* * * FOR ALL
TASK 72-31-46-300-804
1 . Seal Teeth Blend Repair.
A.This procedure gives instructions to repair the compressor discharge pressure (CDP) rotating seal (seal) by blending to remove damage and repair the thermal spray coating on the seal teeth. Refer to Figure 901.
NOTE:
Before this repair is done, do a check to see if there is a repair marking at the forward bore hub face of the seal. If there is a repair marking, this procedure cannot be used to repair the seal.
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.
(i)Do an inspection of the seal serrations for:
1Nicks, tears, dents, or bends:
Maximum repairable limit:
A maximum of one blend for each part is permitted, if 1.25 times damage depth can be removed with a blend that is a maximum of 0.055 inch (1.39 mm) in radial depth and 1.557 inches (39.54 mm) in circumferential length. Radial depth is measured from the uncoated tooth outer diameter.
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  
2445M74P01  
--
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
 
Thermal Spray Holding Fixture
902
 
Machining Fixture
903
B.Consumable Materials.
 
Code No.
Description
 
C04-166
Shot, Peening, Conditioned Cut Wire (CCW14 shot)
 
C07-032
Nickel Chromium Aluminum Yttrium Powder
 
C10-012
Tape, Masking, High Temperature (tape)
 
C10-021
Tape, Plastic
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 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.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. TASK 70-49-35-340-037 (THERMAL BARRIER COATING SYSTEM - YTTRIUM OXIDE STABILIZED ZIRCONIUM OXIDE (8% YTTRIUM OXIDE) OVER NICKEL CHROMIUM ALUMINUM YTTRIUM BONDCOAT) and TASK 70-49-02-340-003 (THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER)).
3 . Dimensional Information.
Subtask 72-31-46-220-044
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 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 72-31-46-350-012
A.Set-up the seal for removing thermal spray coating/shotpeening/grit blasting as follows:
Subtask 72-31-46-930-003
(1)If necessary, make the holding fixture. Refer to Figure 902.
Subtask 72-31-46-350-018
(2)Put the holding fixture on the rotating table.
(3)Install the seal in the holding fixture.
Subtask 72-31-46-220-047
(4)Diameter Y must be concentric with the axis of rotation to 0.050 inch (1.27 mm) or less.
(5)Surface Z must have a runout of 0.050 inch (1.27 mm) or less.
Subtask 72-31-46-350-019
(6)Put the seal on the holding fixture, aft side up, and put the holding fixture ring on the seal.
Subtask 72-31-46-220-048
(7)Diameter AP must have a runout of 0.050 inch (1.27 mm) or less.
(8)Surface C must have a runout of 0.050 inch (1.27 mm) or less.
Subtask 72-31-46-350-020
(9)Tighten the bolts. Refer to TASK 70-51-00-400-004 (TIGHTENING PRACTICES AND TORQUE VALUES).
Subtask 72-31-46-350-013
B.Set-up the seal for machining as follows:
Subtask 72-31-46-930-004
(1)If necessary, make the machining fixture. Refer to Figure 903.
Subtask 72-31-46-350-021
(2)Put the machining fixture on the machining table.
Subtask 72-31-46-220-049
(3)Diameter FB must be concentric with the axis of rotation to 0.001 inch (0.02 mm) or less.
(4)The runout of surface FA must be 0.001 inch (0.02 mm) or less.
Subtask 72-31-46-350-022
(5)Put 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 12 bolts equally-spaced through the seal and into the machining fixture.
Subtask 72-31-46-220-050
(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.
Subtask 72-31-46-350-023
(e)Tighten the bolts. Refer to TASK 70-51-00-400-004 (TIGHTENING PRACTICES AND TORQUE VALUES).
5 . Procedure.
NOTE:
Before this repair is done, make sure if there is a repair marking at the forward bore hub face of the seal. If there is a repair marking, this procedure cannot be used to repair the seal.
Subtask 72-31-46-160-004
A.If necessary, clean the seal. Refer to TASK 72-31-46-100-001 (72-31-46, CLEANING 001).
Subtask 72-31-46-330-001
B.Remove thermal spray coating from the seal teeth as follows:
Subtask 72-31-46-350-014
(1)Set-up the seal in the holding fixture. Refer to Subtask 72-31-46-350-012 (paragraph 4.A.) and Figure 902.
Subtask 72-31-46-330-002
(2)Remove the thermal spray coating from the seal teeth as follows:
 
