* * * FOR ALL
TASK 72-51-01-300-807
1 . Weld Repair of the Inner Diameter in the Forward Flange Erosion Area.
A.This procedure gives instructions to repair the high pressure turbine stage 1 nozzle support (nozzle support) by welding the erosion in area AC of the forward 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.
(g)Do an inspection of the inner diameter of the forward flange area. Refer to Figure 802 and as follows:
1Erosion in area CC:
Maximum repairable limit:
Any amount.
4Erosion in area AC:
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)
 
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. None.
B.Consumable Materials.
 
Code No.
Description
 
C04-113
Abrasive, Grit, Aluminum Oxide (220 mesh abrasive compound)
 
C06-037
Weld Wire, GTD222
 
--
Shims, Hastelloy X (shims)
C.Referenced Procedures.
 
ATA No.
Description
 
70-21-00
Chemical Cleaning
 
70-21-04
Cleaning Method No. 4 - Dry Abrasive Blast Cleaning
 
70-24-00
Etching Procedures for Fluorescent-Penetrant Inspection
 
70-24-01
Swab Etching Procedure
 
70-32-00
Indirect Inspection Methods
 
70-32-02
Fluorescent Penetrant Inspection
 
70-32-03
Spot-Fluorescent-Penetrant Inspection
 
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
 
72-51-01
Cleaning 001
 
72-51-01
Inspection 001
 
72-51-01
Repair 001
 
72-51-01
Repair 011
 
--
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 72-51-01-220-086
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 re-convert from millimeters to inches.
NOTE:
Reference dimensions do not require inspection.
NOTE:
Unless specified differently, all diameter measurements must be the average of eight equally-spaced locations.
NOTE:
Unless specified differently, all drop dimension measurements must be the average of eight equally-spaced circumferential locations.
4 . Setup Information.
Subtask 72-51-01-350-071
A.Set-up the nozzle support for heat treatment as follows:
(1)Put shims on the top of a graphite plate as follows:
CAUTION:
MAKE SURE THAT THE NOZZLE SUPPORT DOES NOT TOUCH THE GRAPHITE PLATE DIRECTLY. IF IT TOUCHES THE GRAPHITE AT THE HEAT TREATMENT TEMPERATURES, DAMAGE TO THE NOZZLE SUPPORT CAN OCCUR.
(a)Put the shims on the top of a graphite plate to make sure that the nozzle support will not touch the graphite plate directly during the heat treatment.
(2)Put the nozzle support on the shims that are equally-spaced on the top surface of the graphite plate.
(3)For the quantity and placement requirements of the load thermocouples, refer to TASK 70-44-00-800-010 (HEAT TREATING), and TASK 70-44-03-370-004 (FURNACE HEAT TREATMENT).
5 . Procedure.
Subtask 72-51-01-160-009
A.If necessary, clean the nozzle support. Refer to TASK 72-51-01-100-801 (72-51-01, CLEANING 001).
Subtask 72-51-01-350-072
B.Remove the shank nuts from the nozzle support. Refer to TASK 72-51-01-300-801 (72-51-01, REPAIR 001).
Subtask 72-51-01-350-113
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 72-51-01-370-027
D.Alternative Procedure Available. 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:
Subtask 72-51-01-350-077
(1)Set-up the nozzle support for heat treatment. Refer to Subtask 72-51-01-350-071 (paragraph 4.A.).
Subtask 72-51-01-370-032
(2)Do a solution heat treatment of the nozzle support as follows:
(a)Use a vacuum of 1.0 micron of mercury or less.
(b)Increase the temperature of the nozzle support to a temperature range of 1835 to 1885°F (1002 to 1029°C) and keep the temperature for 20-30 minutes.
(c)Decrease the temperature of the nozzle support to 1000°F (538°C) in less than 30 minutes.
Subtask 72-51-01-370-028
D.A.Alternative Procedure. 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:
Subtask 72-51-01-350-078
(1)Set-up the nozzle support for heat treatment. Refer to Subtask 72-51-01-350-071 (paragraph 4.A.).
Subtask 72-51-01-370-033
(2)Do a solution heat treatment of the nozzle support as follows:
(a)Use a vacuum of 1.0 micron of mercury or less.
