* * * FOR ALL
TASK 72-32-01-300-805
1 . Thermal Spray Repair of the Circumferential Flanges and Rabbets.
A.This procedure gives instructions to repair the HPC stator forward case assembly (case assembly) by thermal spraying to restore the forward circumferential flange and rabbet (forward flange) and the aft circumferential flange and rabbet (aft flange). 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.
(e)Do an inspection of the circumferential flanges for the following. Refer to Figure 802.
2Nicks and scratches on the mating surface:
Maximum repairable limit:
Any amount, if in the repairable limits of surface B and surface C.
4Fretting or galling on the mating surface:
Maximum repairable limit:
Any amount, if in the repairable limits of surface B and surface C.
(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:
1Diameter A:
Maximum repairable limit:
32.354 inches (821.79 mm).
2Diameter D:
Maximum repairable limit:
32.330 inches (821.18 mm).
6Surface B flatness:
Maximum repairable limit:
Any amount, with a minimum flange thickness of 0.315 inch (8.01 mm) for surface B.
7Surface B parallel to surface C:
Maximum repairable limit:
Any amount, with a minimum flange thickness of 0.255 inch (6.48 mm) for surface C.
8Diameter D concentric with reference axis:
Maximum repairable limit:
Any amount, if in the repairable limits of diameter D.
9Diameter D roundness:
Maximum repairable limit:
Any amount, if in the repairable limits of diameter D.
10Diameter A roundness:
Maximum repairable limit:
Any amount, if in the repairable limits of diameter A.
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)
 
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. None.
(3)Locally Manufactured Tools.
 
Description
Figure
 
Forward Flange Machining Fixture (forward flange fixture)
904
 
Aft Flange Machining Fixture (aft flange fixture)
905
B.Consumable Materials.
 
Code No.
Description
 
C10-012
Tape, Masking, High Temperature (masking tape)
 
C10-155
Shims, Metal (shims)
 
C10-198
Plugs, Silicone Rubber for Thermal Spray 55-75 Durometer (plugs)
C.Referenced Procedures.
 
ATA No.
Description
 
70-00-03
Machining Data
 
70-16-00
Marking Practices
 
70-16-04
Vibro-Peen Marking
 
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
 
70-49-00
Thermal Spraying
 
70-49-36
High Density Inconel 718 Coating Applied by HVOF Thermal Spray
 
72-32-01
Cleaning 001
 
72-32-01
Inspection 001
 
72-32-01
Repair 002
 
72-32-01
Repair 004
D.Expendable Parts. None.
E.SPD Information. None.
F.Special Solutions. None.
G.Test Specimens. Refer to TASK 70-49-36-340-038 (HIGH DENSITY INCONEL 718 COATING APPLIED BY HVOF THERMAL SPRAY) .
3 . Dimensional Information.
Subtask 72-32-01-220-078
A.Refer to Figure 901 and Figure 902 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.
NOTE:
Reference dimensions do not require inspection.
NOTE:
The diameters are measured at ten equally spaced locations. The average diameter dimensions are calculated. The average diameter dimensions are used for this procedure.
NOTE:
A dimension that is at the serviceable limit is always permitted, and repair is not necessary.
NOTE:
If there is sufficient material on the diameter or surface to get the serviceable limits, then the diameter or surface can be machined to make it agree with the serviceable limits.
 
Description
Minimum
In-Process
Dimension
Maximum
In-Process
Dimension
Minimum
Finish
Dimension
Maximum
Finish
Dimension
Reference
Dimension
 
Dia A
32.340 in.
(821.44 mm)
32.354 in.
(821.79 mm)
32.326 in.
(821.09 mm)
32.334 in.
(821.28 mm)
--
 
Dim. BF
0.315 in.
(8.01 mm)
0.322 in.
(8.17 mm)
0.325 in.
(8.26 mm)
0.335 in.
(8.50 mm)
--
 
Rad BR
0.02 in.
(0.6 mm)
0.05 in.
(1.2 mm)
0.02 in.
(0.6 mm)
0.04 in.
(1.0 mm)
--
 
Dim. CF
0.255 in.
(6.48 mm)
0.262 in.
(6.65 mm)
0.265 in.
(6.74 mm)
0.275 in.
(6.98 mm)
--
 
