* * * FOR ALL
TASK 72-51-01-300-805
1 . Braze Voiding Restoration.
A.This procedure gives instructions to repair the high pressure turbine stage 1 nozzle support (nozzle support) by brazing the nozzle support again to restore braze areas. 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.
(d)Do an inspection of the braze joints (inner and outer support wall) for:
1Braze voids and cracks:
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)
 
2303M22G03  
2303M22G04  
2303M22G05  
2303M22G06  
 
2407M46G02  
2407M46G04  
2407M46G06  
2407M46G08  
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
 
Heat Treatment Fixture
902
B.Consumable Materials.
 
Code No.
Description
 
C04-035
Solvent, General (isopropyl alcohol)
 
C06-014
Braze Alloy Powder Ni-Si-B (AMS 4777) (braze alloy)
 
C06-019
Binder
 
C10-015
Braze Stop-Off
 
C10-182
Cloth, Cleaning for Aircraft Structural (SAE-AMS 3819, BMS 15-5) (cleaning cloth)
 
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Shims
C.Referenced Procedures.
 
ATA No.
Description
 
70-31-02
Acceptability Limits for Fluorescent Penetrant Inspection
 
70-32-00
Indirect Inspection Methods
 
70-32-02
Fluorescent Penetrant Inspection
 
70-41-00
Welding and Brazing Practices
 
70-41-03
High Temperature Furnace Braze
 
70-44-00
Heat Treating
 
70-44-03
Furnace Heat Treatment
 
72-51-01
Cleaning 001
 
72-51-01
Inspection 001
 
72-51-01
Repair 001
 
72-51-01
Repair 002
 
72-51-01
Repair 011
 
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GEAE Photo Standard 8311253, Class 30
D.Expendable Parts. None.
E.SPD Information.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. None.
3 . Dimensional Information.
Subtask 72-51-01-220-071
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 re-convert from millimeters to inches.
NOTE:
Reference dimensions do not require inspection.
4 . Setup Information.
Subtask 72-51-01-350-053
A.Set-up the nozzle support for heat treatment/brazing as follows:
Subtask 72-51-01-930-004
(1)If necessary, make the heat treatment/brazing fixture. Refer to Figure 902.
Subtask 72-51-01-350-054
(2)Install the heat treatment/brazing fixture as follows:
(a)Put the graphite plate on a furnace grid.
(b)Put shims on top of the graphite plate.
(3)Put the nozzle support forward flange on top of the shims.
Subtask 72-51-01-370-010
(4)For the quantity and placement requirements of the load thermocouples, refer to TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT) .
5 . Procedure.
Subtask 72-51-01-110-026
A.If necessary, clean the nozzle support. Refer to TASK 72-51-01-100-801 (72-51-01, CLEANING 001).
Subtask 72-51-01-350-055
B.Remove the shank nuts from the nozzle support. Refer to TASK 72-51-01-300-801 (72-51-01, REPAIR 001).
Subtask 72-51-01-350-117
C.For part numbers 2407M46G06   and 2407M46G08   , remove the hard coating from the nozzle support. Refer to TASK 72-51-01-300-811 (72-51-01, REPAIR 011).
Subtask 72-51-01-350-056
D.Prepare the nozzle support joints to apply braze alloy again as follows:
(1)Use carbide burr to remove oxidation from the braze joints or equivalent.
Subtask 72-51-01-110-027
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
CAUTION:
IT IS NOT PERMITTED TO CLEAN THE REPAIR AREA WITH ALUMINUM OXIDE GRIT BLAST CLEANING. THE ALUMINUM OXIDE GRIT CAN CONTAMINATE THE BRAZE JOINTS.
(2)Clean the braze joints area with a clean C10-182  cleaning cloth moist with C04-035  isopropyl alcohol.
Subtask 72-51-01-110-028
E.If necessary, clean the nozzle support. Refer to TASK 72-51-01-100-801 (72-51-01, CLEANING 001).
Subtask 72-51-01-350-057
WARNING:
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
F.Optional Procedure. Put the nozzle support in an oven at a temperature range of 130 to 150°F (54 to 66°C) for 30 minutes minimum to remove all moisture.
