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TASK 72-41-20-300-809
1 . Weld Repair for Damage on the Forward Lip.
A.This procedure gives instructions to repair the stage 10 outlet guide vane (OGV) by welding the forward lip. 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.
(m)Do an inspection of the forward lip for:
1Cracks, nicks, tears, and missing material:
Maximum repairable limit:
Any amount.
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
903
 
Heat Treat Fixture
904
B.Consumable Materials.
 
Code No.
Description
 
C06-039
Weld Wire (Rene 220 weld wire)
 
C10-155
Shims, Metal (shims)
C.Referenced Procedures.
 
ATA No.
Description
 
70-00-03
Machining Data
 
70-24-00
Etching Procedures for Fluorescent-Penetrant Inspection
 
70-24-01
Swab Etching Procedure
 
70-31-02
Acceptability Limits for Fluorescent Penetrant Inspection
 
70-32-00
Indirect Inspection Methods
 
70-32-02
Fluorescent Penetrant Inspection
 
70-32-03
Spot-Fluorescent-Penetrant Inspection
 
Deleted
 
70-33-00
Special Inspection Procedures
 
70-33-02
Capillary Inspection of Open Face Honeycomb Structures
 
70-41-00
Welding and Brazing Practices
 
70-41-03
High Temperature Furnace Braze
 
70-42-00
Blending and Removal of High Metal Procedures
 
70-44-00
Heat Treating
 
70-44-03
Furnace Heat Treatment
 
72-41-20
Cleaning 001
 
72-41-20
Inspection 001
 
72-41-20
Repair 003
 
--
GEAE Photo Standard 8311253, Class 10
 
--
GEAE Photo Standard 8311253, Class 20
D.Expendable Parts. None.
E.SPD Information.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. None.
3 . Dimensional Information.
Subtask 72-41-20-220-123
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.
NOTE:
Applicable only for part numbers: 2303M16G02   , 2303M16G04   , 2303M16G05   , 2303M16G06   , 2303M16G07   , 2763M05G02   , 2763M05G03   , 2763M05G04   , 2763M05G05   , 2763M05G06   , 2763M05G07   , 2763M05G09   , 2763M05G10   , and 2763M05G11   .
NOTE:
Applicable only for part numbers: 2303M16G08   and 2763M05G08   .
 
Minimum
Maximum
Minimum
Maximum
 
In-Process
In-Process
Finish
Finish
Reference
 
Description
Dimension
Dimension
Dimension
Dimension
Dimension
 
Dia AB
--
--
24.978 in.
25.010 in.
--
 
(634.45 mm)
(635.25 mm)
 
Dim. AC
--
--
7.165 in.
7.175 in.
--
 
(182.00 mm)
(182.24 mm)
 
NOTE:
Applicable only for part numbers: 2303M16G02   , 2303M16G04   , 2303M16G05   , 2303M16G06   , 2303M16G07   , 2763M05G02   , 2763M05G03   , 2763M05G04   , 2763M05G05   , 2763M05G06   , 2763M05G07   , 2763M05G09   , 2763M05G10   , and 2763M05G11   .
 
Dim. AC
--
--
7.180 in.
7.190 in.
--
 
(182.38 mm)
(182.62 mm)
 
