* * * FOR ALL
TASK 72-32-01-300-804
1 . Stage 1 and Stage 2 Rub Land Flow-Path Restoration.
A.This procedure gives instructions to repair the high pressure compressor (HPC) stator forward case assembly (case assembly) by removing and replacing the worn abradable flow-path coating (thermal spray coating) on the stage 1 and/or stage 2 rub land flow-path. 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.
(b)Do an inspection of the surfaces of the stages 1 and 2 rotor blade rub lands for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, in the repairable limits of diameter E and diameter G
(5)Dimensional Inspection.
(b)Do a dimensional inspection as follows. Measure each diameter at 10 equally-spaced locations. Calculate the average diameter dimension. Compare the average diameter to the dimensions that follow:
4Diameter E at a point of 17.195 inches (436.75 mm) (dimension J) from surface C:
Maximum repairable limit:
29.728 inch (755.09 mm).
5Diameter G from a point of 11.449 inches (290.80 mm) (dimension H) from surface C:
Maximum repairable limit:
28.517 inch (724.33 mm).
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)
 
2302M67G07  
2302M67G11  
2514M80G01  
2644M01G01  
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
 
Porta-Blast Sand Blast Gun
Lindberg Products
Co.2201D
Lakewood Blvd.
#144 Long Beach,
CA 90815
 
Air Jet, No. 50
Lindberg Products
Co.2201D
Lakewood Blvd.
#144 Long Beach,
CA 90815
(3)Locally Manufactured Tools.
 
Figure
Description
 
904
Erosion Test
B.Consumable Materials
 
Code No.
Description
 
C04-292
Abrasive, Grit, Aluminum Oxide (240-Mesh)
 
C10-012
Tape, Masking, High Temperature (tape)
 
C10-155
Shims, Metal (shims)
 
C10-187
Abrasive Cloth, Aluminum Oxide Super-flexible (abrasive cloth)
 
C10-198
Plugs, Silicone Rubber for Thermal Spraying, 55-75 Durometer (plugs)
 
C10-239
Calibration Panels (Lexan 9034-112)
 
C10-240
Abrasive, Grit, White Aluminum Oxide (240 Grit)
C.Referenced Procedures.
 
ATA No.
Description
 
70-00-03
Machining Data
 
70-18-00
Masking Procedures
 
70-21-00
Chemical Cleaning
 
70-21-03
Cleaning Method No. 3 - Steam Cleaning
 
70-21-22
Cleaning Method No. 22 Light Duty Aqueous Cleaning
 
70-23-00
Stripping Procedures
 
70-23-23
Removal of Coatings by High Pressure Water Stripping
 
70-24-00
Etching Procedures for Fluorescent-Penetrant Inspection
 
70-24-01
Swab Etching Procedures
 
70-31-00
Dimensional Inspection
 
70-32-00
Indirect Inspection Methods
 
70-32-03
Spot-Fluorescent-Penetrant Inspection
 
70-42-00
Blending and Removal of High Metal Procedures
 
70-49-00
Thermal Spraying
 
70-49-10
Thermal Spraying Nickel-Aluminum (Powder)
 
70-49-61
Thermal Spraying Nickel Chromium-Aluminum-Bentonite (Powder)
 
70-71-01
Bond Strength Tensile Testing of Thermal Spray Coatings
 
70-71-04
Metallographic Evaluation of Thermal Spray Coatings
 
70-71-09
Erosion Testing of Thermal Spray Coatings
 
72-32-01
Cleaning 001
 
72-32-01
Inspection 001
 
72-32-01
Repair 005
 
--
GE Photo Standard 8906001
 
--
GE Photo Standard 8906002
 
--
GE Photo Standard 8906003
 
--
GE Photo Standard 8906004
 
--
GE Photo Standard 8906005
 
--
GE Photo Standard 8906006
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.
 
