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TASK 72-53-40-300-803
1 . Blend Repair.
A.This procedure gives instructions to repair the high pressure turbine rotor stage 1 disk (disk) by doing a blend repair. 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 maximum blend of 0.005 inch (0.12 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm).
2Dents:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.005 inch (0.12 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm).
3Scratches:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.005 inch (0.12 mm) in depth, and 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.
1Nicks, dents, and scratches on the forward upper web, do not include the forward radial rabbet fillet area A:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm).
2Nicks, dents, and scratches on the forward lower web and forward hub face:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm).
3Nicks, dents, and scratches on the aft upper web, aft lower web, and aft hub face, do not include the bumper pad:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.004 inch (0.10 mm) in depth, and with a minimum blend radius of 0.500 inch (12.70 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 maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 20 percent of the total area.
3Nicks, dents, and scratches on the forward flange ID:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 20 percent of the total area.
(h)Do an inspection of the stage 2 disk pilot arm interface. Figure 812 and as follows:
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 10 percent of the total area.
6Deleted.
Maximum repairable limit:
Deleted.
7Deleted.
Maximum repairable limit:
Deleted.
(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 maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 10 percent of the total area.
(j)Do an inspection of the mounting face of the sump seal pilot. Refer to Figure 812 and as follows:
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.005 inch (0.12 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 5 percent of the total area.
(l)Deleted.
4Deleted.
Maximum repairable limit:
Deleted.
(n)Do an inspection of the spline surfaces on the aft shaft. Refer to Figure 812 and as follows:
3Nicks, 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).
(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 maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius 0.250 inch (6.35 mm).
(q)Do an inspection of the internal and external surfaces in zone FB (do not include the mounting face of the sump seal pilot and aft shaft fillets) on the aft shaft as follows. Refer to Figure 812.
1Nicks and scratches:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.005 inch (0.12 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm).
2Dents:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.005 inch (0.12 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm).
(r)Do an inspection of the heat shield pilots as follows. Refer to Figure 812.
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.005 inch (0.12 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 10 percent of the total area.
(t)Do an inspection of the No. 4 bearing journal surface on the aft shaft as follows. Refer to Figure 812.
2Nick 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).
(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).
(y)Do an inspection of the interstage seal disk ID bayonet. Refer to Figure 812 and as follows:
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 the dimensions given in Figure 901.
(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)Do an inspection of damper interface on the ID of the forward shaft. Refer to Figure 811 and as follows:.
2Nicks, dents and scratches (other than rib faces):
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 20 percent of the total area.
3Nick, dents and scratches on damper rib faces:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 20 percent of the total area.
(ac)Do an inspection of forward flange aft face. Refer to Figure 811 and as follows:
2Nicks and dents on disk-bolt contact surface:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 20 percent of the total area.
3Scratches on disk-bolt contact surface:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 20 percent of the total area.
4Nicks, dents and scratches on aft face, other than disk-bolt contact surface:
Maximum repairable limit:
Any amount that can be removed with a maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 20 percent of the total area.
(ad)Do an inspection of the stage 2 disk flange rabbet/mate face for:
2Nicks and dents:
Maximum repairable limit:
Any amount, that can be removed with a maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 10 percent of the total area.
3Scratches:
Maximum repairable limit:
Any amount, that can be removed with a maximum blend of 0.002 inch (0.05 mm) in depth, and with a minimum blend radius of 0.250 inch (6.35 mm), if the blended area is not more than 10 percent of the total area.
(af)Do an inspection of the forward seal inner radial rabbet surface. Refer to Figure 811 and as follows:
1Nicks 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).
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)
 
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)
 
C10-021
Tape, Plastic
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
Inspection 001 - Configuration 02
D.Expendable Parts. None.
E.SPD Information.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. None.
3 . Dimensional Information.
Subtask 72-53-40-220-173
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.
None.
5 . Procedure.
Subtask 72-53-40-350-003
A.Blend the disk damaged areas. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), Figure 901, and do as follows:
(1)Do not blend disk areas that have fretting.
(2)Blend the disk to the limits specified in TASK 72-53-40-200-802 (72-53-40, INSPECTION 001, CONFIG 02), as follows:
(a)The minimum blend radius must be 0.250 inch (6.35 mm).
(b)Refer to Figure 901 for areas where blending is not permitted.
Subtask 72-53-40-160-009
(3)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 72-53-40-110-007
B.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 72-53-40-230-007
C.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 72-53-40-230-008
C.A.Alternative Procedure. Do an inspection of the disk blended 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 72-53-40-380-002
D.Peen the disk fretted and/or blended areas. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 902, and do as follows:
(1)Apply mask with C10-021  plastic tape to area BP.
(2)Overspray is permitted but not on the areas that have a protection of masking.
(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.
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Figure 901   (Sheet 1 ) High Pressure Turbine Rotor Disk - Stage 1
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Figure 901   (Sheet 2 ) High Pressure Turbine Rotor Disk - Stage 1
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Figure 901   (Sheet 3 ) High Pressure Turbine Rotor Disk - Stage 1
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Figure 901   (Sheet 4 ) High Pressure Turbine Rotor Disk - Stage 1
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Figure 901   (Sheet 5 ) High Pressure Turbine Rotor Disk - Stage 1
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Figure 901   (Sheet 6 ) High Pressure Turbine Rotor Disk - Stage 1
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Figure 901   (Sheet 7 ) High Pressure Turbine Rotor Disk - Stage 1
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Figure 901   (Sheet 8 ) High Pressure Turbine Rotor Disk - Stage 1
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Figure 902   (Sheet 1 ) High Pressure Turbine Rotor Stage 1 Disk - Shotpeening
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Figure 902   (Sheet 2 ) High Pressure Turbine Rotor Stage 1 Disk - Shotpeening