NOTE:
Applicable only for part numbers: 2303M16G08   and 2763M05G08   .
4 . Setup Information.
Subtask 72-41-20-350-061
A.Set-up the OGV for machining as follows:
Subtask 72-41-20-930-002
(1)If necessary, make the machining fixture. Refer to Figure 903.
Subtask 72-41-20-350-062
(2)Install the machining fixture on the machining table as follows:
(a)Adjust the position of the machining fixture to get the runout of surface X to 0.001 inch (0.02 mm) FIR or less as follows:
1If necessary, put C10-155  shims between the machining fixture and the machining table to get the necessary runout.
(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-head capscrews 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 72-41-20-350-062 (paragraph 4.A.(2)(a)) and Subtask 72-41-20-350-062 (paragraph 4.A.(2)(b)).
(3)Install the OGV onto the machining fixture as follows:
NOTE:
The OGV flange temperature can be decreased to help with its installation onto the machining fixture.
(a)Put the OGV onto the machining fixture, forward side up, and align the boltholes in the flange with the 17 threaded holes in the machining fixture.
(b)Attach the OGV to the machining fixture with seventeen 0.375-16 UNC bolts or screws.
(4)Make sure that the OGV is installed flat on the machining fixture as follows:
(a)The maximum permitted clearance between surface X of the machining fixture and surface F of the OGV is 0.002 inch (0.05 mm).
Subtask 72-41-20-350-063
B.Set-up the OGV for heat-treating. Refer to Figure 904 and as follows:
Subtask 72-41-20-930-003
(1)If necessary, make the heat-treat fixture. Refer to Figure 904.
Subtask 72-41-20-350-064
(2)Put the graphite plate on a furnace grid.
(3)Put C10-155  shims on top of the graphite plate.
(4)Put the OGV onto the graphite plate and C10-155   shims as follows:
(a)Make sure that the position of the OGV is aft end down.
5 . Procedure.
Subtask 72-41-20-160-011
A.If necessary, clean the OGV. Refer to TASK 72-41-20-100-801 (72-41-20, CLEANING 001).
Subtask 72-41-20-350-065
B.If necessary, remove the cover plates from the OGV. Refer to TASK 72-41-20-300-802 (72-41-20, REPAIR 003).
NOTE:
Removal of the cover plate is not necessary if the damage requires only blending.
Subtask 72-41-20-350-066
C.Blend the damage on the forward lip. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), Figure 901, and as follows:
CAUTION:
REMOVE ONLY THE MINIMUM QUANTITY OF MATERIAL NECESSARY OR DAMAGE TO THE OGV CAN OCCUR.
(1)Blend the defects to create a smooth surface with the adjacent surfaces.
(2)A maximum of 15 areas can be blended on the forward lip, and the blend areas must be separated by a distance of 0.250 inch (6.35 mm).
(3)Post blend, the maximum permitted depth of blend is 0.031 inch (0.78 mm) and the maximum width is 0.310 inch (7.87 mm).
(4)Remove all burrs and break sharp edges to 0.005-0.010 inch (0.13-0.25 mm).
(5)If the blend areas do not agree with the criteria above, prepare the area(s) for welding. Refer to Subtask 72-41-20-310-009 (paragraph 5.G.).
Subtask 72-41-20-110-022
D.Etch the lip 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 72-41-20-230-012
E.Do an inspection of the lip area. 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)For acceptability limits, refer to TASK 72-41-20-200-801 (72-41-20, INSPECTION 001).
(3)If the part does not agree with the acceptability limits, continue with Subtask 72-41-20-160-012 (paragraph 5.F.).
(4)If the part agrees with the acceptability limits, do Subtask 72-41-20-350-069 (paragraph 5.R.) as necessary to make the part serviceable.
(5)Deleted.
Subtask 72-41-20-160-012
F.If necessary, clean the OGV. Refer to TASK 72-41-20-100-801 (72-41-20, CLEANING 001).
Subtask 72-41-20-310-009
G.Weld the forward lip repair area. Refer to TASK 70-41-00-310-001 (WELDING AND BRAZING PRACTICES) and as follows:
(1)Prepare the repair area for welding.
(2)Make short passes and let the welded location decrease its temperature between each pass to keep the distortion to a minimum.
(3)Use C06-039  Rene 220 weld wire.