Applicable P/N
Part Material
Strip Methods and Steps
 
2116M68P01  
2445M74P01  
R88dt
(1)
Alternative Procedure Available. Remove thermal spray coating from the seal teeth. 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) .
(1)A.
Alternative Procedure Available. Remove thermal spray coating from the 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) .
 
Applicable P/N
Part Material
Strip Methods and Steps
 
CAUTION:
BE CAREFUL WHEN YOU ADJUST THE PARAMETERS FOR WATER JET STRIPPING AND GRIT BLAST UNTIL YOU REMOVE ONLY THE THERMAL SPRAY COATING, BUT DO NOT REMOVE THE ERODED THE PARENT MATERIAL. IF THE PARAMETERS ARE TOO AGGRESSIVE, DAMAGE TO THE SEAL WILL OCCUR AND IT WILL BE NOT SERVICEABLE.
CAUTION:
MAKE SURE THAT YOU DO NOT USE CHEMICAL STRIPPING ON R65 HARDWARE. DAMAGE TO THE CDP SEAL WILL OCCUR AND IT WILL BECOME UNSERVICEABLE.
 
2383M82P03  
R65
(1)
Remove thermal spray coating from the seal teeth. 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:
(a)
Apply C10-012  tape to the seal areas that do not have thermal spray coating. Refer to Figure 904.
(b)
Overspray is not permitted.
(c)
The maximum pressure must be 40000 psi (275 MPa).
(d)
The minimum feed rate must be 50.0 inches (1270 mm) for each minute.
CAUTION:
MAKE SURE THAT YOU DO NOT USE CHEMICAL STRIPPING ON R65 HARDWARE. DAMAGE TO THE CDP SEAL WILL OCCUR AND IT WILL BECOME UNSERVICEABLE.
(2)
Clean the seal teeth. Refer to TASK 70-21-04-120-001 (CLEANING METHOD NO. 4 - DRY ABRASIVE BLAST CLEANING) , Figure 904, and as follows:
(a)
Use Method 4A (Aluminum Oxide 220 mesh only).
(b)
Apply C10-012  tape to the seal areas that do not have thermal spray coating.
(c)
Overspray is not permitted.
NOTE:
Dry abrasive blast cleaning, Method 4A, can be used a total of two times to grit-blast.
(d)
If you cannot fully remove the thermal spray coating with water jet stripping, use the dry abrasive blast cleaning, Method 4A, to remove the remaining thermal spray coating.
(e)
If thermal spray coating still remains, use the dry abrasive blast cleaning, Method 4A, again to remove the remaining thermal spray coating.
(f)
If thermal spray coating still remains, the part is not serviceable. Contact GE Aviation Engineering.
Subtask 72-31-46-350-015
C.Blend the seal teeth to remove dents. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), Figure 905, and as follows:
(1)Remove all distorted or dented material.
(2)Only one blend on the tooth that is being blended is permitted.
(3)Only one blended tooth for each part is permitted.
Subtask 72-31-46-220-045
D.Do a dimensional inspection of the seal teeth in-process dimension. Refer to Subtask 72-31-46-220-044 (paragraph 3.A.) and as follows:
Subtask 72-31-46-320-005
CAUTION:
REMOVE ONLY THE MINIMUM QUANTITY OF MATERIAL NECESSARY OR DAMAGE TO THE SEAL TEETH CAN OCCUR.
(1)If necessary, machine the seal teeth. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 901, and as follows:
Subtask 72-31-46-350-024
(a)Set-up the seal teeth for machining. Refer to Subtask 72-31-46-350-013 (paragraph 4.B.).
Subtask 72-31-46-320-006
(b)Machine the seal teeth to remove damage and to make the part agree with the in-process dimension.
Subtask 72-31-46-220-051
(c)The runout of diameter B must be 0.002 inch (0.05 mm) maximum.
Subtask 72-31-46-350-016
E.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 sharp edges to 0.0050 inch (0.127 mm) maximum.
Subtask 72-31-46-160-005
F.Clean the seal teeth. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-31-46-110-018
G.Etch the seal teeth 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 72-31-46-230-004
H.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 72-31-46-380-003
I.Peen area BD of the seal. Refer to TASK 70-47-01-380-016 (SHOTPEENING) and do as follows:
Subtask 72-31-46-350-025
(1)Set-up the seal for shotpeening. Refer to Subtask 72-31-46-350-012 (paragraph 4.A.).
(2)Apply C10-021  plastic tape to the areas you will not peen. Refer to Figure 904.
Subtask 72-31-46-380-004
(3)Use C04-166  CCW14 shot.
(4)Peen to an intensity of 0.006-0.012N.
(5)The impingement angle must be a minimum of 35 degrees.
(6)The coverage must be a minimum of 125 percent.
(7)Overspray is permitted.
(8)Intensity verification is necessary with a simulative fixture.
Subtask 72-31-46-350-026
(9)Remove all the plastic tape that you applied.
Subtask 72-31-46-120-004
J.Do a grit blast and solvent cleaning of the seal as follows:
Subtask 72-31-46-350-027
(1)Set-up the seal for grit blasting. Refer to Subtask 72-31-46-350-012 (paragraph 4.A.), Figure 902, and Figure 904.
(2)Use C10-012  tape to apply masking to the part. Refer to Figure 904.
Subtask 72-31-46-120-005
(3)Do a grit blast to area BD. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING) and Figure 904.
(a)Use the surface roughness limits for nickel base alloy.
(4)Do a solvent clean of area BD. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING) and Figure 904.
Subtask 72-31-46-340-005
K.Thermal-spray the seal and the test specimens. 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, Figure 906, and as follows:
NOTE:
The top coating specified 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) must not be applied.
 
