* * * FOR ALL
TASK 72-41-20-300-807
1 . Dimensional Restoration of Surface F and Diameter G.
A.This procedure gives instructions to repair the stage 10 outlet guide vane (OGV) by thermal spraying with Rene 80 surface F and diameter G. 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.
(5)Dimensional Inspection.
(c)Do an inspection of the stage 10 OGV for:
3Diameter G:
Maximum repairable limit:
Any amount, if the parent material thickness, dimension ZZ is 0.059 inch (1.49 mm) or more.
4Diameter G roundness (free state):
Maximum repairable limit:
Any amount, if the parent material thickness, dimension ZZ is 0.059 inch (1.49 mm) or more.
5Surface F flatness (free state):
Maximum repairable limit:
Any amount, if the parent material thickness, dimension YY is 0.085 inch (2.15 mm) or more.
6Dimension H:
Maximum repairable limit:
Any amount, if the parent material thickness, dimension YY is 0.085 inch (2.15 mm) or more.
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)
 
2303M16G02  
2303M16G04  
2303M16G05  
2303M16G06  
 
2303M16G07  
2303M16G08  
2763M05G02  
2763M05G03  
 
2763M05G04  
2763M05G05  
2763M05G06  
2763M05G07  
 
2763M05G08  
2763M05G09  
2763M05G10  
2763M05G11  
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
 
Machining Fixture
902
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
 
70-16-08
Dot Peen Marking for Optical Character Recognition
 
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 Procedure
 
70-31-00
Dimensional Inspection
 
70-31-06
Machined Features Shop-Run Tolerances
 
70-32-00
Indirect Inspection Methods
 
70-32-02
Fluorescent Penetrant Inspection
 
70-32-03
Spot-Fluorescent-Penetrant Inspection
 
70-42-00
Blending and Removal of High Metal Procedures
 
70-44-00
Heat Treating
 
70-44-03
Furnace Heat Treatment
 
70-47-05
Cold-Working Repair
 
70-49-00
Thermal Spraying
 
70-49-56
Thermal Spraying - Standard Practice - Thermal Spraying Rene 80 Coating
 
72-41-20
Cleaning 001
 
72-41-20
Inspection 001
 
72-41-20
Repair 001
 
72-41-20
Repair 003
 
72-41-20
Repair 007
D.Expendable Parts. None.
E.SPD Information.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. Refer to TASK 70-49-56-340-803 (THERMAL SPRAYING - STANDARD PRACTICE - THERMAL SPRAYING RENE 80 COATING) .
3 . Dimensional Information.
Subtask 72-41-20-220-071
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.
NOTE:
Reference dimensions do not require inspection.
NOTE:
To measure a dimension, an average of six equally spaced circumferential locations must be used.
NOTE:
A dimension that is at the serviceable limits is always permitted and repair is not necessary. Refer to TASK 72-41-20-200-801 (72-41-20, INSPECTION 001) for the serviceable limits.
 
Description
Minimum In-Process Dimension
Maximum In-Process Dimension
Minimum Finish Dimension
Maximum Finish Dimension
Reference Dimension
 