Rad CR
0.02 in.
(0.6 mm)
0.05 in.
(1.2 mm)
0.02 in.
(0.6 mm)
0.04 in.
(1.0 mm)
--
 
Dia D
32.316 in.
(820.83 mm)
32.330 in.
(821.18 mm)
32.302 in.
(820.48 mm)
32.310 in.
(820.67 mm)
--
4 . Setup Information.
Subtask 72-32-01-350-023
A.Set-up the case assembly to machine the forward flange. Refer to Figure 901, Figure 904, and as follows:
Subtask 72-32-01-930-001
(1)If necessary, make the forward flange fixture.
Subtask 72-32-01-350-024
(2)Install the forward flange fixture on the machining table and do as follows:
Subtask 72-32-01-350-040
(a)Make surface FX flat to 0.001 inch (0.02 mm) or less and as follows:
1If necessary, put C10-155  shims between the forward flange fixture and the machining table.
Subtask 72-32-01-350-041
(b)Make diameter FW concentric to the machining table axis to 0.001 inch (0.02 mm) or less.
(c)Use clamps or 0.625 inch (15.88 mm) bolts to attach the forward flange fixture to the machining table and do as follows:
1Make sure that surface FX flatness and diameter FW concentricity agree with the requirements specified in Subtask 72-32-01-350-040 (paragraph 4.A.(2)(a)) and Subtask 72-32-01-350-041 (paragraph 4.A.(2)(b)).
(3)Assemble the upper and lower case halves to make the case assembly. Refer to TASK 72-32-01-200-801 (72-32-01, INSPECTION 001), (paragraph 5.A.).
(4)Put the case assembly on the forward flange fixture with the aft flange (surface C) down and as follows:
(a)Put the case assembly on the forward flange fixture and align the aft flange boltholes with the boltholes on the forward flange fixture.
(b)Use twenty-six 0.375-16 bolts with washers to attach the case assembly to the forward flange machining fixture.
Subtask 72-32-01-220-100
(5)Make sure that the case assembly surface C is flat to the aft flange machining fixture surface FX to 0.001 inch (0.02 mm) or less.
(6)Make sure that the plane established by the stage 1 vane bores is perpendicular to the machine spindle to 0.004 inch (0.10 mm) or less as follows:
(a)Use three stage 1 vane bores equally-spaced that do not show wear.
CAUTION:
DO NOT PUT SHIMS BETWEEN THE CASE ASSEMBLY AND THE AFT FLANGE FIXTURE. DAMAGE TO THE CASE ASSEMBLY CAN OCCUR.
(b)If necessary, put C10-155  shims between the forward flange fixture and the machining table.
Subtask 72-32-01-350-026
B.Set-up the case assembly to machine the aft flange. Refer to Figure 901, Figure 905, and as follows:
Subtask 72-32-01-930-002
(1)If necessary, make the aft flange fixture.
Subtask 72-32-01-350-027
(2)Install the aft flange fixture on the machining table and as follows:
Subtask 72-32-01-350-042
(a)Make surface FB flat to 0.001 inch (0.02 mm) or less and as follows:
1If necessary, put C10-155  shims between the aft flange fixture and the machining table.
Subtask 72-32-01-350-043
(b)Make diameter FA concentric to the machining table axis to 0.001 inch (0.02 mm) or less.
(c)Use clamps or 0.625 inch (15.88 mm) bolts to attach the aft flange fixture to the machining table and do as follows:
1Make sure that surface FB flatness and diameter FA concentricity agree with the requirements specified in Subtask 72-32-01-350-042 (paragraph 4.B.(2)(a)) and Subtask 72-32-01-350-043 (paragraph 4.B.(2)(b)).
(3)Assemble the upper and lower case halves to make the case assembly. Refer to TASK 72-32-01-200-801 (72-32-01, INSPECTION 001), (paragraph 5.A.).
(4)Put the case assembly on the aft flange fixture with the forward flange (surface B) down and as follows:
(a)Put the case assembly on the aft flange fixture and align the forward flange boltholes with the boltholes on the aft flange fixture.
(b)Use twenty-eight 0.375-16 bolts with washers to attach the case assembly to the aft flange fixture.
Subtask 72-32-01-220-101
(5)Make sure that the case assembly surface B is flat to the aft flange machining fixture surface FB to 0.001 inch (0.02 mm) or less.
5 . Procedure.
Subtask 72-32-01-160-005
A.Clean the case assembly. Refer to TASK 72-32-01-100-801 (72-32-01, CLEANING 001).
Subtask 72-32-01-220-085
B.Do an inspection of the thermal spray coating on the stage 2 rub land of the case assembly. Refer to TASK 72-32-01-200-801 (72-32-01, INSPECTION 001) and as follows:
