* * * FOR ALL
TASK 72-53-40-300-801
1 . Blend Repair.
A.This procedure gives instructions to repair the HPT rotor stage 1 disk (disk) by blending. 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 rim OD and end faces as follows. Refer to Figure 810.
1Nicks:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.010 inch (0.25 mm) in depth with a minimum blend radius of 0.250 inch (6.35 mm).
2Dents:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.010 inch (0.25 mm) in depth with a minimum blend radius of 0.250 inch (6.35 mm).
3Scratches:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.010 inch (0.25 mm) in depth and 0.150 inch (3.81 mm) in length with a minimum blend radius of 0.250 inch (6.35 mm).
(f)Do an inspection of the web and hub faces as follows. Refer to Figure 810.
NOTE:
Small scratches, nicks, dents, or other surface conditions can be seen on the hub and web areas (not the adjacent radii). It is possible these indications were blended to remove high metal, with a depth no greater than 0.001 inch (0.03 mm) deep. This condition is from new production and will have a surface finish that shows signs of shot peen. These indications are permitted.
1Nicks and scratches (forward upper web, forward lower web, and forward hub faces):
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.005 inch (0.12 mm) in depth with a minimum blend radius of 0.750 inch (19.05 mm).
NOTE:
Blending is not allowed in the rim fillet radius.
2Nicks and scratches (for all other areas):
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.005 inch (0.12 mm) in depth with a minimum blend radius of 0.250 inch (6.35 mm).
3Dents (forward upper web, forward lower web, and forward hub faces):
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.005 inch (0.12 mm) in depth with a minimum blend radius of 0.750 inch (19.05 mm).
4Dents (for all other areas):
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.005 inch (0.12 mm) in depth with a minimum blend radius of 0.250 inch (6.35 mm).
(g)Do an inspection of the forward flange forward face and forward flange ID. Refer to Figure 811 and as follows:
2Nicks, dents, and scratches on the forward flange forward face:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.010 inch (0.25 mm) in depth with a minimum blend radius of 0.250 inch (6.35 mm), if the blend area is not more than 20 percent of the area and is a minimum of 0.250 inch (6.35 mm) from adjacent radii.
(h)Do an inspection of the stage 2 disk pilot arm interface. Refer to Figure 812 and as follows:
2Deleted.
Maximum repairable limit:
Deleted.
3Nicks, dents, and scratches:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.002 inch (0.05 mm) in depth with a minimum blend radius of 0.250 inch (6.35 mm), if the blend area is not more than 10 percent of the area and is a minimum of 0.250 inch (6.35 mm) from adjacent radii.
(i)Do an inspection of the forward seal mounting face as follows. Refer to Figure 811 for:
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.002 inch (0.05 mm) in depth with a minimum blend radius of 0.250 inch (6.35 mm), if the blend area is not more than 10 percent of the area and is a minimum of 0.250 inch (6.35 mm) from adjacent radii.
(j)Do an inspection of the mounting face of the sump seal pilot. Refer to Figure 812 and as follows:
2Nicks and scratches:
Maximum repairable limit:
0.005 inch (0.13 mm) in depth and less than 5 percent of the surface, with a minimum blend radius of 0.250 inch (6.35 mm) after removal of the high metal.
(l)Do an inspection of the damper interface on the ID of the forward shaft. Refer to Figure 811 and as follows:
2Nicks, dents and scratches:
Maximum repairable limit:
Any amount, that can be removed with a blend not more than 0.010 inch (0.25 mm) in depth, with a minimum blend radius of 0.250 inch (6.35 mm), if the blend area is not more than 20 percent of the area and is a minimum of 0.250 inch (6.35 mm) from the adjacent radii.
(n)Do an inspection of the spline surfaces on the aft shaft as follows. Refer to Figure 812.
1Nicks or dents on the end faces:
Maximum repairable limit:
Not more than 0.003 inch (0.07 mm) in depth with a minimum blend radius of 0.250 inch (6.35 mm). Damage is not permitted in the root radii.
2Pickup, high metal, or burrs on all other surfaces:
Maximum repairable limit:
Any amount that can be blended to remove high metal only.
4Nicks, dents, and scratches on major diameter and pressure faces (except root fillets):
Maximum repairable limit:
Any amount, that can be removed with a maximum blend of 0.001 inch (0.02 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 0.004 square inch (2.58 square mm).
(o)Do an inspection of the air duct rabbet/mate face on the aft shaft as follows: Refer to Figure 812.
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.003 inch (0.07 mm) in depth with a minimum blend radius of 0.250 inch (6.35 mm) and not more than 20 percent of surface.
(p)Do an inspection of the internal and external surfaces in zone FA (critical) on the forward shaft as follows. Refer to Figure 811.
1Nicks, dents, and scratches:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.005 inch (0.12 mm) in depth and 0.50 inch (12.7 mm) apart with a minimum blend radius of 0.250 inch (6.35 mm).
(q)Do an inspection of the internal and external surfaces in zone FB (excluding mounting face of the sump seal pilot) on the aft shaft as follows. Refer to Figure 812.