Applicable P/N
Part Material
Coat Methods and Steps
 
2116M68P01  
2445M74P01  
R88dt
(1)
Apply C10-021  plastic tape to the seal. Refer to Figure 904.
(2)
Apply the bond coating to the test specimens and tensile bond buttons for testing.
(3)
Apply the bond coating to area AR and area AS on each seal tooth as follows:
NOTE:
The thermal spray coating must be applied in less than 2 hours after grit blasting.
(a)
Use C07-032  nickel chromium aluminum yttrium powder .
(b)
Overspray is not permitted.
(c)
The bond coating thickness in area AS must be 0.002-0.005 inch (0.06-0.12 mm).
(d)
The bond coating thickness in area AR must be 0.0015-0.0080 inch (0.039-0.203 mm).
(4)
Do a visual inspection and make sure that all the blended areas have thermal spray coating.
 
Applicable P/N
Part Material
Coat Methods and Steps
 
2383M82P03  
R65
(1)
Apply C10-021  plastic tape to the seal. Refer to Figure 904 and Figure 906.
(2)
Apply the bond coating to the test specimens and tensile bond buttons for testing.
(3)
Apply the bond coating to area AR and area AS on each seal tooth as follows:
NOTE:
The thermal spray coating must be applied in less than 2 hours after grit blasting.
(a)
Use C07-032  nickel chromium aluminum yttrium powder .
(b)
Overspray is not permitted.
(c)
The bond coating thickness in area AS must be 0.002-0.005 inch (0.06-0.12 mm).
(d)
The bond coating thickness in area AR must be 0.0015-0.0080 inch (0.039-0.203 mm).
(4)
Do a visual inspection and make sure that no thermal spray coating is on the blended areas.
Subtask 72-31-46-340-006
L.Thermal-spray the seal and 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 904, and as follows:
 
Applicable P/N
Part Material
Coat Methods and Steps
 
2116M68P01  
2445M74P01  
R88dt
(1)
Apply the top coating to the test specimens and tensile bond buttons for testing.
(2)
Apply the top coating to area AR and area AS on each seal tooth as follows:
(a)
Use aluminum oxide powder.
(b)
Overspray is not permitted.
(c)
The thickness of the top coating must be 0.003-0.013 inch (0.08-0.33 mm).
(3)
Remove the masking from the seal.
(4)
Do a visual inspection and make sure that all the blended areas have thermal spray coating.
NOTE:
The blended area tip outer diameter OD will be lower than the rest of the circumference of the repaired tooth.
 
