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TASK 72-53-40-300-804
1 . Inner Bayonet Tab Repair.
A.This procedure gives instructions to repair the HPT rotor stage 1 disk (disk) by thermal spraying the worn bayonet tabs. 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.
(y)Do an inspection of the interstage seal disk ID bayonet. Refer to Figure 812 and as follows:
3Wear on tab mounting faces of the interstage seal bayonet:
Maximum repairable limit:
A maximum of 0.020 inch (0.50 mm) in depth in the two sides, if a minimum thickness of parent material of 0.050 inch (1.27 mm) is kept.
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  
2383M83G03  
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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)
 
C07-041
Inconel 718 Powder HVOF Application (spray powder)
 
C10-012
Tape, Masking, High Temperature (masking tape)
 
C10-021
Tape, Plastic
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
 
70-32-00
Indirect Inspection Methods
 
70-32-03
Spot-Fluorescent-Penetrant Inspection
 
70-42-00
Blending and Removal of High Metal Procedures
 
70-47-01
Shotpeening
 
70-49-00
Thermal Spraying
 
70-49-32
Thermal Spraying Inconel 718 (Powder)
 
72-53-40
Cleaning 001
D.Expendable Parts.
None.
E.SPD Information.
(1)Locally Manufactured SPD. None.
F.Special Solutions.
None.
G.Test Specimens.
Refer to TASK 70-49-32-340-033 (THERMAL SPRAYING INCONEL 718 (POWDER)).
3 . Dimensional Information.
Subtask 72-53-40-220-194
A.Refer to Figure 901, Figure 902, and Figure 904 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.
 
Description
Minimum In-Process Dimension
Maximum In-Process Dimension
Minimum Finish Dimension
Maximum Finish Dimension
Reference Dimension
 
Dia T
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7.319 in. (185.91 mm)
7.329 in. (186.15 mm)
7.329 in. (186.15 mm)
 