1Nicks and scratches:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.010 inch (0.25 mm) in depth with a minimum blend radius of 0.750 inch (19.05 mm).
2Dents:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.010 inch (0.25 mm) in depth with a minimum blend radius of 0.750 inch (19.05 mm).
(r)Do an inspection of the heat shield pilots as follows. Refer to Figure 812.
1Pickup and high metal:
Maximum repairable limit:
Any amount that can be blended to remove high metal only.
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.015 inch (0.38 mm) in depth if the blended area is not more than 10 percent of the total area, with a minimum blend radius of 0.250 inch (6.35 mm).
(t)Do an inspection of the No. 4 bearing journal surface on the aft shaft as follows. Refer to Figure 812.
2Nicks and dents:
Maximum repairable limit:
0.005 inch (0.12 mm) in depth and up to 3 percent of the area in any 90 degree sector, with a minimum blend radius of 0.250 inch (6.35 mm).
3Scores and scratches:
Maximum repairable limit:
0.005 inch (0.12 mm) in depth and up to 3 percent of the area in any 90 degree sector, with a minimum blend radius of 0.250 inch (6.35 mm).
(u)Do an inspection of the air duct threads on the aft shaft. Refer to Figure 812 and as follows:
1Nicks, dents, pickup, or high metal:
Maximum repairable limit:
•
Removal of the first half of the entrance thread is permitted if the remaining threads are not damaged.
•
If the entrance thread is not damaged, the total length of the damage in the other threads must not be more than 50 percent of one full thread.
(v)Do an inspection of the No. 4 bearing radial oil scoop diameter (diameter BE) on the aft shaft as follows. Refer to Figure 812.
2Nicks and dents:
Maximum repairable limit:
0.005 inch (0.12 mm) in depth and up to 5 percent of the area in any 90 degree sector, with a minimum blend radius of 0.250 inch (6.35 mm).
3Scores and scratches:
Maximum repairable limit:
0.005 inch (0.12 mm) in depth and up to 5 percent of the area in any 90 degree sector, with a minimum blend radius of 0.250 inch (6.35 mm).
(x)Do an inspection of the disk post aft face below the retainer outer hook (area B and area K). Refer to Figure 810 and Figure 811 and as follows:
1Nicks, dents, and scratches in area B:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.010 inch (0.25 mm) in depth and within the boundaries of area B. Refer to Figure 802.
2Nicks, dents, and scratches in area K:
Maximum repairable limit:
Any amount, that can be removed with a blend not more than 0.002 inch (0.05 mm) in depth, with a minimum blend radius of 0.250 inch (6.35 mm).
(y)Do an inspection of the interstage seal disk ID bayonet as follows. Refer to Figure 812.
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.005 inch (0.12 mm) in depth each side with a minimum blend radius of 0.250 inch (6.35 mm).
4Wear on the sides of bayonets:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.005 inch (0.12 mm) in depth, each side with a minimum blend radius of 0.250 inch (6.35 mm).
5Nicks, dents, scratches, and wear on the corner of bayonet tabs:
Maximum repairable limit:
Any amount, that can be removed with a minimum blend radius of 0.250 inch (6.35 mm), if the blend dimensions are not more than dimensions given in Figure 902.
(z)Do an inspection of the aft shaft tabs. Refer to Figure 812 and as follows:
1Fretting and wear:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.010 inch (0.25 mm) in depth, with a minimum blend radius of 0.250 inch (6.35 mm).
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount that can be removed with a blend not more than 0.010 inch (0.25 mm) in depth, with a minimum blend radius of 0.250 inch (6.35 mm).
(ab)Deleted.
4Deleted.
Maximum repairable limit:
Deleted.
(ad)Do an inspection of the stage 2 disk flange rabbet/mate face for:
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount, that can be removed with a blend not more than 0.002 inch (0.05 mm) in depth, with a minimum blend radius of 0.250 inch (6.35 mm), if the blend area is not more than 10 percent of the area and is a minimum of 0.250 inch (6.35 mm) from adjacent radii.
(af)Do an inspection of the forward seal inner radial rabbet surface. Refer to Figure 811 and as follows:
2Nicks and dents:
Maximum repairable limit:
Any amount, that can be removed with a blend not more than 0.003 inch (0.07 mm) in depth, with a blend radius of 0.500 inch (12.70 mm). Maximum cumulative circumferential length of blends must be 2.00 inches (50.8 mm).
(ai)Do an inspection of the coupling nut threads on the aft shaft. Refer to Figure 812 and as follows:
1Nicks, dents, pickup, and high metal:
Maximum repairable limit:
Removal of the first half of the entrance thread is permitted if the remaining threads are not damaged.
If the entrance thread is not damaged, the total length of the damage in the other threads must not be more than 50 percent of one full thread.
(aj)Do an inspection of the No. 4 bearing round plain nut threads on the aft shaft. Refer to Figure 812 and as follows:
1Nicks, dents, pickup, and high metal:
Maximum repairable limit:
Removal of the first half of the entrance thread is permitted if the remaining threads are not damaged.
If the entrance thread is not damaged, the total length of the damage in the other threads must not be more than 50 percent of one full thread.
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)
 