(1)If the thermal spray coating agrees with the inspection criteria, apply masking to give protection to the thermal spray coating on the stage 2 rub land as follows:
(a)Use C10-012  masking tape and/or fabricated shields to give protection to thermal spray coating on the stage 2 rub land of the case assembly.
(2)If the thermal spray coating does not agree with the inspection criteria, remove the thermal spray coating applied to the stage 2 rub land of the case assembly. Refer to TASK 72-32-01-300-804 (72-32-01, REPAIR 004).
Subtask 72-32-01-330-001
C.Remove the thermal spray coating applied to the stage 1 rub land of the case assembly. Refer to TASK 72-32-01-300-804 (72-32-01, REPAIR 004).
Subtask 72-32-01-220-086
D.Look near the identification numbers on the upper and lower case halves to see if there is an earlier repair to the case assembly with this procedure. Refer to Figure 901, Figure 902, Figure 903, and as follows:
(1)If there is an earlier repair, the upper and lower case halves will have a Repair 005 mark with a sequence of identifiers.
Subtask 72-32-01-320-003
E.Machine the case assembly diameter A and/or surface B to remove thermal spray coating, indications, or wear. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-32-01-220-078 (paragraph 3.A.), Figure 901, Figure 902, Figure 903, and as follows:
NOTE:
Thermal spray coating will come off in small chips when machined and parent material will come off in a continuous curl when machined.
NOTE:
A surface with thermal spray coating will show a matte finish when machined and a surface without thermal spray coating will show a bright finish when machined.
(1)Set-up the case assembly to machine the forward flange. Refer to Subtask 72-32-01-350-023 (paragraph 4.A.).
(2)Find diameter A identifier and do as follows:
(a)If diameter A was not previously repaired or the identifier is 5, machine diameter A to no more than 32.354 inches (821.79 mm).
(b)If the identifier is 6, machine diameter A to no more than 32.342 inches (821.48 mm).
(c)If the identifier is 7, machine diameter A to no more than 32.346 inches (821.58 mm).
(d)If the identifier is 8, machine diameter A to no more than 32.350 inches (821.69 mm).
(e)If the identifier is 9, machine diameter A to no more than 32.354 inches (821.79 mm).
(3)Find surface B identifier and do as follows:
(a)If surface B was not previously repaired or the identifier is 0, machine dimension BF to no more than 0.325 inch (8.25 mm).
(b)If the identifier is 1, machine dimension BF to no more than 0.321 inch (8.15 mm).
(c)If the identifier is 2, machine dimension BF to no more than 0.319 inch (8.10 mm).
(d)If the identifier is 3, machine dimension BF to no more than 0.317 inch (8.05 mm).
(e)If the identifier is 4, machine dimension BF to no more than 0.315 inch (8.00 mm).
(4)Remove the case assembly from the forward flange fixture.
Subtask 72-32-01-350-029
F.Blend the case assembly diameter A and/or surface B. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
(1)Break all sharp edges to 0.005-0.010 inch (0.13-0.25 mm).
Subtask 72-32-01-110-009
G.Etch the case assembly diameter A and/or surface 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 etchant.
Subtask 72-32-01-230-006
H.Do an inspection of the case assembly diameter A and/or surface 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 D penetrant.
(2)Look for signs of thermal spray coating not applied by HVOF process and as follows:
NOTE:
Thermal spray coating applied by plasma spray process will show up as background fluorescence.
NOTE:
Thermal spray coating applied by HVOF process will not show up as background fluorescence.
(a)If you find thermal spray coating, go to Subtask 72-32-01-320-004 (paragraph 5.I.).
Subtask 72-32-01-220-087
(3)Use the acceptability limits that follow:
Subtask 72-32-01-220-088
(a)Through indications are not permitted.
Subtask 72-32-01-220-089
(b)Indications more than 0.02 inch (0.5 mm) are not permitted in the flange fillets or bases of the flanges.
