
--
 
(4.20 mm)
(4.69 mm)
 
Dim. V
0.001 in.
--
0.003 in.
0.012 in.
--
 
(0.03 mm)
(0.08 mm)
(0.30 mm)
4 . Setup Information.
Subtask 72-31-45-350-016
A.Set-up the spool for machining and shotpeening. Refer to Figure 901 and as follows:
(1)Install the spool in the holding fixture.
(2)Surface L must be flat to 0.001 inch (0.02 mm) or less.
(3)Diameter M must have a runout of 0.001 inch (0.02 mm) or less.
5 . Procedure.
Subtask 72-31-45-160-003
A.Clean the spool. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING), TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-31-45-220-135
B.Do a visual inspection of the spool marking area for indication of repairs done before. Refer to Figure 901 and as follows:
(1)If you find the mark R003, the spool was thermal spray (HVOF) repaired. You cannot repair the spool again with this repair.
Subtask 72-31-45-220-136
C.Do a visual and dimensional inspection of the spool diameter B. Refer to Subtask 72-31-45-220-134 (paragraph 3.A.) and as follows:
(1)If diameter B is less than the minimum in-process limits, you cannot repair the spool with this repair.
(2)If diameter B is more than the minimum finish dimension and there is wear or visual indications on diameter B, machine diameter B to the minimum finish dimensions to remove the indications. Refer to Subtask 72-31-45-320-006 (paragraph 5.D.).
(3)If you cannot remove the indications on diameter B to the minimum finish dimension, machine diameter B to the in-process dimensions. Refer to Subtask 72-31-45-320-006 (paragraph 5.D.).
Subtask 72-31-45-320-006
D.Machine the spool diameter B. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-31-45-220-134 (paragraph 3.A.), Figure 901, Figure 902, and as follows:
(1)Set-up the spool for machining. Refer to Subtask 72-31-45-350-016 (paragraph 4.A.).
CAUTION:
DO NOT MACHINE INTO THE FILLET RADIUS. MACHINE ONLY THE FLAT AREA. DAMAGE TO THE SPOOL CAN OCCUR.
(2)Machine diameter B to remove all the distressed metal and/or prepare it to thermal-spray as follows:
(a)If you can remove the distressed material to the finish dimensional limits of diameter B, thermal-spray is not necessary. Machine diameter B to the finish dimensions.
(b)If you cannot remove the distressed material to the finish dimensional limits of diameter B, thermal-spray is necessary. Machine diameter B to the in-process dimensions.
Subtask 72-31-45-320-007
(c)Machine the spool with the parameters that follow:
NOTE:
It is recommended to use a micrograin carbide cutting tool, uncoated or coated 0.047-0.063 inch (1.20-1.60 mm) nose radius.
1The maximum uniform tool flank wear must be 0.012 inch (0.30 mm).
2The maximum speed must be 80 SFM (surface feet for each minute).
3The maximum feed must be 0.005 IPR (inch for each revolution) (0.12 mm for each revolution).
4The final pass depth of cut must be 0.002-0.006 inch (0.06-0.15 mm).
5The flood of coolant must be continuous.
(d)Use the information from dimension V to set the machining tool and to calculate the depth of cut, and as follows:
1Dimension V must be 0.001 inch (0.03 mm) minimum.
Subtask 72-31-45-350-017
(3)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 the burrs and rolled edges.
(b)Break edges to 0.010 inch (0.25 mm) maximum.
Subtask 72-31-45-110-012
E.Etch the spool diameter B. 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 or Class G etchant.
Subtask 72-31-45-230-004
F.Do an inspection of the spool diameter B. 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 72-31-45-100-009
G.Clean the spool. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING), TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-31-45-380-005
H.Peen the spool repair area. Refer to TASK 70-47-01-380-016 (SHOTPEENING), and do as follows:
(1)Apply C10-021  plastic tape to all areas that you will not peen. Refer to Figure 903.