2352M61G02  
2352M61G03  
--
--
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
 
C04-166
Shot, Peening, Conditioned Cut Wire (CCW14 steel shot)
 
C10-010
Abrasive Cloth
 
C10-021
Tape, Plastic
 
C10-205
Almen Test Strips (Almen test strips type N)
C.Referenced Procedures.
 
ATA No.
Description
 
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
 
70-32-02
Fluorescent Penetrant Inspection
 
70-32-03
Spot-Fluorescent-Penetrant Inspection
 
70-42-00
Blending and Removal of High Metal Procedures
 
70-47-01
Shotpeening
 
72-53-40
Cleaning 001
 
72-53-40
Inspection 001 - Configuration 01
D.Expendable Parts. None.
E.SPD Information.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. None.
3 . Dimensional Information.
Subtask 72-53-40-220-145
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.
4 . Setup Information.
None.
5 . Procedure.
Subtask 72-53-40-160-006
A.If necessary, clean the disk. Refer to TASK 72-53-40-100-801 (72-53-40, CLEANING 001).
Subtask 72-53-40-350-001
B.Blend the disk damaged areas. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), Figure 902, and as follows:
(1)If necessary, blend the disk damaged areas other than the interstage seal bayonet tabs as follows:
(a)Blend the disk to the limits specified in TASK 72-53-40-200-801 (72-53-40, INSPECTION 001, CONFIG 01).
(b)Blend the disk new damaged area only in non-blended areas.
(2)If necessary, blend the disk damaged areas of the interstage seal bayonet tabs as follows:
(a)Blend the disk damaged areas with a small abrasive stone.
(b)Blend the disk new damaged area only in non-blended areas.
(c)Remove high metal and sharp edges from the disk.
(d)Blend to the limits specified in Subtask 72-53-40-220-155 (72-53-40, INSPECTION 001, CONFIG 01) (paragraph 4.Y.) and Figure 902.
Subtask 72-53-40-220-146
(e)A minimum tab thickness of 0.068 inch (1.73 mm) is permitted in the disk blended areas, if blend depth is not more than 0.005 inch (0.12 mm) on each side of the tab.
Subtask 72-53-40-160-007
C.Clean the disk blended areas. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-53-40-110-005
D.Etch the disk 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 or Class G etchant.
Subtask 72-53-40-230-005
E.Alternative Procedure Available. Do an inspection of the disk blended 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 G penetrant.
(2)Indications less than 0.015 inch (0.38 mm) are permitted.
(3)No other indications are permitted.
Subtask 72-53-40-230-006
E.A.Alternative Procedure. Do an inspection of the disk repaired 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 G penetrant.
(2)Indications less than 0.015 inch (0.38 mm) are permitted.
(3)No other indications are permitted.
Subtask 72-53-40-350-002
WARNING:
USE EYE PROTECTION WHEN YOU POLISH MATERIAL OR PARTS. THE PARTICLES CAN CAUSE AN INJURY TO YOUR EYES. USE IN A WELL-VENTILATED AREA.
F.Polish the disk to remove the effects of the swab etching procedure as follows:
(1)Use C10-010  abrasive cloth.
Subtask 72-53-40-380-001
G.Peen the disk blended areas. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 903, and as follows:
(1)Apply a mask with C10-021  plastic tape to area BP.
(2)Overspray is permitted in area BL and area CR.
(3)Use C04-166  CCW14 steel shot.
(4)Peen the disk to an intensity of 6-12N.
(5)Coverage of the disk must be a minimum of 125 percent.
(6)Direct impingement is necessary.
(7)Ricochet peening is permitted in area BB.
(8)Use simulative fixture for intensity verification.
(9)Remove all the plastic tape from the disk.
Subtask 72-53-40-160-008
H.Clean the disk blended areas. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING)
Subtask 72-53-40-220-147
I.Do a final visual inspection of the disk. Refer to TASK 72-53-40-200-801 (72-53-40, INSPECTION 001, CONFIG 01).
* * * FOR ALL
Figure 901   High Pressure Turbine Rotor Stage 1 Disk
* * * FOR ALL
Figure 902   (Sheet 1 ) High Pressure Turbine Rotor Stage 1 Disk - Dimensional Information
* * * FOR ALL
Figure 902   (Sheet 2 ) High Pressure Turbine Rotor Stage 1 Disk - Dimensional Information
* * * FOR ALL
Figure 903   (Sheet 1 ) High Pressure Turbine Rotor Stage 1 Disk - Shotpeening
* * * FOR ALL
Figure 903   (Sheet 2 ) High Pressure Turbine Rotor Stage 1 Disk - Shotpeening