Dia G
16.218 in. (411.94 mm)
--
16.238 in. (412.45 mm)
16.242 in. (412.54 mm)
--
 
Dim. H
6.949 in. (176.51 mm)
--
6.959 in. (176.76 mm)
6.979 in. (177.26 mm)
--
 
Dim. YY
0.085 in. (2.16 mm)
--
0.105 in. (2.67 mm)
0.115 in. (2.92 mm)
--
 
Dim. ZZ
0.059 in. (1.50 mm)
--
0.069 in. (1.76 mm)
0.081 in. (2.05 mm)
--
4 . Setup Information.
Subtask 72-41-20-350-032
A.Set-up the OGV for machining. Refer to Figure 902 and as follows:
Subtask 72-41-20-930-001
(1)If necessary, make the machining fixture.
Subtask 72-41-20-350-031
(2)Install the machining fixture on the machining table as follows:
Subtask 72-41-20-350-045
(a)Adjust the position of the machining fixture to get the runout of surface X to 0.001 inch (0.02 mm) full indicator reading (FIR) or less as follows:
1If necessary, put C10-155  shims between the machining fixture and the machining table to get the necessary runout.
Subtask 72-41-20-350-046
(b)If necessary, adjust the position of the machining fixture to make sure that the runout of diameter Y is 0.001 inch (0.02 mm) FIR or less.
(c)Use four 0.500-13 UNC socket headed cap screws to hold the machining fixture to the machining table and as follows:
1Make sure that the runouts of surface X and diameter Y agree with the requirements specified in Subtask 72-41-20-350-045 (paragraph 4.A.(2)(a)) and Subtask 72-41-20-350-046 (paragraph 4.A.(2)(b)) .
Subtask 72-41-20-350-044
(3)Install the OGV onto the machining fixture as follows:
(a)Put the OGV onto the machining fixture with the forward side down.
(b)Use clamps to attach the OGV to the OGV machining fixture.
Subtask 72-41-20-350-047
(c)Adjust the runout of the OGV diameter G in 0.004 inch (0.10 mm) or less as follows:
1If necessary, add C10-155  shims to diameter J.
Subtask 72-41-20-220-078
(4)Make sure that you install the OGV flat on the machining fixture as follows:
(a)The maximum permitted clearance between surface X of the machining fixture and the OGV is 0.002 inch (0.05 mm).
5 . Procedure.
Subtask 72-41-20-350-033
CAUTION:
MAKE SURE THAT YOU DO NOT DO THIS REPAIR MORE THAN TWO TIMES. DAMAGE TO THE HONEYCOMB CAN OCCUR.
A.You can do this repair a maximum of two times with the heat treatment procedures specified in Subtask 72-41-20-370-002 (paragraph 5.L.). If it is necessary to do this repair more than two times, you must remove the honeycomb. Refer to TASK 72-41-20-300-804 (72-41-20, REPAIR 007).
Subtask 72-41-20-160-007
B.If necessary, clean the OGV. Refer to TASK 72-41-20-100-801 (72-41-20, CLEANING 001).
Subtask 72-41-20-350-034
C.For P/N 2303M16G02   and P/N 2303M16G05   , remove the seal pins, springs, and leaf seals from the OGV. Refer to TASK 72-41-20-300-801 (72-41-20, REPAIR 001).
Subtask 72-41-20-350-035
D.Remove the three cover plates from the OGV. Refer to TASK 72-41-20-300-802 (72-41-20, REPAIR 003).
Subtask 72-41-20-230-006
E.Do an inspection of the OGV surface F/diameter G to find areas with thermal spray coating or indications/wear on parent material. 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 A penetrant.
(2)Look for signs of thermal spray coating and as follows:
NOTE:
Thermal spray coating applied by the plasma spray process will show up as background fluorescence.
(a)If there is remaining thermal spray coating, go to Subtask 72-41-20-320-008 (paragraph 5.F.).
(3)Refer to TASK 72-41-20-200-801 (72-41-20, INSPECTION 001) for acceptability limits.
Subtask 72-41-20-320-008
CAUTION:
MAKE SURE TO REMOVE THE MINIMUM QUANTITY OF PARENT MATERIAL NECESSARY TO REMOVE DEFECTS. DAMAGE TO THE OGV CAN OCCUR.
F.Alternative Procedure Available. If necessary, machine the OGV surface F/diameter G to remove thermal spray coating or indications/wear on the parent material. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-41-20-220-071 (paragraph 3.A.), Figure 901, and as follows:
NOTE:
Thermal spray coating will come off in small chips when machined and parent metal 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.
Subtask 72-41-20-350-041
(1)Set-up the OGV for machining. Refer to Subtask 72-41-20-350-032 (paragraph 4.A.).
Subtask 72-41-20-320-011
(2)Machine the OGV to remove thermal spray coating or indications/wear on the parent material as follows:
(a)Surface F/diameter G must agree with the in-process limits.