Subtask 72-31-45-350-018
(2)Set-up the spool for shotpeening. Refer to Subtask 72-31-45-350-016 (paragraph 4.A.) and as follows:
(a)The runout of surface L and diameter M must be 0.050 inch (1.27 mm) maximum.
(3)Use C10-205   almen N test strips.
(4)Use C04-166   CCW14 steel shot with an intensity of 0.006-0.012N.
(5)Coverage must be a minimum of 125 percent.
(6)Intensity verification is necessary in the repair area. Refer to Figure 904.
(7)Remove the plastic tape.
Subtask 72-31-45-340-005
WARNING:
DO NOT THERMAL SPRAY IF YOU ARE NOT APPROVED (TRAINED AND QUALIFIED). USE PERSONAL PROTECTION EQUIPMENT AND APPROVED SAFETY PROCEDURES. USE EITHER A CONTINUOUS-FLOW EXHAUST SYSTEM OR A WATER-CURTAIN EXHAUST SYSTEM. WATER-CURTAIN EXHAUST SYSTEMS MAY COLLECT OVERSPRAY PARTICLES OF SOME METALS (MAGNESIUM, ALUMINUM AND IRON) AND CAN FORM HYDROGEN. WHEN MIXED WITH AIR, HYDROGEN CAN BURN AND IS EXPLOSIVE.
I.Thermal-spray the spool and test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-36-340-038 (HIGH DENSITY INCONEL 718 COATING APPLIED BY HVOF THERMAL SPRAY), Subtask 72-31-45-220-134 (paragraph 3.A.), Figure 901, and do as follows:
CAUTION:
TO PREVENT TOO MUCH BLASTING, YOU MUST NOT GRIT BLAST TOO MUCH IN ONE SPOT. DAMAGE TO THE SPOOL CAN OCCUR.
NOTE:
If diameter B was machined to remove visual indications at Subtask 72-31-45-320-006 (paragraph 5.D.), but diameter B agrees with the finish dimensions, it is not necessary to thermal-spray the spool.
(1)Grit-blast the spool diameter B and the test specimens as follows:
(a)Apply C10-012  masking tape to the spool. Refer to Figure 905.
(b)The final roughness average must be consistent with a nickel base superalloy.
(c)Grit blast overspray on the fillet radius is not permitted.
CAUTION:
MAKE SURE THAT YOU APPLY MASKING TO THE FILLET RADIUS. THERMAL SPRAY COATING IS NOT PERMITTED ON THE FILLET RADIUS. DAMAGE TO THE SPOOL CAN OCCUR.
(2)Apply masking to the spool with a combination of C10-012   masking tape and hard masking as follows:
NOTE:
It is permitted to use high temperature RTV, silicon rubber, metal plates, or an equivalent material for the hard masking.
(a)Make sure that you keep the clearance between the hard masking and the C10-012  masking tape to a minimum to prevent that the HVOF stream does not remove the C10-012  masking tape.
Subtask 72-31-45-160-004
WARNING:
REFER TO THE PRODUCT LABEL AND MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF CONSUMABLE PRODUCTS.
(3)Clean the repair area and the test specimens as follows:
(a)Use a C10-182  cleaning cloth moist with C04-035  isopropyl alcohol or C04-003  acetone to wipe the repair area.
(b)Replace each dirty cleaning cloth with a new C10-182   cleaning cloth until the last moist cleaning cloth stays clean.
Subtask 72-31-45-340-006
CAUTION:
MAKE SURE THAT YOU APPLY MASKING TO THE FILLET RADIUS. THERMAL SPRAY COATING IS NOT PERMITTED ON THE FILLET RADIUS. DAMAGE TO THE SPOOL CAN OCCUR.
(4)Apply thermal spray coating to diameter B and to the test specimens. Refer to Subtask 72-31-45-220-134 (paragraph 3.A.) and as follows:
NOTE:
It is important that sufficient thermal spray coating is applied to make sure that the spool agrees with the finish dimensions after final machining.
