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TASK 72-53-40-300-805
1 . Thermal Spray Repair of the Forward Rabbet Diameter G.
A.This procedure gives instructions to repair the HPTR stage 1 disk (disk) by thermal spraying the surface of the forward rabbet diameter G at the interface of the compressor discharge pressure seal. 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.
(s)Do an inspection of the forward flange rabbet as follows. Refer to Figure 811.
1Fretting/wear:
Maximum repairable limit:
Any amount if the damage depth can be removed 1.25 times in accordance with the limits specified in TASK 72-53-40-300-805 (72-53-40, REPAIR 008).
(5)Dimensional Inspection.
(b)Do an inspection of the stage 1 disk for:
2Diameter G:
Maximum repairable limit:
15.224 inches (386.69 mm) minimum.
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)
 
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.
 
Description
Manufacturer
 
Micrograin Carbide, Uncoated or Coated cutting tool
Local Purchase
(3)Locally Manufactured Tools. None.
B.Consumable Materials.
 
Code No.
Description
 
C04-035
Solvent, General (isopropyl alcohol)
 
C04-166
Shot, Peening, Conditioned Cut Wire (CCW14, conditioned cut wire steel shot)
 
C10-012
Tape, Masking, High Temperature (masking tape)
 
C10-021
Tape, Plastic
 
C10-105
Abrasive, Sandpaper, Roll (sandpaper)
 
C10-182
Cloth, Cleaning for Aircraft Structural (SAE-AMS 3819, BMS 15-5) (cloth)
C.Referenced Procedures.
 
ATA No.
Description
 
70-00-03
Machining Data
 
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
 
70-49-00
Thermal Spraying
 
70-49-36
High Density Inconel 718 Coating Applied by HVOF Thermal Spray
 
72-53-40
Cleaning 001
 
72-53-40
Inspection 001 - Configuration 01
 
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. Refer to TASK 70-49-36-340-038 (HIGH DENSITY INCONEL 718 COATING APPLIED BY HVOF THERMAL SPRAY).
3 . Dimensional Information.
Subtask 72-53-40-220-199
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.
For All Part Numbers:
 
Description
Minimum In-Process Dimension
Maximum In-Process Dimension
Minimum Finish Dimension
Maximum Finish Dimension
Reference Dimension
 
Cham D
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0.060 in. (1.53 mm)
0.080 in. (2.03 mm)
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Dia G
15.224 in. (386.69 mm)
15.240 in. (387.09 mm)
15.248 in. (387.30 mm)
15.252 in. (387.40 mm)
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Dim. M
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0.690 in. (17.53 mm)
0.740 in. (18.79 mm)
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Dia P
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15.030 in (381.76 mm)
For Part Number 2352M61G03:
 
Description
Minimum In-Process Dimension
Maximum In-Process Dimension
Minimum Finish Dimension
Maximum Finish Dimension
Reference Dimension
 
Dia V
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16.425 in (417.20 mm)
For Part Number 2383M83G03:
 
Description
Minimum In-Process Dimension
Maximum In-Process Dimension
Minimum Finish Dimension
Maximum Finish Dimension
Reference Dimension
 
