* * * FOR ALL
TASK 72-31-46-300-801
1 . Repair for the Compressor Discharge Pressure Rotating Seal.
A.This procedure gives instructions to repair the high pressure compressor discharge pressure (CDP) rotating seal (seal) by replacing the thermal spray coating on the seal teeth. Refer to Figure 901.
B.The following maximum repairable limits apply to this repair:
NOTE:
The information below gives maximum/minimum repairable limits for the applicable Inspection sections. The paragraphs are numbered the same as the manual Inspection sections.
(4)Visual Inspection.
(i)Do an inspection of the seal serrations for:
2Missing Coating:
Maximum repairable limit:
Any amount
(5)Dimensional Inspection.
(c)Do an inspection of the CDP seal diameters for:
3Diameter AP (free state) (without coating):
Minimum repairable limit:
16.326 inches (414.68 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)
 
2116M68P01  
2383M82P03  
2383M82P04  
2445M74P01  
D.Proprietary/Complex Process Statement.
(1)None.
2 . Tools, Equipment, and Materials.
NOTE:
You can use equivalent alternatives for tools, equipment, and consumable materials.
A.Tools and Equipment.
(1)Special Tools. None.
(2)Standard Tools and Equipment. None.
(3)Locally Manufactured Tools.
 
Description
Figure
 
Locally Manufactured Thermal Spray Holding Fixture
902
 
Locally Manufactured Machining Fixture
903
B.Consumable Materials.
 
Code No.
Description
 
C04-035
Solvent, General (isopropyl alcohol)
 
C04-113
Abrasive, Grit, Aluminum Oxide (220 mesh abrasive grit)
 
C04-166
Shot, Peening, Conditioned Cut Wire (CCW14 shot)
 
C07-003
Aluminum Oxide Powder
 
C07-032
Nickel Chromium Aluminum Yttrium Powder
 
C10-012
Tape, Masking, High Temperature (tape)
 
C10-021
Tape, Plastic (plastic tape)
 
C10-182
Cloth, Cleaning for Aircraft Structural (cloth)
C.Referenced Procedures.
 
ATA No.
Description
 
70-00-03
Machining Data
 
70-21-00
Chemical Cleaning
 
70-21-03
Cleaning Method 3 - Steam Cleaning
 
70-21-04
Cleaning Method 4 - Dry Abrasive Blast Cleaning
 
70-23-00
Stripping Procedures
 
70-23-12
Stripping Thermal Sprayed Coatings
 
70-23-23
Removal of Coatings by High Pressure Water Stripping
 
70-23-28
Stripping Thermal Sprayed Aluminum Oxide/Nickel Chrome Aluminum Yttrium Thermal Spray Seal Teeth Coating on Rene 88DT Parts
 
70-24-00
Etching Procedures for Fluorescent-Penetrant Inspection
 
70-24-01
Swab Etching Procedure
 
70-31-06
Machined Features - Shop Run Tolerances
 
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)
 
70-49-35
Thermal Barrier Coating System - Yttrium Oxide Stabilized Zirconium Oxide (8% Yttrium Oxide) Over Nickel Chromium Aluminum Yttrium Bondcoat
 
70-51-00
Tightening Practices and Torque Values
 
72-31-46
Cleaning 001
 
72-31-46
Inspection 001
D.Expendable Parts. None.
E.SPD Information. None.
F.Special Solutions. None.
G.Test Specimens. None.
3 . Dimensional Information.
Subtask 72-31-46-220-030
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
 