(a)The thermal spray coating thickness must be 0.003-0.040 inch (0.08-1.01 mm).
(b)Overspray is not permitted.
(5)Do all quality assurance testing specified in TASK 70-49-36-340-038 (HIGH DENSITY INCONEL 718 COATING APPLIED BY HVOF THERMAL SPRAY).
CAUTION:
MAKE SURE THAT YOU DO NOT CAUSE DAMAGE TO THE THERMAL SPRAY COATING WHEN YOU REMOVE THE MASKING.
(6)Remove all the masking.
Subtask 72-31-45-320-008
J.Machine the spool diameter B to the finish dimensions. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 901, Figure 902, and as follows:
NOTE:
If diameter B was machined to remove visual indications at Subtask 72-31-45-320-006 (paragraph 5.D.), but diameter B agrees with the finish dimensions, it is not necessary to machine diameter B again.
(1)Set-up the spool for machining. Refer to Subtask 72-31-45-350-016 (paragraph 4.A.).
CAUTION:
DO NOT MACHINE INTO THE FILLET RADIUS. MACHINE ONLY THE FLAT AREA. DAMAGE TO THE SPOOL CAN OCCUR.
(2)Machine diameter B to the finish dimensions. Refer to Subtask 72-31-45-220-134 (paragraph 3.A.).
(3)Surface finish must be 90 microinches (2.2 micrometers) or better.
(4)Machine the thermal spray coating on the rabbet aft end to repair the chamfer initial contour.
(5)Break edges 0.005-0.015 inch (0.13-0.38 mm).
Subtask 72-31-45-220-137
(6)Do a visual inspection of the machined coating as follows:
(a)Spalling, flaking, or cracking of the coating is not permitted.
Subtask 72-31-45-100-011
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 72-31-45-350-019
L.Put the mark R003 in the spool area K near the part number or serial number. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-08-350-001 (DOT PEEN MARKING FOR OPTICAL CHARACTER RECOGNITION), Figure 901, and as follows:
NOTE:
If diameter B was machined to remove visual indications at Subtask 72-31-45-320-006 (paragraph 5.D.), but diameter B agrees with the finish dimensions and it was not thermal sprayed, it is not necessary to put a mark in area K.
(1)Use method number 2 Intermediate.
(2)Do not put a mark less than 0.05 inch (1.3 mm) from an edge or a radius.
(3)This mark is only necessary if you thermal sprayed the spool. If you did not thermal-spray the spool, do not put a mark in area K.
Subtask 72-31-45-220-138
M.Do a dimensional inspection of the spool diameter B. Refer to Subtask 72-31-45-220-134 (paragraph 3.A.), Figure 901, and as follows:
(1)Diameter B must agree with the finish dimensions.
(2)Make sure that the concentricity of diameter B with respect to datum L and datum M is 0.0015 inch (0.038 mm) or less.
Subtask 72-31-45-220-139
N.Do a final inspection of the spool. Refer to TASK 72-31-45-200-807 (72-31-45, INSPECTION 001).
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Figure 901   (Sheet 1 ) High Pressure Compressor Rotor Stages 6-10 Spool - Dimensional Information
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Figure 901   (Sheet 2 ) High Pressure Compressor Rotor Stages 6-10 Spool - Dimensional Information
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Figure 901   (Sheet 3 ) High Pressure Compressor Rotor Stages 6-10 Spool - Dimensional Information
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Figure 902   (Sheet 1 ) Machining Information
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Figure 902   (Sheet 2 ) Machining Information
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Figure 903   Shotpeen Masking Information
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Figure 904   Peening Intensity Verification
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Figure 905   (Sheet 1 ) Thermal Spray Masking Information
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Figure 905   (Sheet 2 ) Thermal Spray Masking Information