Dia V
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16.427 in (417.25 mm)
4 . Setup Information.
Subtask 72-53-40-350-007
A.Set-up the disk for machining. Refer to Figure 901 and as follows:
(1)If necessary, make an applicable machining fixture as follows:
(a)Make sure that the machining fixture gives the correct runouts of the disk in the machining process.
(2)Install the disk in the machining fixture and then put the machining fixture on the machine table.
(3)Adjust the position of the disk. Refer to Figure 901 and as follows:
(a)The runout of surface N must be 0.002 inch (0.05 mm) or less.
Subtask 72-53-40-350-008
(b)Alternative Procedure Available. The runout of diameter P must be 0.001 inch (0.02 mm) or less and as follows:
1If there are local blends on diameter P, move the gage up or down to find a location without blended areas.
2The runout of diameter G after setup and before machining must be 0.0045 inch (0.114 mm) or less.
Subtask 72-53-40-350-009
(b).A.Alternative Procedure. The runout of diameter V must be 0.001 inch (0.02 mm) or less and as follows:
1The runout of diameter G after setup and before machining must be 0.0045 inch (0.114 mm) or less.
Subtask 72-53-40-350-010
B.Set-up the disk for shotpeening/grit blasting and thermal spraying. Refer to Figure 901 and as follows:
(1)If necessary, make an applicable shotpeening/grit blasting and thermal spraying support fixture.
(2)Install the shotpeening/grit blasting and thermal spraying support fixture on the machine table, and adjust the position of the fixture axis concentric with the machining axis of rotation.
(3)Put the disk in the shotpeening/grit blasting and thermal spraying support fixture with the aft end down.
5 . Procedure.
Subtask 72-53-40-110-011
A.Alternative Procedure Available. If necessary, clean the disk. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-53-40-160-010
A.A.Alternative Procedure. If necessary, clean the disk. Refer to TASK 72-53-40-100-801 (72-53-40, CLEANING 001).
Subtask 72-53-40-220-200
B.Do an inspection of the disk diameter G for HVOF thermal spray coating as follows:
(1)Etch the disk surface G. Refer to TASK 70-24-00-110-033 (ETCHING PROCEDURES FOR FLUORESCENT-PENETRANT INSPECTION), TASK 70-24-01-110-034 (SWAB ETCHING PROCEDURE), Figure 901, and as follows:
NOTE:
After the swab etching procedure, the parent material will become dark gray.
(a)Use Class C or Class G etchant.
Subtask 72-53-40-320-003
C.Machine the disk. Refer to TASK 70-00-03-800-004 (MACHINING DATA) and as follows:
(1)Set-up the disk for machining. Refer to Subtask 72-53-40-350-007 (paragraph 4.A.).
CAUTION:
DO NOT MACHINE THE DISK TO LESS THAN THE MINIMUM IN-PROCESS DIMENSION OR THE DISK WILL BECOME UNSERVICEABLE.
(2)Machine the disk diameter G to remove damage and/or HVOF thermal spray coating. Refer to Subtask 72-53-40-220-199 (paragraph 3.A.), Figure 901, and as follows:
NOTE:
HVOF thermal spray coating will come off in small matt colored chips when machined and base material will come off in a continuous shiny curl when machined.
(a)Use a cutting tool machine. The parameters must be as follows:
NOTE:
Micrograin carbide, uncoated or coated cutting tool.
1The maximum constant flank tool wear must be 0.012 inch (0.30 mm).
2The maximum speed must be 33-165 surface feet per minute (SFM).
3The feed must be 0.001-0.010 inch per revolution (IPR).
4The final pass depth of cut must be 0.002-0.006 inch (0.06-0.15 mm).
5The flood of coolant must be continuous.
(b)Remove only the minimum quantity of material necessary from the disk. Make sure that the machining limits agree with the in-process dimensions.
Subtask 72-53-40-350-011
(c)Blend the disk burrs and sharp edges. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
1Use C10-105  sandpaper.
2Break edges to 0.005-0.015 inch (0.13-0.38 mm).
(d)All machined surfaces finish must be 63 microinches (1.6 micrometers) or better.
Subtask 72-53-40-350-012
(3)Remove the disk from the machining fixture.
Subtask 72-53-40-220-201
D.Do a dimensional inspection of the disk diameter G. Refer to Subtask 72-53-40-220-199 (paragraph 3.A.) and as follows:
(1)All values must agree with the in-process limits and as follows:
(a)If one of the values are less than the minimum in-process limits, the disk is not repairable with this procedure.
Subtask 72-53-40-110-013
E.Alternative Procedure Available. If necessary, clean the disk. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-53-40-160-011
E.A.Alternative Procedure. If necessary, clean the disk. Refer to TASK 72-53-40-100-801 (72-53-40, CLEANING 001).
Subtask 72-53-40-110-015
F.Etch the disk repair area. Refer to TASK 70-24-00-110-033 (ETCHING PROCEDURES FOR FLUORESCENT-PENETRANT INSPECTION), TASK 70-24-01-110-034 (SWAB ETCHING PROCEDURE), Figure 901, and as follows:
(1)Use Class C or Class G etchant.
Subtask 72-53-40-230-010
G.Alternative Procedure Available. Do an inspection of the disk. 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)For the limits refer to TASK 72-53-40-200-801 (72-53-40, INSPECTION 001 - CONFIG 01) and TASK 72-53-40-200-802 (72-53-40, INSPECTION 001 - CONFIG 02).