Dia AP
16.326 in.
16.348 in.
16.358 in.
16.362 in.
--
 
(414.69 mm)
(415.23 mm)
(415.50 mm)
(415.59 mm)
4 . Setup Information.
Subtask 72-31-46-930-001
A.If necessary, make the locally manufactured thermal spray holding fixture (holding fixture). Refer to Figure 902.
Subtask 72-31-46-350-003
B.Set-up the holding fixture. Refer to Figure 902 and as follows:
(1)Put the holding fixture on the rotating table.
(2)Diameter Y must be concentric with the axis of rotation to 0.050 inch (1.27 mm) or less.
(3)Surface Z must have a runout of 0.050 inch (1.27 mm) or less.
(4)Put the seal on the holding fixture with the aft side up and put the holding fixture ring on the seal.
(5)Diameter AP must have a runout of 0.050 inch (1.27 mm) or less.
(6)Surface C must have a runout of 0.050 inch (1.27 mm) or less.
(7)Tighten the bolts. Refer to TASK 70-51-00-400-004 (TIGHTENING PRACTICES AND TORQUE VALUES).
Subtask 72-31-46-930-002
C.If necessary, make the locally manufactured machining fixture (machining fixture). Refer to Figure 903.
Subtask 72-31-46-350-005
D.Set-up the machining fixture. Refer to Figure 901, Figure 903, and as follows:
(1)Put the machining fixture on the machine.
(2)Diameter FB must be concentric with the axis of rotation to 0.001 inch (0.02 mm) or less.
(3)The runout of surface FA must be 0.001 inch (0.02 mm) or less.
(4)Set-up the seal on the machining fixture as follows:
(a)Put the seal in the machining fixture base with the aft side up.
(b)Install 12 washers and bolts equally spaced through the seal and into the machining fixture.
(c)Diameter B must have a runout of 0.001 inch (0.02 mm) or less.
(d)Surface C must have a runout of 0.001 inch (0.02 mm) or less.
(e)Tighten the bolts. Refer to TASK 70-51-00-400-004 (TIGHTENING PRACTICES AND TORQUE VALUES).
5 . Procedure.
Subtask 72-31-46-100-007
CAUTION:
BE CAREFUL NOT TO DAMAGE OR SCORE THE CDP SEAL BOLT HOLES. THE BOLT HOLE IS THE LIFE LIMITING LOCATION OF THE CDP SEAL.
A.If necessary, clean the seal. Refer to TASK 72-31-46-100-001 (72-31-46, CLEANING 001).
Subtask 72-31-46-350-007
B.Remove the coating from the seal teeth as follows:
(1)Set-up the seal in the holding fixture. Refer to Figure 902, Subtask 72-31-46-930-001 (paragraph 4.A.), and Subtask 72-31-46-350-003 (paragraph 4.B.).
CAUTION:
BE CAREFUL NOT TO USE 70-23-28 CHEMICAL STRIP ON R65 HARDWARE. DAMAGE TO THE PART WILL OCCUR AND THE PART WILL NOT BE SERVICEABLE.
(2)Remove the coating from the seal teeth as follows:
 
Applicable P/N
Part Material
Strip Methods Permitted
 
2116M68P01  
2445M74P01  
R88dt
Refer to TASK 70-23-00-100-001 (STRIPPING PROCEDURES) and TASK 70-23-28-110-801 (STRIPPING THERMAL SPRAYED ALUMINUM OXIDE/NICKEL CHROME ALUMINUM YTTRIUM THERMAL SPRAY SEAL TEETH COATING ON RENE 88DT PARTS)
--OR--
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). Refer to Figure 904
 
CAUTION:
BE CAREFUL TO ADJUST PARAMETERS FOR WATER JET STRIP AND GRIT BLAST SO THAT THE COATING IS REMOVED, BUT THE PARENT MATERIAL IS NOT ERODED. IF THE PARAMETERS ARE TOO AGRESSIVE, DAMAGE TO THE PART WILL OCCUR AND THE PART WILL NOT BE SERVICEABLE.
 