Subtask 72-41-20-320-009
(b)If necessary, work the OGV diameter G until it agrees with the runout specified in Subtask 72-41-20-350-047 (paragraph 4.A.(3)(c)) . Refer to TASK 70-47-05-350-023 (COLD-WORKING REPAIR).
NOTE:
It is permitted to use diameter T as reference during the cold work operation.
(c)Do not machine the fillet that connects surface F and diameter G.
(d)If you cannot remove the thermal spray coating, indications, or wear by machining to the in-process limits, then you cannot repair the OGV with this procedure.
(3)Remove the OGV from the machining fixture.
(4)If necessary do Subtask 72-41-20-230-006 (paragraph 5.E.) and Subtask 72-41-20-320-008 (paragraph 5.F.) again.
Subtask 72-41-20-330-002
F.A.Alternative Procedure. If necessary, remove the thermal spray coating from surface F/diameter G of the OGV. Refer to TASK 70-23-00-100-001 (STRIPPING PROCEDURES), TASK 70-23-23-330-008 (REMOVAL OF COATINGS BY HIGH PRESSURE WATER STRIPPING), Subtask 72-41-20-220-071 (paragraph 3.A.), and Figure 901.
Subtask 72-41-20-220-072
G.Do a dimensional inspection of the OGV repair area. Refer to Subtask 72-41-20-220-071 (paragraph 3.A.), Figure 901, and as follows:
(1)Make sure that dimension H/diameter G/dimension ZZ/dimension YY agree with the minimum in-process limits.
Subtask 72-41-20-350-036
H.Blend the OGV surface F/diameter G. 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 72-41-20-110-013
I.Etch the OGV machined areas. 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 72-41-20-230-007
J.Do an inspection of the OGV repair areas. 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 A penetrant.
NOTE:
Areas with plasma thermal spray will show as background fluorescence.
(2)Thermal spray coating is not permitted.
(3)Refer to TASK 72-41-20-200-801 (72-41-20, INSPECTION 001) for acceptability limits.
(4)If you find indications that do not agree with these limits, you cannot repair the OGV with this procedure.
Subtask 72-41-20-160-008
K.Clean the OGV. Refer to TASK 72-41-20-100-801 (72-41-20, CLEANING 001).
Subtask 72-41-20-370-002
L.If you did Subtask 72-41-20-320-009 (paragraph 5.F.(2)(b)), heat-treat the OGV, otherwise go to Subtask 72-41-20-340-006 (paragraph 5.P.). Refer to TASK 70-44-00-800-010 (HEAT TREATING), TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT), and as follows:
Subtask 72-41-20-370-003
(1)For P/N 2303M16G02   , P/N 2303M16G04   , P/N 2303M16G06   , P/N 2763M05G02   , P/N 2763M05G03   , P/N 2763M05G05   , P/N 2763M05G06   , P/N 2763M05G09   , and P/N 2763M05G10   do as follows:
(a)Increase the temperature of the OGV to 1475°F plus or minus 25°F (802°C plus or minus 14°C) for 7 hours 50 minutes to 8 hours 10 minutes.
(b)Decrease the temperature of the OGV to 1325°F plus or minus 25°F (718°C plus or minus 14°C) and hold this temperature for 7 hours 50 minutes to 8 hours 10 minutes.
(c)Decrease the temperature of the OGV to 1150°F plus or minus 25°F (621°C plus or minus 14°C) at a minimum rate of 100°F (55.6°C) for each hour and hold this temperature for 7 hours 50 minutes to 8 hours 10 minutes.
(d)Air-cool the OGV to room temperature.
Subtask 72-41-20-370-004
(2)For P/N 2303M16G05   , P/N 2303M16G07   , P/N 2303M16G08   , P/N 2763M05G04   , P/N 2763M05G07   , P/N 2763M05G08   , and P/N 2763M05G11   do as follows:
(a)Increase the temperature of the OGV to 1450°F plus or minus 25°F (787°C plus or minus 14°C) for 1 hour 45 minutes to 2 hours 15 minutes.
(b)Decrease the temperature of the OGV to 1300°F plus or minus 25°F (704°C plus or minus 14°C) and hold this temperature for 7 hours 45 minutes to 8 hours 15 minutes.
(c)Decrease the temperature of the OGV to 1150°F plus or minus 25°F (621°C plus or minus 14°C) at a minimum rate of 100°F (55.6°C) for each hour and hold this temperature for 7 hours 45 minutes to 8 hours 15 minutes.
(d)Air-cool the OGV to room temperature.
Subtask 72-41-20-110-014
M.Etch the OGV machined areas. 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 72-41-20-230-008
N.Do an inspection of the OGV repair areas. Refer to TASK 70-32-00-200-002 (INDIRECT INSPECTION METHODS), TASK 70-32-02-230-001 (FLUORESCENT PENETRANT INSPECTION), and as follows:
(1)Use Class A penetrant.
NOTE:
Areas with plasma thermal spray will show as background fluorescence.