Subtask 72-51-01-350-058
G.Apply the braze slurry to the nozzle support as follows:
(1)Make a slurry as follows:
(a)Use C06-014  braze alloy.
(b)Use C06-019  binder.
(2)Apply a braze slurry bead of approximately 0.062-0.120 inch (1.58-3.04 mm) in diameter as necessary to braze the nozzle support repair areas again.
Subtask 72-51-01-350-059
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
H.Apply C10-015  braze stop-off to the nozzle support areas adjacent to the braze joints to prevent braze flow during the brazing procedure.
Subtask 72-51-01-310-008
I.Braze the nozzle support. 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:
(1)Set-up the nozzle support for heat treatment/brazing. Refer to Subtask 72-51-01-350-053 (paragraph 4.A.).
(2)Put the heat treatment/brazing fixture and the nozzle support in the furnace.
(3)Increase the temperature of the nozzle support to a temperature range of 1700 to 1750°F (927 to 954°C) and as follows:
(a)Keep this temperature for 10-15 minutes or until the vacuum rate gets back to a vacuum pressure of 5.0 X 10-4 mm Hg or less.
CAUTION:
DO NOT KEEP THE TEMPERATURE OF THE NOZZLE SUPPORT AT MORE THAN 1900°F (1038°C) FOR MORE THAN 30 MINUTES (TOTAL ACCUMULATED TIME) OR DAMAGE TO THE HONEYCOMB CAN OCCUR.
(4)Increase the temperature of the nozzle support to a temperature range of 1875 to 1925°F (1024 to 1052°C) at a rate of 20 to 25°F (11 to 14°C) for each minute and as follows:
(a)Keep this temperature for a maximum of 3-5 minutes.
NOTE:
The accumulated time for the honeycomb above 1900°F (1038°C) must be 30 minutes or less. If this time is more, the honeycomb must be replaced.
(5)Decrease the temperature of the nozzle support to a temperature range of 1750 to 1800°F (954 to 982°C) at a minimum rate of 20°F (11°C) for each minute and as follows:
(a)Keep this temperature for 10-15 minutes.
(6)Decrease the temperature of the nozzle support to 975 to 1025°F (524 to 552°C) within 30 minutes or less.
NOTE:
The rate of temperature decrease below 1000°F (538°C) is not important.
WARNING:
USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
(7)Remove the nozzle support from the furnace.
Subtask 72-51-01-220-072
J.Do a visual inspection of the nozzle support braze joints. Refer to Figure 901 and as follows:
(1)The two sides of the braze joints must show braze material fully around the braze joint.
(2)Through voids are not permitted.
(3)Irregular fillets and pinholes (surface porosity) are permitted.
(4)Indications 0.015 inch (0.38 mm) or less are permitted.
(5)The diameter or length of each void or unbounded area must not be more than 0.080 inch (2.03 mm).
(6)Local or continuous concavity is permitted.
(7)The minimum distance between adjacent voids or unbonded areas must be two times the size of the largest adjacent void or unbonded area.
(8)There must be three voids or unbonded areas or less for each 1.0 inch (25 mm) of braze material.
(9)Braze overflow is permitted as follows:
(a)A maximum height of 0.005 inch (0.12 mm) for braze overflow is permitted on the parent metal at a distance of 0.150 inch (3.81 mm) or more from the braze joint.
Subtask 72-51-01-350-060
K.If necessary, repair the nozzle support incorrect braze area as follows:
(1)Do Subtask 72-51-01-350-058 (paragraph 5.F.) thru Subtask 72-51-01-220-072 (paragraph 5.I.) again.
NOTE:
The accumulated time for the honeycomb above 1900°F (1038°C) must be 30 minutes or less. If this time is more, the honeycomb must be replaced.
Subtask 72-51-01-220-073
L.Do an inspection of the honeycomb. Refer to TASK 72-51-01-300-802 (72-51-01, REPAIR 002) (paragraph 5.R. or paragraph 5.R.A.) and as follows:
(1)If necessary, repair the unacceptable honeycomb braze area. Refer to TASK 72-51-01-300-802 (72-51-01, REPAIR 002).
Subtask 72-51-01-370-011
M.Do a heat treatment of the nozzle support. Refer to TASK 70-44-00-800-010 (HEAT TREATING), TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT), and as follows:
(1)For part numbers 2303M22G03   , 2303M22G04   , 2303M22G05   , and 2303M22G06   , do a heat treatment of the nozzle support as follows:
(a)Set-up the nozzle support for heat treatment/brazing. Refer to Subtask 72-51-01-350-053 (paragraph 4.A.).
(b)Put the nozzle support and the heat treatment/brazing fixture in the furnace.
(c)Heat-treat the nozzle support. Refer to TASK 70-44-00-800-010 (HEAT TREATING), TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT) , and as follows:
1Do an age heat treatment of the nozzle support as follows:
aUse Cycle V-13 or Cycle I-9.
(2)For part numbers 2407M46G02   , 2407M46G04   , 2407M46G06   , and 2407M46G08   , do a heat treatment of the nozzle support as follows:
(a)Set-up the nozzle support for heat treatment/brazing. Refer to Subtask 72-51-01-350-053 (paragraph 4.A.).
(b)Put the nozzle support and the heat treatment/brazing fixture in the furnace.
(c)Heat-treat the nozzle support. Refer to TASK 70-44-00-800-010 (HEAT TREATING), TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT) , and as follows:
1Do an age heat treatment of the nozzle support as follows:
aAge the nozzle support at 1450 to 1500°F (788 to 816°C) for 8 hours.
WARNING:
REFER TO THE PRODUCT LABEL AND THE MANUFACTURER’S (MATERIAL) SAFETY DATA SHEET (SDS) FOR INSTRUCTIONS ON THE HAZARDS, STORAGE, SAFE HANDLING AND PROPER USE OF THIS PRODUCT.
bDecrease the temperature of the nozzle support to 1000°F (538°C) with cool nitrogen, helium, or argon gas at a rate not less than 25°F (13.89°C) for each minute.
cDecrease the temperature of the nozzle support to room temperature.
dRemove the nozzle support from the furnace.
Subtask 72-51-01-350-118
N.For part numbers 2407M46G06   and 2407M46G08   , apply the hard coating from the nozzle support. Refer to TASK 72-51-01-300-811 (72-51-01, REPAIR 011).
Subtask 72-51-01-230-013
O.Do an inspection of the nozzle support. 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 C penetrant.
(2)For part number 2303M22   item 1 only. Refer to TASK 70-31-02-220-003 (ACCEPTABILITY LIMITS FOR FLUORESCENT PENETRANT INSPECTION) , for the acceptance limits and as follows:
(a)Use Class A limits.
(3)For other items of part number 2303M22   and all items of part number 2407M46   , use the acceptability limits that follow:
(a)Indications 0.030 inch (0.76 mm) or less are not interpretable and are permitted.
(b)Non-linear indications 0.060 inch (1.52 mm) or less with a minimum distance of between indications of 0.15 inch (3.9 mm) are permitted.
(c)Linear indications more than 0.030 inch (0.76 mm) are not permitted.
NOTE:
Linear indications are indications that are at least four times longer than they are wide.
(d)Through indications are not permitted.
(e)Microshrinkage must agree with GEAE Photo Standard 8311253, Class 30.
Subtask 72-51-01-220-074
P.Do a dimensional inspection of the nozzle support. Refer to TASK 72-51-01-200-801 (72-51-01, INSPECTION 001).
Subtask 72-51-01-350-061
Q.Install the shank nuts to the nozzle support. Refer to TASK 72-51-01-300-801 (72-51-01, REPAIR 001).
* * * FOR ALL
Figure 901   (Sheet 1 ) High Pressure Turbine Stage 1 Nozzle Support
* * * FOR ALL
Figure 901   (Sheet 2 ) High Pressure Turbine Stage 1 Nozzle Support
* * * FOR ALL
Figure 901   (Sheet 3 ) High Pressure Turbine Stage 1 Nozzle Support
* * * FOR ALL
Figure 901   (Sheet 4 ) High Pressure Turbine Stage 1 Nozzle Support
* * * FOR ALL
Figure 902   Heat Treatment/Brazing Fixture