Standard
Quantity
 
70-71-01, Bond Strength Tensile Testing
6 (three bond coating only, three coating systems)
Coating system = bond coating
(0.003-0.007 inch (0.08-0.17 mm) + top coating (0.030-0.035 inch (0.77-0.88 mm))
 
70-71-04, Metallographic Evaluation
4 (two bond coat only, two coating systems)
Coating system = bond coating
(0.003-0.007 inch (0.08-0.17 mm) + top coating (0.060-0.085 inch (1.52-2.15 mm))
 
70-71-09, Erosion Test
3 (three coating systems)
Coating system = bond coating
(0.003-0.007 inch (0.08-0.17 mm) + top coating (0.030-0.035 inch (0.77-0.88 mm))
3 . Dimensional Information.
Subtask 72-32-01-220-132
A.Refer to Figure 901, Figure 902, and Figure 903 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.
NOTE:
Unless otherwise specified, measure the diameters at 10 equally-spaced locations. Calculate the average diameter dimensions. Use the average diameter dimensions in this procedure.
4 . Setup Information.
Subtask 72-32-01-350-088
A.Set-up the case assembly for machining. Refer to Figure 901 and as follows:
(1)If necessary, make a machining fixture (fixture) to attach surface C and diameter D of the case assembly to the machine table.
(2)Put the case assembly aft end down on the machine table, and do as follows:
(a)Adjust the position of the case assembly on the machine table until the flatness of surface C is 0.001 inch (0.02 mm) or less and as follows:
1If necessary, use C10-155  shims between the fixture and machine table to adjust the flatness.
(b)Adjust the position of the case assembly on the machine table until the circular runout of diameter D is 0.001 inch (0.02 mm) or less, full indicator reading (FIR).
(c)Attach the case assembly to the machine table.
(3)Do a check of the forward flange dimensions as follows:
(a)Surface B must be parallel to surface C in 0.002 inch (0.05 mm) or less.
(b)Diameter A must be concentric to diameter B in 0.003 inch (0.07 mm) or less.
(4)If necessary, do Subtask 72-32-01-350-088 (paragraph 4.A.) again to get the correct dimensions.
5 . Procedure.
Subtask 72-32-01-160-015
NOTE:
This document provides key processes and requirements that are necessary to agree with engineering requirements. Additional manufacturing level setup and operations can be necessary to successfully complete the repair.
NOTE:
Alternative equivalent processes are permitted with GE Aviation approval and if necessary, regulatory agency approval.
A.If necessary, clean the case assembly. Refer to TASK 72-32-01, CLEANING 001, and as follows:
(1)If necessary, disassemble the two halves of the case assembly before cleaning.
Subtask 72-32-01-350-089
B.Remove the thermal spray coating from the case assembly repair areas. Refer to Figure 901, Figure 902, and as follows:
NOTE:
The repair areas are the stage 1 rub land (area GM) and/or stage 2 rub land (area GN).
(1)Alternative Procedure Available. Remove the thermal spray coating from the repair areas of the case assembly. 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).
Subtask 72-32-01-350-090
CAUTION:
MACHINE ONLY THE MINIMUM QUANTITY OF MATERIAL NECESSARY TO FULLY REMOVE THE THERMAL SPRAY COATING OR DAMAGE TO THE CASE ASSEMBLY PARENT MATERIAL CAN OCCUR.
(1).A.Alternative Procedure. Remove the thermal spray coating from the repair areas of the case assembly. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 902, and as follows:
(a)Set-up the case assembly for machining. Refer to Subtask 72-32-01-350-088 (paragraph 4.A.).
(b)Machine the case assembly to remove the thermal spray coating.
NOTE:
Worn thermal spray coating will come off in small chips when machined, and parent material will come off in a continuous curl when machined.
NOTE:
If worn thermal spray coating cannot be fully removed by machining to the in-process dimensions, the case assembly cannot be repaired with this procedure.
(c)Remove the case assembly from the machine table.
Subtask 72-32-01-230-011
C.Do an inspection of the repair areas of the case assembly for signs of remaining thermal spray coating. 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 D penetrant.
(2)Look for signs of remaining thermal spray coating, and do as follows:
(a)If you find remaining thermal spray coating, go to Subtask 72-32-01-350-089 (paragraph 5.B.).
NOTE:
Areas with thermal spray coating will show up as background fluorescence.
(b)If you do not find remaining thermal spray coating, go to Subtask 72-32-01-160-016 (paragraph 5.C.(3)).