(b)Increase the temperature of the nozzle support to a range of 1700 to 1750ºF (927 to 954ºC) and as follows:
1Keep 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 (6.7 X 10-4 millibar) or less.
CAUTION:
DO NOT KEEP THE TEMPERATURE OF THE NOZZLE SUPPORT AT MORE THAN 1900ºF (1038ºC) FOR MORE THAN 30 MINUTES (TOTAL ACCUMULATED TIME) OR DAMAGE TO THE HONEYCOMB CAN OCCUR.
(c)Increase the temperature of the nozzle support to a temperature range of 1875 to 1925ºF (1024 to 1052ºC) at a rate of 20 to 25ºF (11 to 14ºC) for each minute and as follows:
1Keep this temperature for a maximum of 3-5 minutes.
2The accumulated time at more than 1900ºF must be 30 minutes or less.
(d)Decrease the temperature of the nozzle support to a temperature range of 1750 to 1800ºF (954 to 982ºC) at a minimum rate of 20ºF (11ºC) for each minute and as follows:
1Keep this temperature for 10-15 minutes.
(e)Decrease the temperature of the nozzle support to 975 to 1025ºF (524 to 552ºC) in 30 minutes or less.
NOTE:
The rate of temperature decrease less than 1000ºF (538ºC) is not important.
(f)Remove the nozzle support from the furnace.
Subtask 72-51-01-350-073
E.Optional Procedure. Blend the nozzle support area AC to prepare it for welding process. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
(1)Blend the nozzle support on the erosion surfaces.
Subtask 72-51-01-160-010
F.Optional Procedure. Clean the nozzle support repair area. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING), TASK 70-21-04-120-001 (CLEANING METHOD NO. 4 - DRY ABRASIVE BLAST CLEANING), and as follows:
(1)Apply masking to the honeycomb and inducer passages.
(2)Clean the nozzle support with C04-113  220 mesh abrasive compound.
Subtask 72-51-01-160-011
G.If necessary, clean the nozzle support. Refer to TASK 72-51-01-100-801 (72-51-01, CLEANING 001).
Subtask 72-51-01-110-033
H.If you did Subtask 72-51-01-350-073 (paragraph 5.D.) and/or Subtask 72-51-01-160-010 (paragraph 5.E.), etch the nozzle support blended 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 72-51-01-230-020
I.Alternative Procedure Available. If you did Subtask 72-51-01-350-073 (paragraph 5.D.) and/or Subtask 72-51-01-160-010 (paragraph 5.E.), do an inspection of the nozzle support repair 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)Indications 0.030 inch (0.76 mm) or less are not interpretable and are permitted.
(3)Non-linear indications 0.060 inch (1.52 mm) or less with a minimum distance of 0.15 inch (3.9 mm) between indications are permitted.
(4)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.
(5)Through indications are not permitted.
(6)Microshrinkage must agree with GEAE Photo Standard 8311253, Class 30.
Subtask 72-51-01-230-021
I.A.Alternative Procedure. If you did Subtask 72-51-01-350-073 (paragraph 5.D.) and/or Subtask 72-51-01-160-010 (paragraph 5.E.), do an inspection of the nozzle support repair area. 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.
(2)Indications 0.030 inch (0.76 mm) or less are not interpretable and are permitted.
(3)Non-linear indications 0.060 inch (1.52 mm) or less with a minimum distance of 0.15 inch (3.9 mm) between indications are permitted.
(4)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.
(5)Through indications are not permitted.
(6)Microshrinkage must agree with GEAE Photo Standard 8311253, Class 30.
Subtask 72-51-01-310-011
CAUTION:
MAKE SURE THAT YOU USE CHILLING BLOCKS TO CONTROL SHRINKAGE OF THE PARENT METAL IN THE NOZZLE SUPPORT DURING THE WELDING PROCESS. IF YOU DO NOT CONTROL THE OUTER DIAMETER CYLINDRICAL SURFACE ON THE INNER SIDE OF THE NOZZLE SUPPORT DURING THE WELDING PROCESS, YOU CAN CAUSE DEFORMATION OF THE CYLINDRICAL SURFACE AND MAKE IT BECOME FLAT.
J.Weld the nozzle support to build-up the necessary wall thickness at the repair areas. Refer to TASK 70-41-00-310-001 (WELDING AND BRAZING PRACTICES) and as follows:
(1)Use C06-037  GTD 222 weld wire.
NOTE:
Use chilling blocks to control shrinkage of parent metal during the welding process. Outer diameter cylindrical surface can deform from its initial shape, flatten, if not controlled on the inner side.