2383M82P03  
2383M82P04  
R65
Refer to TASK 70-23-00-100-001 (STRIPPING PROCEDURES), TASK 70-23-23-330-008 (REMOVAL OF COATINGS BY HIGH PRESSURE WATER STRIPPING), and as follows:
NOTE:
Successful bond coat removal has been demonstrated with 40,000 psi (275 MPa) pressure and 50-225 inches for minute (21-95 mm for second) surface footage due to part rotation.
Masking is not required. Refer to Figure 904
Deleted.
Deleted.
Refer to TASK 70-21-04-120-001 (CLEANING METHOD NO. 4 - DRY ABRASIVE BLAST CLEANING), TASK 70-21-04-120-A01 (DRY ABRASIVE BLAST CLEANING METHOD 4A) (220 mesh only), and as follows:
Mask all areas that are not coated. No overspray permitted. Refer to Figure 904.
NOTE:
Dry Abrasive Blast Cleaning Method 4A (220 mesh only) can be used a total of two times to grit blast.
NOTE:
If water jet stripping does not fully remove the coating, use Dry Abrasive Blast Cleaning Method 4A (220 mesh only) to remove remaining coating. If coating still remains, use Dry Abrasive Blast Cleaning Method 4A (220 mesh only) again to remove remaining coating. If coating still remains, the part is not serviceable. Contact GE Aviation Engineering.
Subtask 72-31-46-100-005
(3)Deleted.
Subtask 72-31-46-100-006
B.A.Deleted.
Subtask 72-31-46-220-035
C.Do a dimensional inspection of the seal teeth in-process dimension. Refer to Subtask 72-31-46-220-030 (paragraph 3.A.), Dimensional Information and as follows:
Subtask 72-31-46-320-002
(1)If necessary, machine the seal teeth. Refer to TASK 70-00-03-800-004 (MACHINING DATA) and as follows:
(a)Set-up the seal for machining. Refer to Subtask 72-31-46-930-002 (paragraph 4.C.), Setup Information and Subtask 72-31-46-350-008 (paragraph 4.D.), Setup Information.
NOTE:
Remove only the minimal amount of material required to remove any damage from the seal teeth.
(b)Machine the seal teeth to remove the damage and to make the part agree with the in-process dimensions.
Subtask 72-31-46-220-036
(c)The runout to diameter B must be 0.002 inch (0.05 mm) maximum.
Subtask 72-31-46-350-008
D.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 the edges to 0.0050 inch (0.127 mm) maximum.
Subtask 72-31-46-100-001
E.Clean the seal. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD 3 - STEAM CLEANING).
Subtask 72-31-46-110-016
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 C etchant.
Subtask 72-31-46-200-003
G.Do an inspection of the seal teeth. 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.
Subtask 72-31-46-380-001
H.Peen area BD of the seal. Refer to TASK 70-47-01-380-016 (SHOTPEENING) and do as follows:
(1)Set-up the seal for shotpeening. Refer to Subtask 72-31-46-350-003 (paragraph 4.B.), Setup Information.
(2)Apply C10-021  plastic tape to areas that have thermal spray coating.
(3)Use C04-166   CCW14 shot.
(4)Peen to an intensity of 0.006-0.012N.
(5)Deleted.
(6)The coverage must be a minimum of 125 percent.
(7)Overspray is permitted.
(8)Intensity verification is necessary with a simulative fixture.
(9)Remove all plastic tape from the part.
Subtask 72-31-46-340-001
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.Do a grit blast and solvent clean of the seal as follows:
(1)Install the seal on the holding fixture. Refer to Figure 902, Subtask 72-31-46-930-001 (paragraph 4.A.), Setup Information and Subtask 72-31-46-350-003 (paragraph 4.B.), Setup Information.
(2)Apply a mask to the part. Refer to Figure 904 and as follows:
(a)Use C10-012   tape or hard mask.
(3)Do a grit blast to area BD. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING) and Figure 904.
(4)Do a solvent clean of area BD. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING) and Figure 904.
Subtask 72-31-46-340-002