Subtask 72-32-01-160-016
(3)Clean the case assembly. Refer to TASK 72-32-01-100-801 (72-32-01, CLEANING 001), and as follows:
(a)If necessary, disassemble the two halves of the case assembly before cleaning.
Subtask 72-32-01-220-133
D.Etch the repair areas of the case assembly. 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 72-32-01-230-012
E.Do an inspection of the repair areas of the case assembly. 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 D penetrant.
(2)Use the acceptability limits that follow:
(a)Through indications are not permitted.
(b)All indications 0.03 inch (0.7 mm) or less that are not specified in Subtask 72-32-01-230-012 (paragraph 5.E.(2)(a)) are permitted.
(c)Indications 0.03-0.06 inch (0.8-1.5 mm) that are not specified in Subtask 72-32-01-230-012 (paragraph 5.E.(2)(a)) and Subtask 72-32-01-230-012 (paragraph 5.E.(2)(b)) are permitted, and as follows:
1No linear indications are permitted.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
2There must be a minimum distance of 0.25 inch (6.4 mm) between indications.
Subtask 72-32-01-320-018
(3)If necessary, machine the repair areas to remove not permitted indications as follows:
(a)Set-up the case assembly for machining. Refer to Subtask 72-32-01-350-088 (paragraph 4.A.).
CAUTION:
MACHINE ONLY THE MINIMUM QUANTITY OF MATERIAL NECESSARY TO FULLY REMOVE THE INDICATIONS OR DAMAGE TO THE CASE ASSEMBLY PARENT MATERIAL CAN OCCUR.
(b)Machine the areas with not permitted indications. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 902, and as follows:
1Machine the minimum quantity of material to remove the indications.
NOTE:
If indications cannot be fully removed by machining to the in-process dimensions, the case assembly cannot be repaired with this procedure.
(c)Remove the case assembly from the machine table.
(d)Blend the areas of the case assembly that you machined. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
1Break all sharp edges.
(e)Do the etch and FPI procedures specified in Subtask 72-32-01-220-133 (paragraph 5.D.) and Subtask 72-32-01-230-012 (paragraph 5.E.) again to make sure that you removed the indications.
Subtask 72-32-01-110-021
F.Clean the case assembly as follows:
(1)If necessary, disassemble the two halves of the case assembly before cleaning.
(2)Alternative Procedure Available. Clean the two halves of the case assembly. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
(2).A.Alternative Procedure. Clean the two halves of the case assembly. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-22-110-042 (CLEANING METHOD NO. 22 - LIGHT DUTY AQUEOUS CLEANING).
(3)If necessary, assemble the two halves of the case assembly. Refer to TASK 72-32-01-200-801 (72-32-01, INSPECTION 001).
Subtask 72-32-01-220-134
G.Do a dimensional inspection of the repair areas of the case assembly. Refer to TASK 70-31-00-220-001 (DIMENSIONAL INSPECTION), Figure 902 and as follows:
NOTE:
If the dimensions in the repair areas do not agree with the in-process limits, you cannot repair the case assembly with this procedure.
Subtask 72-32-01-340-005
H.Thermal-spray the case assembly in the repair areas. Refer to Figure 901, Figure 902, and as follows:
(1)Test specimens must be thermal-sprayed at the same time as you thermal-spray the case assembly. Refer to Subtask 72-32-01-220-134 (paragraph 2.G.)for coating thickness requirements.
(2)Before you thermal-spray, apply masking to the areas adjacent to the repair areas. Refer to TASK 70-18-00-330-801 (MASKING PROCEDURES), Figure 901, Figure 905, and as follows:
(a)Apply masking to the stage 1 and/or stage 2 VSV bores, as applicable for the repair areas, as follows:
1Use C10-198  plugs.
(b)Apply masking to the forward face and the rabbet diameter on the forward circumferential flange as follows:
NOTE:
It is possible that the forward face and rabbet diameter were repaired with the thermal spray restoration repair TASK 72-32-01-300-805 (72-32-01, REPAIR 005).
1Alternative Procedure Available. Use fabricated shields and C10-012  tape.
1.A.Alternative Procedure. Use C10-012   tape and as follows:
aMake sure that all the edges tightly touch with the case assembly during the thermal spray process.
(3)Thermal-spray the bond coat on the repair areas of the case assembly and the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-10-340-011 (THERMAL SPRAYING NICKEL-ALUMINUM (POWDER)), Figure 901, and as follows:
(a)Apply the bond coating to the applicable repair areas as follows:
NOTE:
Test specimens for bond coating must only be thermal-sprayed at the same time and at the same spray angle as the finished part.
1Use a combustion flame spray process.
NOTE:
Hypervelocity oxy-fuel (HVOF) spray processes are not permitted
2Use multiple spray passes to build-up the bond coating to the necessary thickness.
3Bond coating thickness must be 0.003-0.007 inch (0.08-0.17 mm).
4Overspray and mismatch are permitted in areas GP only.
(b)Do all the quality assurance testing as follows:
1Do all the quality assurance testing for the bond coating on the test specimens as specified in TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-10-340-011 (THERMAL SPRAYING NICKEL-ALUMINUM (POWDER)), and as follows:
aUniformity of bond coating coverage must be as follows:
(1)The bond coating on the coating system test specimen must show uniformity of bond coating coverage not less than C-2 in GE Photo Standard 8906004.
(2)A maximum of 10 percent of the total specimen interface length can show uniformity of bond coating coverage not less than C-3 in GE Photo Standard 8906004.
2Do the tensile test on the test specimen. Refer to TASK 70-71-01-700-002 (BOND STRENGTH TENSILE TESTING OF THERMAL SPRAY COATINGS), and as follows:
aBond coating adhesion must be as follows:
(1)Test the tensile bond strength of the bond coating and use the requirements that follow:
(a)The tensile bond strength of the bond coating at room temperature 65 to 85°F (18 to 29°C) must be a minimum of 2750 psi (19.0 MPa).
bFailures on the tensile bond strength testing for the bond coating must be cohesive (in the coating) or epoxy failures.
3Do the metallographic examination to the test specimens. Refer to TASK 70-71-04-700-005 (METALLOGRAPHIC EVALUATION OF THERMAL SPRAY COATINGS), but use the specific requirements that follow:
aBond coating microstructure must be as follows:
(1)The bond coating on the coating system test specimen must show unmelts and voids not more than UV-2 in GE Photo Standard 8906001 and delaminations must be not more than D-2 in GE Photo Standard 8906002.
bA maximum of 10 percent of the total specimen bond coating area can show unmelts and voids not more than UV-3 in GE Photo Standard 8906001 and delaminations not more than D-3 in GE Photo Standard 8906002.
4Substrate/bond coating interface grit and contamination must be as follows:
aThe substrate/bond coating interface grit and contamination of the coating system test specimen must not be more than I-2 in GE Photo Standard 8906003.
bA maximum of 10 percent of the total specimen interface can show grit and contamination not more than I-3 in GE Photo Standard 8906003.
(c)If one of the quality assurance tests for the bond coating test specimens is unsatisfactory, go back to Subtask 72-32-01-350-089 (paragraph 5.B.) to remove the bond coating, and do the procedure again.
(4)Thermal-spray the top coating on the repair areas of the case assembly and the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), 70-49-61-340-000 (THERMAL SPRAY PROCEDURES - THERMAL SPRAYING NICKEL CHROMIUM-ALUMINUM-BENTONITE (POWDER)), Figure 901, and as follows:
NOTE:
Spraying parameters will be listed in equipment manuals or are readily available from thermal spray equipment manufacturers or powder suppliers. Modifications can be necessary for your location and product application. When the final spraying parameters are developed, all values must be recorded to make sure that you get a consistent achievement of high quality coatings.
(a)Apply the top coating to the applicable repair areas as follows:
NOTE:
Test specimens for coating system must be thermal-sprayed at the same time and at the same spray angle as the finished part.
1Use a combustion flame spray process.
NOTE:
Hypervelocity oxy-fuel (HVOF) spray processes are not permitted.
2Apply sufficient material to make sure that the part agrees with finish dimensions and useful coating thickness range after final machining and as follows:
NOTE:
Useful coating thickness range must be 0.030-0.085 inch (0.77-2.15 mm).
aFor tensile bond and erosivity number test specimens, top coating thickness must be 0.030-0.035 inch (0.77-0.88 mm).
3Overspray and mismatch is permitted in areas GP only.
(b)Do all the quality assurance testing as follows:
1Do all the quality assurance testing for the coating system test specimens as specified in TASK 70-49-00-340-001 (THERMAL SPRAYING), 70-49-61-340-000 (THERMAL SPRAY PROCEDURES - THERMAL SPRAYING NICKEL CHROMIUM-ALUMINUM-BENTONITE (POWDER)), and as follows:
aMeasure the top coat thickness as follows:
(1)Use a standard flat-anvil-and-spindle micrometer.
(2)The top coat must have a minimum thickness of 0.060 inch (1.52 mm).
(3)Calculate the coating thickness to the nearest 0.001 inch (0.03 mm) at three different locations.
bDo a visual inspection of the top coating to make sure that it agrees with the requirements that follow:
(1)The top coating must show full and equal coverage in the repair areas.
NOTE:
The top coating is not permitted in areas other than the repair areas and areas GP
(2)Overspray and mismatch are permitted in areas GP only.
(3)The top coating must show no spalling or lifting
(4)The top coating must have no cracks, blisters, spatter, chipping, and flaking.
2Do the metallographic examination to the test specimens. Refer to TASK 70-71-04-700-005 (METALLOGRAPHIC EVALUATION OF THERMAL SPRAY COATINGS), but use the specific requirements that follow:
aTop coating microstructure must be as follows:
(1)The top coating must have a constant microstructure made of a metal matrix with oval bentonite particles equally-spaced (or fragments of bentonite particles).
(2)The top coating must have a constant intentional porosity.
(3)See GE Photo Standard 8906005 and GE Photo Standard 8906006 for typical permitted microstructures for the top coating.
(4)Do not examine transverse cracks in the top coating microstructure to accept or reject them.
3Do the tensile test on the test specimen. Refer to TASK 70-71-01-700-002 (BOND STRENGTH TENSILE TESTING OF THERMAL SPRAY COATINGS), and as follows:
aTop coating adhesion must be as follows:
(1)Test the tensile bond strength of the top coating system and use the requirements that follow:
(a)The tensile bond strength of the top coating at room temperature 65 to 85°F (18 to 29°C) must be in the range of 300-800 psi (2.1-5.5 MPa).
4Do the erosion test on the top coating of the test specimen. Refer to TASK 70-71-09-700-000 (EROSION TESTING OF THERMAL SPRAY COATINGS) and Figure 904 for test procedure and acceptability criteria.
(c)If one of the quality assurance tests for the top coating test specimens is unsatisfactory, go back to Subtask 72-32-01-350-089 (paragraph 5.B.) to remove the bond coating and top coating, and do the procedure again.
Subtask 72-32-01-320-019
I.Machine the repair areas of the case assembly to the finish dimensions. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 901, Figure 903, and as follows:
(1)Set-up the case assembly for machining. Refer to Subtask 72-32-01-350-088 (paragraph 4.A.).
(2)Machine the top coating until the case assembly agrees with the finish dimensions.
NOTE:
Grinding is not recommended for machining of the top coating.
(3)Remove the case assembly from the machine table.
(4)Blend the case assembly. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), and as follows:
(a)Break all sharp edges.
Subtask 72-32-01-160-017
J.Clean the case assembly. Refer to TASK 72-32-01-100-801 (72-32-01, CLEANING 001), and as follows:
(1)If necessary, disassemble the two halves of the case assembly before cleaning.
Subtask 72-32-01-220-135
K.Do an inspection of the top coating in the repair areas of the case assembly. Refer to Figure 901 and as follows:
(1)Do a check of the surface finish of the machined top coating and as follows:
(a)The maximum surface finish must not be more than 1000 RA.
(2)Do a visual inspection of the top coating as follows:
(a)Chips and local discontinuities are permitted if they are not more than the visual limits that follow:
1Maximum diameter of 0.08 inch (2.0 mm).
2Maximum depth of 0.02 inch (0.5 mm).
3Maximum of 10 each in areas GM and GN if there is a minimum distance of 0.12 inch (3.1 mm) between defects.
(b)Steps that point forward are not permitted.
(c)If the repaired case assembly does not agree with the visual inspection criteria, go back to Subtask 72-32-01-350-089 (paragraph 5.B.) to remove all thermal spray coating, and do the procedure again.
Subtask 72-32-01-230-013
L.Etch the case assembly adjacent to the repaired stage 1 and stage 2 rub lands. 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 72-32-01-230-014
M.Do an inspection of the areas adjacent to the repaired stage 1 and stage 2 rub lands on the case assembly. 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 D penetrant.