(c)Other indications than those given in Subtask 72-32-01-220-088 (paragraph 5.H.(3)(a)) and Subtask 72-32-01-220-089 (paragraph 5.H.(3)(b)) , use the acceptability limits that follow:
1Indications less than 0.030 inch (0.76 mm) are permitted if they are clearly separated.
2Indications 0.030-0.060 inch (0.77-1.52 mm) are permitted if they agree with the conditions that follow:
aThe indications are not interpreted as linear.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
bThere must be a minimum distance of 0.25 inch (6.4 mm) between indications.
Subtask 72-32-01-220-090
(4)If the case assembly does not agree with the acceptability limits for diameter A and/or surface B after machining, go to Subtask 72-32-01-320-004 (paragraph 5.I.).
Subtask 72-32-01-320-004
CAUTION:
REMOVE A MINIMUM QUANTITY OF PARENT MATERIAL FROM THE CASE ASSEMBLY OR DAMAGE TO THE CASE ASSEMBLY CAN OCCUR.
I.If necessary, machine the case assembly diameter A and/or surface B to remove thermal spray coating, indications, or wear. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-32-01-220-078 (paragraph 3.A.), Figure 901, Figure 902, Figure 903, and as follows:
NOTE:
Thermal spray coating will come off in small chips when machined and parent material will come off in a continuous curl when machined.
NOTE:
A surface with thermal spray coating will show a matte finish when machined and a surface without thermal spray coating will show a bright finish when machined.
(1)Set-up the case assembly to machine the forward flange. Refer to Subtask 72-32-01-350-023 (paragraph 4.A.).
(2)Machine the case assembly to remove thermal spray coating, indications, or wear as follows:
(a)Diameter A and/or surface B must agree with the in-process dimensions.
(b)If you cannot remove the thermal spray coating, indications, or wear when you machine to the in-process dimensions, then you cannot repair the case assembly with this procedure.
(3)Remove the case assembly from the forward flange fixture.
(4)Do Subtask 72-32-01-350-029 (paragraph 5.F.), Subtask 72-32-01-110-009 (paragraph 5.G.), and Subtask 72-32-01-230-006 (paragraph 5.H.) again.
Subtask 72-32-01-350-030
J.If you applied masking to the thermal spray coating on the stage 2 rub land of the case assembly in Subtask 72-32-01-220-085 (paragraph 5.B.), remove the masking from the case assembly.
Subtask 72-32-01-160-008
K.Clean 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).
Subtask 72-32-01-220-091
L.Measure and record the values for the case assembly diameter A and dimension BF. Refer to Subtask 72-32-01-220-078 (paragraph 3.A.), Figure 902, and as follows:
(1)If the values of diameter A and dimension BF agree with the finish dimensions, go to Subtask 72-32-01-220-093 (paragraph 5.T.).
(2)If one of the values agrees with the in-process dimensions, go to Subtask 72-32-01-340-001 (paragraph 5.M.).
Subtask 72-32-01-340-001
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.
M.Thermal-spray the case assembly diameter A and/or surface B and the 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), Figure 901, Figure 902, and as follows:
(1)Apply masking to the case assembly as follows:
(a)If there is thermal spray coating on the stage 2 rub land, do as follows:
1Use C10-012  masking tape and/or fabricated shields to give protection to thermal spray coating on the stage 2 rub land of the case assembly.
2The masking you apply to the thermal spray coating on the stage 2 rub land must stay on the case assembly when you machine the thermal spray coating applied to diameter A and/or surface B.
(b)Thermal spray coating is not permitted in boltholes and as follows:
1Use C10-198  plugs or equivalent to apply masking to the boltholes.
(2)Apply thermal spray coating to the case assembly. Refer to Subtask 72-32-01-220-078 (paragraph 3.A.) and as follows:
(a)Apply sufficient thermal spray coating to make sure that the case assembly agrees with the finish dimensions after final machining and as follows:
1After final machining a minimum of 0.003 inches (0.08 mm) of thermal spray coating is necessary.