Applicable P/N
Part Material
Coat Methods and Steps
 
2383M82P03  
R65
(1)
Apply the top coating to the test specimens and tensile bond buttons for testing.
(2)
Apply the top coating to area AR and area AS on each seal tooth as follows:
(a)
Use aluminum oxide powder.
(b)
Overspray is not permitted.
(c)
The thickness of the top coating must be 0.003-0.013 inch (0.08-0.33 mm).
(3)
Remove the masking from the seal.
(4)
Do a visual inspection and make sure that no thermal spray coating is on the blended areas.
NOTE:
The blended area tip outer diameter OD will be lower than the rest of the circumference of the repaired tooth.
(5)
If necessary, blend the thermal spray coated edges to make a smooth transition and to remove the step between the coated area and the uncoated area. Refer to Figure 906.
Subtask 72-31-46-340-007
M.Do all the quality assurance tests specified in TASK 70-49-02-340-003 (THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER)), 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 coating must be less than or equal to V-4.
Subtask 72-31-46-320-004
N.If necessary, machine the seal to finish dimensions. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-31-46-220-044 (paragraph 3.A.), Figure 901, and as follows:
Subtask 72-31-46-350-028
(1)Set-up the seal for machining. Refer to Subtask 72-31-46-350-013 (paragraph 4.B.) and Figure 903.
Subtask 72-31-46-320-007
(2)Machine diameter AP to the finish dimensions. Refer to Subtask 72-31-46-220-044 (paragraph 3.A.), Figure 901, and as follows:
(a)The minimum top coating thickness in area AS must be 0.003 inch (0.08 mm).
Subtask 72-31-46-350-017
O.Put a mark on the forward bore hub face of the seal. 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:
(1)Put the mark near the part number or serial number.
(2)Intermediate depth must be 0.001-0.004 inch (0.03-0.10 mm).
(3)If you blended the seal teeth one, put the mark 55BLDT1 on it.
(4)If you blended the seal teeth two, put the mark 55BLDT2 on it.
(5)If you blended the seal teeth three, put the mark 55BLDT3 on it.
(6)If you blended the seal teeth four, put the mark 55BLDT4 on it.
Subtask 72-31-46-160-006
P.Clean the seal. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-31-46-220-046
Q.Do a visual inspection of the thermal spray coating that you replaced 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
* * * FOR ALL
Figure 901   (Sheet 2 ) High Pressure Turbine Compressor Discharge Pressure Rotating Seal - Dimensional Information
* * * FOR ALL
Figure 901   (Sheet 3 ) High Pressure Turbine Compressor Discharge Pressure Rotating Seal - Dimensional Information
* * * FOR ALL
Figure 902   (Sheet 1 ) Thermal Spray Holding Fixture
* * * FOR ALL
Figure 902   (Sheet 2 ) Thermal Spray Holding Fixture
* * * FOR ALL
Figure 902   (Sheet 3 ) Thermal Spray Holding Fixture
* * * FOR ALL
Figure 903   (Sheet 1 ) Machining Fixture
* * * FOR ALL
Figure 903   (Sheet 2 ) Machining Fixture
* * * FOR ALL
Figure 904   Compressor Discharge Pressure Rotating Seal - Thermal Spray Masking /Coverage Requirements
* * * FOR ALL
Figure 905   Compressor Discharge Pressure Rotating Seal - Blend Repair Area
* * * FOR ALL
Figure 906   Compressor Discharge Pressure Rotating Seal - Masking Area