Subtask 72-53-40-230-011
G.A.Alternative Procedure. Do an inspection of the disk. 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)For the limits refer to TASK 72-53-40-200-801 (72-53-40, INSPECTION 001 - CONFIG 01) and TASK 72-53-40-200-802 (72-53-40, INSPECTION 001 - CONFIG 02).
Subtask 72-53-40-110-016
H.Alternative Procedure Available. If necessary, clean the disk. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-53-40-160-012
H.A.Alternative Procedure. If necessary, clean the disk. Refer to TASK 72-53-40-100-801 (72-53-40, CLEANING 001).
Subtask 72-53-40-380-004
I.Peen the disk diameter G. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 901, and as follows:
(1)Apply C10-021  plastic tape to all adjacent areas of the disk that you will not peen.
(2)Set-up the disk for shotpeening. Refer to Subtask 72-53-40-350-010 (paragraph 4.B.).
(3)Use C04-166  CCW14, conditioned cut wire steel shot.
(4)Peen to an intensity of 0.006-0.012N.
(5)125 percent coverage is necessary and as follows:
(a)Make sure that you do the intensity verification with a simulative fixture.
(6)Remove the plastic tape from the disk.
(7)Make sure that during the shotpeening process the corner does not rollover.
(8)Remove the disk from the shotpeening support fixture.
Subtask 72-53-40-340-002
WARNING:
DO NOT THERMAL SPRAY IF YOU ARE NOT APPROVED (TRAINED AND QUALIFIED). USE PERSONAL PROTECTION EQUIPMENT AND APPROVED SAFETY PROCEDURES. USE EITHER A CONTINUOUS-FLOW EXHAUST SYSTEM OR A WATER-CURTAIN EXHAUST SYSTEM. WATER-CURTAIN EXHAUST SYSTEMS MAY COLLECT OVERSPRAY PARTICLES OF SOME METALS (MAGNESIUM, ALUMINUM AND IRON) AND CAN FORM HYDROGEN. WHEN MIXED WITH AIR, HYDROGEN CAN BURN AND IS EXPLOSIVE.
J.Thermal-spray the disk and the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-36-340-038 (HIGH DENSITY INCONEL 718 COATING APPLIED BY HVOF THERMAL SPRAY), Subtask 72-53-40-220-199 (paragraph 3.A.), Figure 901, and as follows:
(1)Apply C10-012  masking tape to all the areas of the disk you will not thermal spray as follows:
(a)Apply masking into the masking tolerance zone.
(b)Masking must not start aft of the machining breakout point.
Subtask 72-53-40-350-013
(2)Set-up the disk for grit blasting and thermal spraying. Refer to Subtask 72-53-40-350-010 (paragraph 4.B.).
(3)Grit-blast the disk diameter G and the test specimens and as follows:
(a)The surface finish must be 80-150 microinches (2.1-3.8 micrometers RA).
Subtask 72-53-40-110-018
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.
(4)Clean the repair surfaces with a clean, lint-free C10-182   cloth moist with C04-035  isopropyl alcohol and as follows:
(a)Replace each dirty cloth with a clean C10-182  cloth until the last moist C10-182  cloth stays clean.
Subtask 72-53-40-350-014
(5)Thermal-spray the disk diameter G and the test specimens to a maximum as-sprayed thickness of 0.030 inch (0.76 mm) and as follows:
(a)Make sure that you apply thermal spray coating to the test specimens at the same time and to the same thickness as the disk.
(b)Apply a sufficient quantity of thermal spray coating to get the finish dimensional limits specified in Subtask 72-53-40-220-199 (paragraph 3.A.).
(c)Overspray is permitted on the chamfer.
(6)Do all the quality assurance testing specified in TASK 70-49-36-340-038 (HIGH DENSITY INCONEL 718 COATING APPLIED BY HVOF THERMAL SPRAY).
(7)Remove the masking tape from the disk.
(8)Remove the disk from the grit blasting and thermal spraying support fixture.
Subtask 72-53-40-320-004
K.Machine the disk diameter G to the finish dimensions. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-53-40-220-199 (paragraph 3.A.), Figure 901, and as follows:
(1)Set-up the disk for machining. Refer to Subtask 72-53-40-350-007 (paragraph 4.A.).
(2)Machine the disk diameter G to the finish dimensions.
(3)The thermal spray coating must be 0.004-0.014 inch (0.11-0.35 mm) in thickness after the final machining.
(4)Make sure that the chamfer requirements agree with the machining results. Refer to Figure 901.
(5)All machined surfaces finish must be 63 microinches (1.6 micrometers) or better.
(6)Break the sharp edges to 0.005-0.015 inch (0.13-0.38 mm) and remove the unwanted thermal spray material or burrs from diameter G.
(7)Remove the disk from the machining fixture.
Subtask 72-53-40-110-019
L.Alternative Procedure Available. If necessary, clean the disk. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-53-40-160-013
L.A.Alternative Procedure. If necessary, clean the disk. Refer to TASK 72-53-40-100-801 (72-53-40, CLEANING 001).
Subtask 72-53-40-220-204
M.Do a visual inspection of the thermal spray coating in the disk as follows:
(1)Spalling, chipping, cracking, or separation of the thermal spray coating is not 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 901   (Sheet 4 ) High Pressure Turbine Rotor Stage 1 Disk - Dimensional Information