Dim. V
0.090 in. (2.29 mm)
0.150 in. (3.81 mm)
0.090 in. (2.29 mm)
0.150 in. (3.81 mm)
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Dim. W
0.050 in. (1.27 mm)
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0.078 in. (1.99 mm)
0.082 in. (2.08 mm)
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Dim. X
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2.546 in. (64.67 mm)
2.556 in. (64.92 mm)
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4 . Setup Information.
Subtask 72-53-40-350-004
A.Set-up the disk for machining. Refer to Figure 901 and as follows:
(1)Surface A runout to the machine table face must be 0.002 inch (0.05 mm) or less.
(2)The concentricity of diameter T to the machine table centerline must be 0.001 inch (0.02 mm) or less.
5 . Procedure.
Subtask 72-53-40-320-001
A.Machine the disk. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Figure 901, Figure 902, and as follows:
(1)Set-up the disk for machining. Refer to Subtask 72-53-40-350-004 (paragraph 4.A.).
(2)Machine surface L and/or surface M as follows:
(a)Fully remove wear, galling, and thermal spray coating.
(b)Remove sufficient parent material to let a minimum of 0.004 inch (0.11 mm) of thermal spray coating is on each repaired surface.
(c)Make sure that surface L and surface M agree with the in-process dimensions in Subtask 72-53-40-220-194 (paragraph 3.A.).
(3)Surface finish of the machined surfaces must be 63 microinches (1.6 micrometers) or better.
Subtask 72-53-40-350-005
(4)Blend the disk machined areas. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
(a)Break the sharp edges to 0.005-0.015 inch (0.13-0.38 mm).
Subtask 72-53-40-110-008
(5)Clean the disk. Refer to TASK 72-53-40-100-801 (72-53-40, CLEANING 001).
Subtask 72-53-40-110-009
B.Etch the machined areas of the disk. 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 or Class G etchant.
Subtask 72-53-40-230-009
C.Do an inspection of the disk machined 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 not interpretable as linear indications and are permitted.
(3)Indications more than 0.015 inch (0.38 mm) are not permitted.
Subtask 72-53-40-380-003
D.Peen the machined areas of the disk. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 901, Figure 902, and as follows:
(1)If necessary, apply C10-021  plastic tape to the threads and the splines. Overspray is permitted, but not on splines or threads.
(2)Use C04-166  CCW14 steel shot.
(3)Peen to an intensity of 0.006-0.012N.
(4)Coverage must be a minimum of 125 percent.
Subtask 72-53-40-340-001
E.Thermal-spray the disk machined areas and the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-32-340-033 (THERMAL SPRAYING INCONEL 718 (POWDER)), Subtask 72-53-40-220-194 (paragraph 3.A.), Figure 903, and as follows:
NOTE:
Hard masking is recommended.
(1)Apply C10-012  masking tape to areas adjacent to area P. Overspray is only permitted on diameter T.
(2)Prepare the surfaces of area P and the test specimens as follows:
(a)Grit-blast area P on the disk and the test specimens to the surface roughness limits for nickel based materials.
(3)Apply sufficient thermal spray coating layer to area P and the test specimens that will let area P agree with the finish dimensional limits and as follows:
NOTE:
C07-041  spray powder is permitted as an alternative spray powder for the thermal spray process.
(a)The maximum coating thickness after thermal-spray must be less than 0.025 inch (0.63 mm).
(b)The minimum thermal spray coating thickness must be 0.004 inch (0.11 mm) after finish machining.
(4)Do the quality assurance testing on the test specimens.
CAUTION:
DO NOT USE METALLIC INSTRUMENTS TO REMOVE THE MASKING. YOU CAN CAUSE DAMAGE TO THE DISK.
(5)Remove the masking material from the disk.
Subtask 72-53-40-320-002
F.Machine the disk. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-53-40-220-194 (paragraph 3.A.), Figure 904, and as follows:
(1)Set-up the disk for machining. Refer to Subtask 72-53-40-350-004 (paragraph 4.A.).
(2)Machine the disk thermal sprayed areas to the finished dimensions.
(3)If you thermal sprayed diameter T, machine diameter T to the parent material to remove all thermal spray. Diameter T must agree with the limits specified in Subtask 72-53-40-220-194 (paragraph 3.A.).
(4)The minimum coating thickness after machining must be 0.004 inch (0.11 mm).
(5)Dimension V at finish machining must be equal to dimension V at in-process machining to plus or minus 0.002 (0.05 mm). Dimension V must agree with the limits specified in Subtask 72-53-40-220-194 (paragraph 3.A.).
Subtask 72-53-40-350-006
(6)Blend the disk machined areas. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and do as follows:
(a)Break the sharp edges to 0.005-0.015 inch (0.13-0.38 mm).
(b)Hand-polish all the remaining thermal spray coating.
(c)Shotpeening not required after blending and polishing.
(7)Surface finish of the machined surfaces must be 63 microinches (1.6 micrometers) or better.
Subtask 72-53-40-110-010
(8)Clean the disk. Refer to TASK 72-53-40-100-801 (72-53-40, CLEANING 001).
Subtask 72-53-40-220-195
(9)Do a visual inspection of the machined thermal spray coating and as follows:
(a)No chipping, flaking, or spalling is permitted.
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Figure 901   (Sheet 1 ) High Pressure Turbine Rotor Stage 1 Disk - Dimensional Information
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Figure 901   (Sheet 2 ) High Pressure Turbine Rotor Stage 1 Disk - Dimensional Information
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Figure 901   (Sheet 3 ) High Pressure Turbine Rotor Stage 1 Disk - Dimensional Information
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Figure 902   High Pressure Turbine Rotor Stage 1 Disk - In Process Machining
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Figure 903   Masking for Grit Blast and Thermal Spray
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Figure 904   High Pressure Turbine Rotor Stage 1 Disk - Finish Machining