(3)Do all the quality assurance testing specified in TASK 70-49-00-340-001 (THERMAL SPRAYING) and TASK 70-49-36-340-038 (HIGH DENSITY INCONEL 718 COATING APPLIED BY HVOF THERMAL SPRAY).
Subtask 72-32-01-350-031
N.Remove the masking from the case assembly as follows:
(1)Remove the masking from the boltholes.
(2)If you applied masking to the thermal spray coating on the stage 2 rub land of the case assembly in Subtask 72-32-01-340-001 (paragraph 5.M.), do not remove this masking from the case assembly.
Subtask 72-32-01-320-005
O.Machine the case assembly diameter A and/or surface B to the finish dimensions. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-32-01-220-078 (paragraph 3.A.), Figure 901, Figure 902, and as follows:
(1)Set-up the case assembly to machine the forward flange. Refer to Subtask 72-32-01-350-023 (paragraph 4.A.).
(2)Machine the case assembly to the finish dimensions.
(3)Remove the case assembly from the forward flange fixture.
Subtask 72-32-01-350-032
P.Blend the case assembly diameter A and/or surface B. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
(1)Break all sharp edges to 0.005-0.010 inch (0.13-0.25 mm).
Subtask 72-32-01-350-033
Q.If you applied masking to the thermal spray coating on the stage 2 rub land of the case assembly in Subtask 72-32-01-340-001 (paragraph 5.M.), remove the masking from the case assembly.
Subtask 72-32-01-160-006
R.Clean the case assembly. Refer to TASK 72-32-01-100-801 (72-32-01, CLEANING 001).
Subtask 72-32-01-220-092
S.Do a visual inspection of the thermal spray coating applied to the case assembly diameter A and/or surface B and as follows:
(1)If the thermal spray coating does not agree with the acceptability limits specified in TASK 70-49-00-340-001 (THERMAL SPRAYING), and TASK 70-49-36-340-038 (HIGH DENSITY INCONEL 718 COATING APPLIED BY HVOF THERMAL SPRAY), do as follows:
Subtask 72-32-01-320-011
(a)Machine the case assembly diameter A and/or surface B to remove the thermal spray coating. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 901, Figure 902, and as follows:
1Set-up the case assembly to machine the forward flange. Refer to Subtask 72-32-01-350-023 (paragraph 4.A.).
2Machine diameter A and/or surface B to make it agree with the values recorded in Subtask 72-32-01-220-091 (paragraph 5.L.).
3Remove the case assembly from the forward flange fixture.
(b)Do Subtask 72-32-01-350-029 (paragraph 5.F.) thru Subtask 72-32-01-220-092 (paragraph 5.S.) again.
Subtask 72-32-01-220-093
T.Do an inspection of the case assembly. Refer to Subtask 72-32-01-220-078 (paragraph 3.A.), Figure 901, Figure 902, and as follows:
(1)Record the values for diameter A and dimension BF.
Subtask 72-32-01-340-002
U.If there is thermal spray coating on the stage 2 rub land, apply masking to give protection to the thermal spray coating on the stage 2 rub land as follows:
(1)Use C10-012  masking tape and/or fabricated shields to give protection to thermal spray coating on the stage 2 rub land of the case assembly.
Subtask 72-32-01-350-044
V.Remove the self-locking inserts from the aft flange (surface C) of the case assembly. Refer to TASK 72-32-01-300-802 (72-32-01, REPAIR 002).
Subtask 72-32-01-320-006
W.Machine the case assembly diameter D and/or surface C to remove thermal spray coating, indications, or wear. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-32-01-220-078 (paragraph 3.A.), Figure 901, Figure 902, Figure 903, and as follows:
NOTE:
Thermal spray coating will come off in small chips when machined and parent material will come off in a continuous curl when machined.
NOTE:
A surface with thermal spray coating will show a matte finish when machined and a surface without thermal spray coating will show a bright finish when machined.
(1)Set-up the case assembly to machine the aft flange. Refer to Subtask 72-32-01-350-026 (paragraph 4.B.).
(2)Find diameter D identifier and do as follows:
(a)If diameter D was not previously repaired or the identifier is 5, machine diameter D to no more than 32.310 inches (820.67 mm).
(b)If the identifier is 6, machine diameter D to no more than 32.318 inches (820.87 mm).