J.Thermal-spray the seal. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-35-340-037 (THERMAL BARRIER COATING SYSTEM - YTTRIUM OXIDE STABILIZED ZIRCONIUM OXIDE (8% YTTRIUM OXIDE) OVER NICKEL CHROMIUM ALUMINUM YTTRIUM BONDCOAT), Figure 904, and as follows:
NOTE:
Do not apply the top coating described in TASK 70-49-35-340-037 (THERMAL BARRIER COATING SYSTEM - YTTRIUM OXIDE STABILIZED ZIRCONIUM OXIDE (8% YTTRIUM OXIDE) OVER NICKEL CHROMIUM ALUMINUM YTTRIUM BONDCOAT).
(1)Apply the bond coating to the coupons and tensile bond buttons for testing.
(2)Apply the bond coat to areas AR and AS on each seal tooth as follows:
NOTE:
Spray coat must be applied within 2 hours after grit blasting.
(a)Use C07-032   nickel chromium aluminum yttrium powder.
(b)No overspray is permitted.
(c)The thickness of the bond coat in area AS must be 0.002-0.005 inch (0.06-0.12 mm).
(d)The thickness of the bond coat in area AR must be 0.0015-0.0080 inch (0.039-0.203 mm).
Subtask 72-31-46-340-003
K.Thermal-spray the seal. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-02-340-003 (THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER)), Figure 904, and as follows:
(1)Apply the top coating to the coupons and tensile bond buttons for testing.
(2)Apply the top coat to the areas AR and AS on each seal tooth as follows:
(a)Use C07-003   aluminum oxide powder.
(b)No overspray is permitted.
(c)The thickness of the topcoat must be 0.003-0.013 inch (0.08-0.33 mm).
(3)Remove the mask.
Subtask 72-31-46-340-004
L.Do the quality assurance tests. Refer to TASK 70-49-02-340-003 (THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER)), and TASK 70-49-35-340-037 (THERMAL BARRIER COATING SYSTEM - YTTRIUM OXIDE STABILIZED ZIRCONIUM OXIDE (8% YTTRIUM OXIDE) OVER NICKEL CHROMIUM ALUMINUM YTTRIUM BONDCOAT), except as follows:
(1)The porosity for the top coat must be less than or equal to V-4.
Subtask 72-31-46-320-003
M.Machine the seal. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-31-46-220-030 (paragraph 3.A.), Dimensional Information and as follows:
(1)Set-up the seal in the machining fixture. Refer to Subtask 72-31-46-930-002 (paragraph 4.C.), Setup Information, Subtask 72-31-46-350-005 (paragraph 4.D.), Setup Information, and Figure 903.
(2)Machine diameter AP to the finish dimension. Refer to Subtask 72-31-46-220-030 (paragraph 3.A.), Dimensional Information, Figure 901, and as follows:
(a)The minimum topcoat thickness in area AS must be 0.003 inch (0.08 mm).
Subtask 72-31-46-100-002
N.Clean the seal. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD 3 - STEAM CLEANING).
Subtask 72-31-46-220-037
O.Do a visual inspection of the machined coating on the seal teeth. Refer to TASK 72-31-46-200-801 (72-31-46, INSPECTION 001).
* * * FOR ALL
Figure 901   (Sheet 1 ) High Pressure Turbine Compressor Discharge Pressure Rotating Seal - Dimensional Information
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Figure 901   (Sheet 2 ) High Pressure Turbine Compressor Discharge Pressure Rotating Seal - Dimensional Information
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Figure 902   (Sheet 1 ) Locally Manufactured Thermal Spray Holding Fixture
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Figure 902   (Sheet 2 ) Locally Manufactured Thermal Spray Holding Fixture
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Figure 902   (Sheet 3 ) Locally Manufactured Thermal Spray Holding Fixture
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Figure 903   (Sheet 1 ) Locally Manufactured Machining Fixture
* * * FOR ALL
Figure 903   (Sheet 2 ) Locally Manufactured Machining Fixture
* * * FOR ALL
Figure 904   Compressor Discharge Pressure Rotating Seal - Thermal Spray Masking/Coverage Requirements
* * * FOR ALL
Figure 905   DELETED