(2)Thermal spray coating is not permitted.
(3)Refer to TASK 72-41-20-200-801 (72-41-20, INSPECTION 001) for acceptability limits.
Subtask 72-41-20-160-009
O.Clean the OGV. Refer to TASK 72-41-20-100-801 (72-41-20, CLEANING 001).
Subtask 72-41-20-340-006
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.
P.Thermal-spray the OGV surface F/diameter G and the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-56-340-803 (THERMAL SPRAYING - STANDARD PRACTICE - THERMAL SPRAYING RENE 80 COATING) , and as follows:
(1)Apply C10-012  masking tape to the OGV adjacent areas to surface F/diameter G where thermal spray is not permitted. Refer to Figure 903.
(2)Thermal spray coating is not permitted in the boltholes and as follows:
(a)Use C10-198  plugs or similar for masking the boltholes and the slots of the scalloped flange.
(3)Apply thermal spray coating to a maximum thickness of 0.040 inch (1.01 mm).
(4)Do all the quality assurance testing specified in TASK 70-49-56-340-803 (THERMAL SPRAYING - STANDARD PRACTICE - THERMAL SPRAYING RENE 80 COATING).
CAUTION:
DO NOT USE METALLIC INSTRUMENTS TO APPLY OR REMOVE THE MASKING TAPE. YOU CAN CAUSE DAMAGE TO THE OGV AND REDUCE THE FATIGUE LIFE OF THE OGV IF YOU USE METALLIC INSTRUMENTS.
(5)Remove the masking tape from the OGV. Carefully pull the masking tape away from the thermal spray coating.
Subtask 72-41-20-320-010
Q.Machine the OGV surface F/diameter G to agree with the finish limits. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-41-20-220-071 (paragraph 3.A.), Figure 901, and as follows:
(1)Make sure that there is a minimum thermal spray coating thickness of 0.004 inch (0.11 mm) in surface F and diameter G after final machining.
Subtask 72-41-20-350-043
(2)Set-up the OGV for machining. Refer to Subtask 72-41-20-350-032 (paragraph 4.A.).
Subtask 72-41-20-320-012
(3)Machine the OGV surface F/diameter G to agree with the finish limits.
(4)For tolerances, refer to TASK 70-31-00-220-001 (DIMENSIONAL INSPECTION) and TASK 70-31-06-220-001 (MACHINED FEATURES SHOP-RUN TOLERANCES).
(5)Remove the OGV from the machining fixture.
Subtask 72-41-20-350-037
R.Blend the OGV. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES).
Subtask 72-41-20-160-010
S.Clean the OGV. Refer to TASK 72-41-20-100-801 (72-41-20, CLEANING 001).
Subtask 72-41-20-220-073
T.Do a visual inspection of the thermal spray coating that you applied to the OGV. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-56-340-803 (THERMAL SPRAYING - STANDARD PRACTICE - THERMAL SPRAYING RENE 80 COATING), and as follows:
(1)No steps or undercuts are permitted.
Subtask 72-41-20-220-074
U.Do a dimensional inspection of the OGV. Refer to TASK 72-41-20-200-801 (72-41-20, INSPECTION 001).
Subtask 72-41-20-350-038
V.For P/N 2303M16G02   and P/N 2303M16G05   , install the seal pins, springs, and leaf seals in the OGV. Refer to TASK 72-41-20-300-801 (72-41-20, REPAIR 001).
Subtask 72-41-20-350-039
W.Install the three cover plates onto the OGV. Refer to TASK 72-41-20-300-802 (72-41-20, REPAIR 003).
Subtask 72-41-20-350-040
X.Put a mark on the case to show that the OGV was repaired by this repair. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-08-350-001 (DOT PEEN MARKING FOR OPTICAL CHARACTER RECOGNITION), and as follows:
(1)Put a mark adjacent to the part number.
(2)Use method 2 and put REPAIR YYY-XX adjacent to the part number and as follows:
(a)If there is no mark in the repair, write 01 adjacent to YYY.
(b)If there is a 01 mark, replace it by 02.
NOTE:
XX is the number of times that repair YYY was done to the OGV.
* * * FOR ALL
Figure 901   (Sheet 1 ) Stage 10 Outlet Guide Vane
* * * FOR ALL
Figure 901   (Sheet 2 ) Stage 10 Outlet Guide Vane
* * * FOR ALL
Figure 901   (Sheet 3 ) Stage 10 Outlet Guide Vane
* * * FOR ALL
Figure 901   (Sheet 4 ) Stage 10 Outlet Guide Vane
* * * FOR ALL
Figure 901   (Sheet 5 ) Stage 10 Outlet Guide Vane
* * * FOR ALL
Figure 901   (Sheet 6 ) Stage 10 Outlet Guide Vane
* * * FOR ALL
Figure 902   (Sheet 1 ) Machining Fixture
* * * FOR ALL
Figure 902   (Sheet 2 ) Machining Fixture
* * * FOR ALL
Figure 903   (Sheet 1 ) Masking Areas
* * * FOR ALL
Figure 903   (Sheet 2 ) Masking Areas
* * * FOR ALL
Figure 903   (Sheet 3 ) Masking Areas