Subtask 72-51-01-350-074
K.Blend the nozzle support to the initial contour. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
(1)Remove unwanted weld material from area AC and, if necessary, from the opposite side of area AC.
(2)The transition between welded and non-welded areas must be flush to a maximum of 0.002 inch (0.05 mm).
(3)Wall thickness at the repair area must not be less than the wall thickness specified in Figure 902.
Subtask 72-51-01-160-012
L.Clean the nozzle support. Refer to TASK 72-51-01-100-801 (72-51-01, CLEANING 001).
Subtask 72-51-01-110-034
M.Etch the nozzle support. 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 72-51-01-230-022
N.Alternative Procedure Available. Do an inspection of the nozzle support repair 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)Indications 0.030 inch (0.76 mm) or less are not interpretable and are permitted.
(3)Non-linear indications 0.060 inch (1.52 mm) or less with a minimum distance of 0.15 inch (3.9 mm) between indications are permitted.
(4)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.
(5)Through indications are not permitted.
(6)Microshrinkage must agree with GEAE Photo Standard 8311253, Class 30.
Subtask 72-51-01-230-023
N.A.Alternative Procedure. Do an inspection of the nozzle support repair area. 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.
(2)Indications 0.030 inch (0.76 mm) or less are not interpretable and are permitted.
(3)Non-linear indications 0.060 inch (1.52 mm) or less with a minimum distance of 0.15 inch (3.9 mm) between indications are permitted.
(4)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.
(5)Through indications are not permitted.
(6)Microshrinkage must agree with GEAE Photo Standard 8311253, Class 30.
Subtask 72-51-01-350-075
O.If necessary, do Subtask 72-51-01-370-027 (paragraph 5.C.) thru Subtask 72-51-01-350-075 (paragraph 5.N.), again until you remove all the rejected indications from the nozzle support repair area.
Subtask 72-51-01-160-013
P.If necessary, clean the nozzle support. Refer to TASK 72-51-01-100-801 (72-51-01, CLEANING 001).
Subtask 72-51-01-370-029
Q.Alternative Procedure Available. 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:
Subtask 72-51-01-350-079
(1)Set-up the nozzle support for heat treatment. Refer to Subtask 72-51-01-350-071 (paragraph 4.A.).
Subtask 72-51-01-370-034
(2)Do a solution heat treatment of the nozzle support as follows:
(a)Use a vacuum of 1.0 micron of mercury or less.
(b)Increase the temperature of the nozzle support to a temperature range of 1835 to 1885°F (1002 to 1029°C) and keep the temperature for 20-30 minutes.
(c)Decrease the temperature of the nozzle support to 1000°F (538°C) in less than 30 minutes.
Subtask 72-51-01-370-030
Q.A.Alternative Procedure. 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:
Subtask 72-51-01-350-080
(1)Set-up the nozzle support for heat treatment. Refer to Subtask 72-51-01-350-071 (paragraph 4.A.).
Subtask 72-51-01-370-035
(2)Do a solution heat treatment of the nozzle support as follows:
(a)Use a vacuum of 1.0 micron of mercury or less.
(b)Increase the temperature of the nozzle support to a temperature range of 1700 to 1750ºF (927 to 954ºC) and as follows:
1Keep 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 (6.7x10-4 millibar) or less.
CAUTION:
DO NOT KEEP THE TEMPERATURE OF THE NOZZLE SUPPORT AT MORE THAN 1900ºF (1038ºC) FOR MORE THAN 30 MINUTES (TOTAL ACCUMULATED TIME) OR DAMAGE TO THE HONEYCOMB CAN OCCUR.
(c)Increase the temperature of the nozzle support to a temperature range of 1875 to 1925ºF (1024 to 1052ºC) at a rate of 20 to 25ºF (11 to 14ºC) for each minute and as follows:
1Keep this temperature for a maximum of 3-5 minutes.
2The accumulated time at more than 1900ºF must be 30 minutes or less.
(d)Decrease the temperature of the nozzle support to a temperature range of 1750 to 1800ºF (954 to 982ºC) at a minimum rate of 20ºF (11ºC) for each minute and as follows:
1Keep this temperature for 10-15 minutes.
(e)Decrease the temperature of the nozzle support to 975 to 1025ºF (524 to 552ºC) in 30 minutes or less.
NOTE:
The rate of temperature decrease less than 1000ºF (538ºC) is not important.
(f)Remove the nozzle support from the furnace.
Subtask 72-51-01-370-031
R.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:
Subtask 72-51-01-350-081
(1)Set-up the nozzle support for heat treatment. Refer to Subtask 72-51-01-350-071 (paragraph 4.A.).
Subtask 72-51-01-370-036
(2)Do an age heat treatment of the nozzle support as follows:
(a)Heat-treat the nozzle support at 1450 to 1500°F (788 to 815°C) for eight hours.
(b)Decrease the temperature of the nozzle support to 1000°F (538°C) at a rate not less than 25°F (14°C) for each minute.
(c)Decrease the nozzle support temperature to room temperature.
(d)Remove the nozzle support from the furnace.
Subtask 72-51-01-220-091
S.Do a visual inspection in the nozzle support brazed areas. 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)The diameter or length of one void and non-bonded areas must not be more than 0.08 inch (2.0 mm).
(2)There must not be more than three voids or non-bonded areas in a section with a length of 1.0 inch (25 mm) of a braze bonded area.
(3)Irregular surface porosity is permitted.
(4)Indications 0.015 inch (0.38 mm) or less are not interpretable.
(5)Through voids are not permitted.
Subtask 72-51-01-220-092
T.Alternative Procedure Available. Do an inspection of the honeycomb in the nozzle support. 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)You must fully bond the honeycomb core to its backing surface in 80 percent of the total contact area.
(2)Unbonded areas cannot contain more than 10 totally unbonded adjacent cells circumferentially by five totally unbonded adjacent cells axially.
(3)Honeycomb core node bond is not interpretable.
(4)Unbonded areas must be separated by a minimum of five adjacent bonded cells.
(5)An unbonded area cannot include open cells, partial cells, or splices.
Subtask 72-51-01-220-093
T.A.Alternative Procedure. Do an inspection of the honeycomb in the nozzle support as follows:
(1)Use a video microscope with a minimum of 10X magnification.
(2)You must fully bond the honeycomb core to its backing surface in 80 percent of the total contact area.
(3)Unbonded areas cannot contain more than 10 totally unbonded adjacent cells circumferentially by five totally unbonded adjacent cells axially.
(4)Honeycomb core node bond is not interpretable.
(5)Unbonded areas must be separated by a minimum of five adjacent bonded cells.
(6)An unbonded area cannot include open cells, partial cells, or splices.
Subtask 72-51-01-230-019
U.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), and as follows:
(1)Use Class A penetrant.
(2)Indications 0.030 inch (0.76 mm) or less are not interpretable and are permitted.
(3)Non-linear indications 0.060 inch (1.52 mm) or less with a minimum distance of 0.15 inch (3.9 mm) between indications are permitted.
(4)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.
(5)Through indications are not permitted.
(6)Microshrinkage must agree with GEAE Photo Standard 8311253, Class 30.
Subtask 72-51-01-350-114
V.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 72-51-01-160-014
W.Clean the nozzle support. Refer to TASK 72-51-01-100-801 (72-51-01, CLEANING 001).
Subtask 72-51-01-220-094
X.Do an inspection of the nozzle support. Refer to TASK 72-51-01-200-801 (72-51-01, INSPECTION 001).
Subtask 72-51-01-350-076
Y.Install the shank nuts in the nozzle support. Refer to TASK 72-51-01-300-801 (72-51-01, REPAIR 001).
* * * FOR ALL
Figure 901   High Pressure Turbine Stage 1 Nozzle Support
* * * FOR ALL
Figure 902   (Sheet 1 ) High Pressure Turbine Stage 1 Nozzle Support - Dimensional Information
* * * FOR ALL
Figure 902   (Sheet 2 ) High Pressure Turbine Stage 1 Nozzle Support - Dimensional Information