(c)If the identifier is 7, machine diameter D to no more than 32.322 inches (820.97 mm).
(d)If the identifier is 8, machine diameter D to no more than 32.326 inches (821.08 mm).
(e)If the identifier is 9, machine diameter D to no more than 32.330 inches (821.18 mm).
(3)Find surface C identifier and do as follows:
(a)If surface C was not previously repaired or the identifier is 0, machine dimension CF to no more than 0.265 inch (6.73 mm).
(b)If the identifier is 1, machine dimension CF to no more than 0.261 inch (6.62 mm).
(c)If the identifier is 2, machine dimension CF to no more than 0.259 inch (6.57 mm).
(d)If the identifier is 3, machine dimension CF to no more than 0.257 inch (6.52 mm).
(e)If the identifier is 4, machine dimension CF to no more than 0.255 inch (6.47 mm).
(4)Remove the case assembly from the aft flange fixture.
Subtask 72-32-01-350-034
X.Blend the case assembly diameter D and/or surface C. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
(1)Break all sharp edges to 0.005-0.010 inch (0.13-0.25 mm).
Subtask 72-32-01-110-012
Y.Etch the case assembly diameter D and/or surface C. 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 72-32-01-230-007
Z.Do an inspection of the case assembly diameter D and/or surface C. 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 thermal spray coating not applied by HVOF process and do as follows:
NOTE:
Thermal spray coating applied by plasma spray process will show up as background fluorescence.
NOTE:
Thermal spray coating applied by HVOF process will not show up as background fluorescence.
(a)If you find thermal spray coating, go to Subtask 72-32-01-320-008 (paragraph 5.AA.).
Subtask 72-32-01-220-094
(3)Use the acceptability limits that follow:
Subtask 72-32-01-220-095
(a)Through indications are not permitted.
Subtask 72-32-01-220-096
(b)Indications more than 0.02 inch (0.5 mm) are not permitted in the flange fillets or bases of the flanges.
(c)Other indications than those given in Subtask 72-32-01-220-095 (paragraph 5.Z.(3)(a)) and Subtask 72-32-01-220-096 (paragraph 5.Z.(3)(b)) , use the acceptability limits that follow:
1Indications less than 0.030 inch (0.76 mm) are permitted if they are clearly separated.
2Indications 0.030-0.060 inch (0.77-1.52 mm) are permitted if they agree with the conditions that follow:
aThe indications are not interpreted as linear.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
bThere must be a minimum distance of 0.25 inch (6.4 mm) between indications.
Subtask 72-32-01-320-007
(4)If the case assembly does not agree with the acceptability limits for diameter D and/or surface C after machining, go to Subtask 72-32-01-320-008 (paragraph 5.AA.).
Subtask 72-32-01-320-008
CAUTION:
REMOVE ONLY THE MINIMUM AMOUNT OF MATERIAL NECESSARY OR DAMAGE TO THE CASE ASSEMBLY CAN OCCUR.
AA.If necessary, machine the case assembly diameter D and/or surface C to remove thermal spray coating, indications, or wear. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-32-01-220-078 (paragraph 3.A.), Figure 901, Figure 902, Figure 903, and as follows:
NOTE:
Thermal spray coating will come off in small chips when machined and parent material will come off in a continuous curl when machined.
NOTE:
A surface with thermal spray coating will show a matte finish when machined and a surface without thermal spray coating will show a bright finish when machined.
(1)Set-up the case assembly to machine the aft flange. Refer to Subtask 72-32-01-350-026 (paragraph 4.B.).
(2)Machine the case assembly to remove thermal spray coating, indications, or wear as follows:
(a)Diameter D and/or surface C must agree with the in-process dimensions.
(b)If you cannot remove the thermal spray coating, indications, or wear when you machine to the in-process dimensions, then you cannot repair the case assembly with this procedure.
(3)Remove the case assembly from the aft flange fixture.
(4)Do Subtask 72-32-01-350-034 (paragraph 5.X.), Subtask 72-32-01-110-012 (paragraph 5.Y.), and Subtask 72-32-01-230-007 (paragraph 5.Z.) again.
Subtask 72-32-01-350-035