(4)Keep the heat input to a minimum during the welding procedure.
(5)Multiple passes can be necessary to weld build-up the worn areas and agree with the parent metal thickness.
(6)Make sure to put sufficient weld material to get the finish dimensions.
Subtask 72-41-20-350-067
H.Alternative Procedure Available. Blend the welded area of the OGV forward lip. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), Figure 901, and as follows:
(1)Blend carefully the welded areas to the finish dimensions.
(2)Remove all burrs and sharp edges to 0.020 inch (0.50 mm) or less.
Subtask 72-41-20-320-013
H.A.Alternative Procedure. Machine the OGV forward lip. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-41-20-220-123 (paragraph 3.A.), Figure 901, and as follows:
(1)Set-up the OGV for machining. Refer to Subtask 72-41-20-350-061 (paragraph 4.A.).
(2)Machine the OGV area D to the finish dimensions. Refer to Figure 901.
Subtask 72-41-20-350-068
(2)Blend the OGV repair area. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
(a)Break all sharp edges to 0.005-0.010 inch (0.13-0.25 mm).
Subtask 72-41-20-110-023
I.Etch the OGV 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 72-41-20-230-013
J.Do an inspection of the lip area. 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)For acceptability limits, refer to TASK 72-41-20-200-801 (72-41-20, INSPECTION 001).
(3)Deleted.
Subtask 72-41-20-260-001
K.Deleted.
Subtask 72-41-20-310-010
L.Heat-treat the OGV. Refer to TASK 70-41-00-310-001 (WELDING AND BRAZING PRACTICES), TASK 70-41-03-310-004 (HIGH TEMPERATURE FURNACE BRAZE), and as follows:
NOTE:
The removal of the honeycomb is not necessary before the heat treatment procedure.
(1)Set-up the OGV for heat-treating. Refer to Subtask 72-41-20-350-063 (paragraph 4.B.) and Figure 904.
(2)Attach four equally spaced thermocouples to the honeycomb support outer diameter.
(3)Install the OGV in a clean vacuum furnace.
(4)Decrease the vacuum furnace temperature to a vacuum of 5x10-4 Torr (0.5 micron) or better.
(5)Increase the temperature of the OGV to a range of 1700 to 1800°F (927 to 982°C) and as follows:
(a)Keep the temperature of the OGV at a range of 1700 to 1800°F (927 to 982°C) for 10-15 minutes.
(6)Increase the temperature of the OGV to a range of 1900 to 1950°F (1038 to 1065°C) at a rate of not more than 35°F (19°C) for each minute and as follows:
(a)Keep the temperature of the OGV at the braze temperature until the braze alloy wets.
(b)Do not keep the temperature of the OGV at the braze temperature for more than 5 minutes.
(7)Decrease the temperature of the OGV to a range of 1700 to 1800°F (927 to 982°C) at a rate of not more than 35°F (19°C) for each minute and as follows:
(a)Keep the temperature of the OGV at a range of 1700 to 1800°F (927 to 982°C) for 15 minutes maximum.
(8)Decrease the temperature of the OGV to below 1100°F (593°C).
(9)The temperature decrease from 1950°F (1065°C) maximum to below 1100°F (593°C) must be in 30 minutes or less.
(10)The cooling rate below 1100°F (593°C) is not important.
Subtask 72-41-20-220-088
M.Alternative Procedure Available. Do an inspection of the braze joint on the replacement honeycomb seal and the OGV backing strip surface. Refer to TASK 70-33-00-999-001 (SPECIAL INSPECTION PROCEDURES), TASK 70-33-02-220-005 (CAPILLARY INSPECTION OF OPEN FACE HONEYCOMB STRUCTURES), and as follows:
(1)Make sure that the honeycomb ring is fully bonded to its backing surface in 80 percent of the total contact area.
(2)The contact area(s) of the honeycomb that are not bonded must agree with the limits that follow:
(a)The unbonded area of the replacement honeycomb seal must be less than 10 fully adjacent cells circumferentially and five fully adjacent cells axially.
(b)The unbonded areas must be separated by a minimum of five adjacent bonded cells.
(c)The unbonded area of the replacement honeycomb seal must not include partial cells.
Subtask 72-41-20-220-089
M.A.Alternative Procedure. Do an inspection of the braze joint on the honeycomb seal and the OGV backing strip surface as follows:
(1)Use a video microscope with 10X magnification.
(2)Refer to the limits in Subtask 72-41-20-220-088 (paragraph 5.M.(1)) thru Subtask 72-41-20-220-088 (paragraph 5.M.(2)).
Subtask 72-41-20-370-007
N.Heat-treat the OGV in a vacuum furnace. Refer to TASK 70-44-00-800-010 (HEAT TREATING), TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT), Figure 901, and as follows:
(1)Set-up the OGV for heat-treating. Refer to Subtask 72-41-20-350-063 (paragraph 4.B.).
(2)Attach four equally spaced thermocouples to the OGV.
(3)Install the OGV setup in a clean vacuum furnace.
(4)Decrease the furnace to a vacuum of 5x10-4 Torr (0.5 micron) or better.
(5)Increase the temperature of the OGV to a range of 1450 to 1500°F (788 to 815°C) and as follows:
(a)Keep the temperature of the OGV at a range of 1450 to 1500°F (788 to 815°C) for 8 hours and plus or minus 10 minutes.
(6)Decrease the temperature of the OGV to a range of 1300 to 1350°F (705 to 732°C) and as follows:
(a)Keep the temperature of the OGV at a range of 1300 to 1350°F (705 to 732°C) for 8 hours and plus or minus 10 minutes.
(7)Decrease the temperature of the OGV to a range of 1125 to 1175°F (608 to 635°C) at a minimum rate of 100°F (38°C) for each hour and as follows:
(a)Keep the temperature of the OGV at a range of 1125 to 1175°F (608 to 635°C) for 8 hours and plus or minus 10 minutes.
(5)Increase the temperature of the OGV to a range of 1425 to 1475°F (774 to 801°C) and as follows:
(a)Keep the temperature of the OGV at a range of 1425 to 1475°F (774 to 801°C) for 2 hours and plus or minus 15 minutes.
(6)Decrease the temperature of the OGV to a range of 1275 to 1325°F (691 to 718°C) and as follows:
(a)Keep the temperature of the OGV at a range of 1275 to 1325°F (691 to 718°C) for 8 hours and plus or minus 15 minutes.
(7)Decrease the temperature of the OGV to a range of 1125 to 1175°F (608 to 635°C) and as follows:
(a)Keep the temperature of the OGV at a range of 1125 to 1175°F (608 to 635°C) for 8 hours and plus or minus 15 minutes.
(8)Decrease the temperature of the OGV to room temperature.
Subtask 72-41-20-230-014
O.Do an inspection of the OGV. Refer to TASK 70-32-00-200-002 (INDIRECT INSPECTION METHODS), TASK 70-32-02-230-001 (FLUORESCENT PENETRANT INSPECTION), Figure 901, and as follows:
(1)Use Class A penetrant.
(2)For acceptability limits, refer to TASK 72-41-20-200-801 (72-41-20, INSPECTION 001).
(3)Deleted.
(4)Deleted.
(5)Do an inspection of the honeycomb support and the aft flange as specified in TASK 70-31-02-220-003 (ACCEPTABILITY LIMITS FOR FLUORESCENT PENETRANT INSPECTION) and as follows:
(a)Use Class A limits.
(6)Through indications are not permitted.
Subtask 72-41-20-220-090
P.Do an inspection of the OGV for thermal spray coating at the W-seal of surface N, W-seal of surface M, surface F, diameter G, and rabbet diameter C. Refer to TASK 72-41-20-200-801 (72-41-20, INSPECTION 001) and as follows:
(1)Use 10X magnification and white light.
(2)Do not lift or remove the thermal spray coating from the parent metal.
(3)Cracks, blisters, chipping, flaking, spalling, or splatter are not permitted.
(4)If the thermal spray coating is damaged, remove it and replace it. Refer to TASK 72-41-20-200-801 (72-41-20, INSPECTION 001).
Subtask 72-41-20-220-091
Q.Do a dimensional inspection of the OGV. Refer to TASK 72-41-20-200-801 (72-41-20, INSPECTION 001).
Subtask 72-41-20-350-069
R.Install the cover plates into the OGV. Refer to TASK 72-41-20-300-802 (72-41-20, REPAIR 003).
* * * 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
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Figure 901   (Sheet 5 ) Stage 10 Outlet Guide Vane - Blend Repair Information
* * * FOR ALL
Figure 901   (Sheet 6 ) Stage 10 Outlet Guide Vane - Dimensional Information for Machining Only
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Figure 902   DELETED
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Figure 903   Machining Fixture
* * * FOR ALL
Figure 904   Heat Treat Fixture