(2)Use the acceptability limits that follow:
(a)Through indications are not permitted.
(b)All indications 0.03 inch (0.7 mm) or less that are not specified in Subtask 72-32-01-230-014 (paragraph 5.M.(2)(a)) are permitted.
(c)All indications more than 0.03-0.06 inch (0.8-1.5 mm) that are not specified in Subtask 72-32-01-230-014 (paragraph 5.M.(2)(a)) and Subtask 72-32-01-230-014 (paragraph 5.M.(2)(b)) are permitted, and as follows:
1No linear indications are permitted.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
2There must be a minimum distance of 0.25 inch (6.4 mm) between indications.
(3)If necessary, machine the case assembly to remove not permitted indications as follows:
(a)Set-up the case assembly for machining. Refer to Subtask 72-32-01-350-088 (paragraph 4.A.).
CAUTION:
MACHINE ONLY THE MINIMUM QUANTITY OF MATERIAL NECESSARY TO FULLY REMOVE THE INDICATIONS OR DAMAGE TO THE CASE ASSEMBLY PARENT MATERIAL CAN OCCUR.
(b)Machine the case assembly areas with not permitted indications. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 902, and as follows:
1Machine the minimum quantity of material to remove the indications.
NOTE:
If indications cannot be fully removed with machining process to the in-process dimensions, the case assembly cannot be repaired with this procedure.
(c)Remove the case assembly from the machine table.
(d)Blend the case assembly areas that you machined. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), and as follows:
1Break all sharp edges.
(e)Do the etch and FPI procedures in Subtask 72-32-01-230-013 (paragraphs 5.L.) and Subtask 72-32-01-230-014 (paragraph 5.M.) again to make sure that you removed all the indications.
Subtask 72-32-01-160-018
N.Clean the case assembly as follows:
(1)If necessary, disassemble the two halves of the case assembly before cleaning.
(2)Alternative Procedure Available. Clean the two halves of the case assembly. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
(2).A.Alternative Procedure. Clean the two halves of the case assembly. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-22-110-801 (CLEANING METHOD NO. 22 - LIGHT DUTY AQUEOUS CLEANING).
(3)If necessary, assemble the two halves of the case assembly. Refer to TASK 72-32-01-200-801 (72-32-01, CLEANING 001).
Subtask 72-32-01-220-136
O.Do a dimensional inspection of the flowpath in the case assembly repair areas. Refer to TASK 70-31-00-220-001 (DIMENSIONAL INSPECTION), Figure 901, and as follows:
(1)Measure and record the flowpath dimensions in the repair areas as follows:
(a)Measure radius DU at 10 degree increments around the whole circumference for each rub land inspection point as follows:
NOTE:
Average of measurements is not permitted
1For stage 1 rub land, measure point HA, point HB, and point HC.
2For stage 2 rub land, measure point HD, point HE, and point HF.
3Surface profile at each point must be 0.006 inch (0.15 mm) or less and as follows:
aIf radius DU measurement does not agree with this surface profile, go back to Subtask 72-32-01-350-089 (paragraph 5.B.) to remove all thermal spray coating, and do the procedure again.
* * * FOR ALL
Figure 901   (Sheet 1 ) High Pressure Compressor Forward Case Assembly - Finish Dimensions
* * * FOR ALL
Figure 901   (Sheet 2 ) High Pressure Compressor Forward Case Assembly - Finish Dimensions
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Figure 901   (Sheet 3 ) High Pressure Compressor Forward Case Assembly - Finish Dimensions
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Figure 902   (Sheet 1 ) High Pressure Compressor Forward Case Assembly - In-Process Dimensions
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Figure 902   (Sheet 2 ) High Pressure Compressor Forward Case Assembly - In-Process Dimensions
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Figure 903   Flowpath Machining Data
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Figure 904   (Sheet 1 ) Erosion Test
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Figure 904   (Sheet 2 ) Erosion Test
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Figure 904   (Sheet 3 ) Erosion Test
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Figure 904   (Sheet 4 ) Erosion Test
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Figure 904   (Sheet 5 ) Erosion Test
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Figure 905   Forward Circumferential Flange Masking Locations