AB.If you applied masking to the thermal spray coating on the stage 2 rub land of the case assembly in Subtask 72-32-01-340-002 (paragraph 5.U.), remove the masking from the case assembly.
Subtask 72-32-01-160-004
AC.Clean 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).
Subtask 72-32-01-220-097
AD.Measure and record the values for the case assembly diameter D and dimension CF. Refer to Subtask 72-32-01-220-078 (paragraph 3.A.), Figure 902, and as follows:
(1)If the values of diameter D and dimension CF agree with the finish dimensions, go to Subtask 72-32-01-340-004 (paragraph 5.AL.).
(2)If one of the values agrees with the in-process dimensions, go to Subtask 72-32-01-340-003 (paragraph 5.AE.).
Subtask 72-32-01-340-003
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.
AE.Thermal-spray the case assembly diameter D and/or surface C and the 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), Figure 901, Figure 902, and as follows:
(1)Apply masking to the case assembly as follows:
(a)If there is thermal spray coating on the stage 2 rub land, do as follows:
1Use C10-012  masking tape and/or fabricated shields to give protection to thermal spray coating on the stage 2 rub land of the case assembly.
2The masking you apply to the thermal spray coating on the stage 2 rub land must stay on the case assembly when you machine the thermal spray coating applied to diameter D and/or surface C.
(b)Thermal spray coating is not permitted in the self-locking insert bores.
(c)Thermal spray coating is not permitted in boltholes and as follows:
1Use C10-198  plugs or equivalent to apply masking to the boltholes.
(2)Apply thermal spray coating to the case assembly. Refer to Subtask 72-32-01-220-078 (paragraph 3.A.) and as follows:
(a)Apply sufficient thermal spray coating to make sure that the case assembly agrees with the finish dimensions after final machining and as follows:
1After final machining, a minimum of 0.003 inch (0.08 mm) of thermal spray coating is necessary.
(3)Do all the quality assurance testing specified in TASK 70-49-00-340-001 (THERMAL SPRAYING) and TASK 70-49-36-340-038 (HIGH DENSITY INCONEL 718 COATING APPLIED BY HVOF THERMAL SPRAY).
Subtask 72-32-01-350-036
AF.Remove the masking from the case assembly as follows:
(1)Remove the masking from the self-locking insert bores.
(2)Remove the masking from the boltholes.
(3)If you applied masking to the thermal spray coating on the stage 2 rub land of the case assembly in Subtask 72-32-01-340-003 (paragraph 5.AE.), do not remove this masking from the case assembly.
Subtask 72-32-01-320-009
AG.Machine the case assembly diameter D and/or surface C to the finish dimensions. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-32-01-220-078 (paragraph 3.A.), Figure 901, Figure 902, and as follows:
(1)Set-up the case assembly to machine the aft flange. Refer to Subtask 72-32-01-350-026 (paragraph 4.B.).
(2)Machine the case assembly to the finish dimensions.
(3)Remove the case assembly from the aft flange fixture.
Subtask 72-32-01-350-037
AH.Blend the case assembly diameter D and/or surface C. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
(1)Break all sharp edges to 0.005-0.010 inch (0.13-0.25 mm).
Subtask 72-32-01-350-038
AI.If you applied masking to the thermal spray coating on the stage 2 rub land of the case assembly in Subtask 72-32-01-340-003 (paragraph 5.AE.), remove the masking from the case assembly.
Subtask 72-32-01-160-007
AJ.Clean the case assembly. Refer to TASK 72-32-01-100-801 (72-32-01, CLEANING 001).
Subtask 72-32-01-220-098
AK.Do a visual inspection of the thermal spray coating applied to the case assembly diameter D and/or surface C and as follows:
(1)If the thermal spray coating does not agree with the acceptability limits specified in TASK 70-49-00-340-001 (THERMAL SPRAYING), and TASK 70-49-36-340-038 (HIGH DENSITY INCONEL 718 COATING APPLIED BY HVOF THERMAL SPRAY), do as follows:
Subtask 72-32-01-320-010
(a)Machine the case assembly diameter D and/or surface C to remove the thermal spray coating. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 901, Figure 902, and as follows:
1Set-up the case assembly to machine the aft flange. Refer to Subtask 72-32-01-350-026 (paragraph 4.B.).
2Machine diameter D and/or surface C to make it agree with the values recorded in Subtask 72-32-01-220-097 (paragraph 5.AD.).
3Remove the case assembly from the aft flange fixture.
(b)Do Subtask 72-32-01-350-034 (paragraph 5.X.) thru Subtask 72-32-01-220-098 (paragraph 5.AK.) again.
Subtask 72-32-01-340-004
AL.Thermal-spray the stage 1 rub land and the stage 2 rub land. Refer to TASK 72-32-01-300-804 (72-32-01, REPAIR 004) and as follows:
(1)Prepare the stage 1 rub land and apply the thermal spray coating.
(2)If necessary, prepare the stage 2 rub land and apply the thermal spray coating.
Subtask 72-32-01-350-045
AM.Install the self-locking inserts in the aft flange (surface C). Refer to TASK 72-32-01-300-802 (72-32-01, REPAIR 002).
Subtask 72-32-01-220-099
AN.Do an inspection of the case assembly. Refer to Subtask 72-32-01-220-078 (paragraph 3.A.), Figure 901, Figure 902, and as follows:
(1)Record the values for diameter D and dimension CF.
Subtask 72-32-01-350-039
AO.Alternative Procedure Available. Put a mark on the case assembly. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-04-350-019 (VIBRO-PEEN MARKING), Figure 902, Figure 903, and as follows:
(1)Refer to Subtask 72-32-01-220-091 (paragraph 5.L.) and Subtask 72-32-01-220-097 (paragraph 5.AD.) for parent material measurement values.
(2)If there is an earlier repair to the case assembly with this procedure, line-out the existing identifiers after the Repair 005 mark on the upper and lower case halves.
(3)Put a mark on the upper and lower case halves near the identification numbers to show the quantity of parent material on the flange and rabbet features.
Subtask 72-32-01-350-063
AO.A.Alternative Procedure. Put a mark on the case assembly. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-08-350-001 (DOT PEEN MARKING FOR OPTICAL CHARACTER RECOGNITION), Figure 902, Figure 903, and as follows:
(1)Intermediate depth must be 0.001-0.004 inch (0.03-0.10 mm).
(2)Refer to Subtask 72-32-01-220-091 (paragraph 5.L.) and Subtask 72-32-01-220-097 (paragraph 5.AD.) for parent material measurement values.
(3)If there is an earlier repair to the case assembly with this procedure, line-out the existing identifiers after the Repair 005 mark on the upper and lower case halves.
(4)Put a mark on the upper and lower case halves near the identification numbers to show the quantity of parent material on the flange and rabbet features.
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Figure 901   (Sheet 1 ) High Pressure Compressor Stator Forward Case Assembly
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Figure 901   (Sheet 2 ) High Pressure Compressor Stator Forward Case Assembly
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Figure 902   (Sheet 1 ) High Pressure Compressor Stator Forward Case Assembly - Dimensional Information
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Figure 902   (Sheet 2 ) High Pressure Compressor Stator Forward Case Assembly - Dimensional Information
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Figure 903   High Pressure Compressor Stator Forward Case Assembly - Repair Marking
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Figure 904   (Sheet 1 ) Forward Flange Machining Fixture
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Figure 904   (Sheet 2 ) Forward Flange Machining Fixture
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Figure 904   (Sheet 3 ) Forward Flange Machining Fixture
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Figure 904   (Sheet 4 ) Forward Flange Machining Fixture
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Figure 905   (Sheet 1 ) Aft Flange Machining Fixture
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Figure 905   (Sheet 2 ) Aft Flange Machining Fixture
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Figure 905   (Sheet 3 ) Aft Flange Machining Fixture
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Figure 905   (Sheet 4 ) Aft Flange Machining Fixture