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TASK 72-53-41-300-802
1 . Repair for the High Pressure Turbine Rotor Stage 2 Disk.
A.This procedure gives instructions to repair the high pressure turbine (HPT) rotor stage 2 disk (disk) by blending to remove surface damage. 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.
NOTE:
For 72-53-41, Inspection 001, refer to TASK 72-53-41-200-801 (72-53-41, INSPECTION 001) .
(4)Visual Inspection.
(a)Do an inspection of the dovetail serrations for:
1Nicks and dents:
Maximum repairable limit:
Two nicks or dents on each dovetail post, not more than 0.010 inch (0.25 mm) in depth after the removal of high metal.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm).
2Scratches:
Maximum repairable limit:
Not more than 0.010 inch (0.25 mm) in depth after the removal of high metal.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm).
(e)Do an inspection of the rim OD and end faces for:
1Nicks:
Maximum repairable limit:
Any amount, if you can remove the damage with a blend not more than 0.010 inch (0.25 mm) in depth.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm).
2Dents:
Maximum repairable limit:
Any amount, if you can remove the damage with a blend not more than 0.010 inch (0.25 mm) in depth, after the removal of high metal.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm).
3Scratches:
Maximum repairable limit:
Any amount, if you can remove the damage with a blend not more than 0.010 inch (0.25 mm) in depth and 0.150 inch (3.81 mm) in length.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm).
4Galling and fretting:
Maximum repairable limit:
Blend to not more than 0.010 inch (0.25 mm) in depth and 0.100 inch (2.54 mm) in width.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm).
(f)Do an inspection of the forward and aft web and hub faces for:
1Nicks and scratches that are 0.25 inch (6.4 mm) or less from any fillet radius:
Maximum repairable limit:
Any amount, if you can remove the damage with a blend not more than 0.003 inch (0.08 mm) in depth, except area CX. Refer to Figure 902.
Repair method:
Blend with a minimum radius of 0.50 inch (12.7 mm). Blend radius in the FWD rim fillet must be a minimum of 0.170 inch (4.32 mm).
2Nicks and scratches in other areas:
Maximum repairable limit:
Not more than 0.003 inch (0.08 mm) in depth after you blend.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm), except area CX. Refer to Figure 902.
3Dents:
Maximum repairable limit:
Not more than 0.003 inch (0.08 mm) in depth after the removal of high metal.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm).
(g)Do an inspection of the aft seal mounting face for:
1Fretting:
Maximum repairable limit:
Not more than 0.010 inch (0.25 mm) in depth after the removal of high metal.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm).
2Nicks, dents, and scratches:
Maximum repairable limit:
Not more than 0.010 inch (0.25 mm) in depth after the removal of high metal. Repair area must not be more than 20 percent of the area or within 0.25 inch (6.4 mm) from any bolthole.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm).
(h)Do an inspection of the disk bore and disk bore edge radii for:
1Nicks and scratches:
Maximum repairable limit:
Any amount, if you can remove the damage with a blend not more than 0.005 inch (0.13 mm) in depth and 0.50 inch (12.7 mm) in length.
Repair method:
Blend with a minimum radius of 0.50 inch (12.7 mm).
2Dents:
Maximum repairable limit:
Not more than 0.005 inch (0.13 mm) in depth after the removal of high metal.
Repair method:
Blend with a minimum radius of 0.50 inch (12.7 mm).
3Deleted.
Maximum repairable limit:
Deleted.
Repair method:
Deleted.
(i)Do an inspection of area A for:
1Nicks, dents, scratches, or other damage:
Maximum repairable limit:
Not more than 0.003 inch (0.08 mm) in depth after you blend.
Repair method:
Blend with a minimum radius of 0.50 inch (12.7 mm).
(j)Do an inspection of area B for:
1Nicks, dents, scratches, or other damage:
Maximum repairable limit:
Not more than 0.003 inch (0.08 mm) in depth after you blend.
Repair method:
Blend with a minimum radius of 0.50 inch (12.7 mm).
(l)Do an inspection of the aft seal rabbet OD, ID, and axial interfaces for:
2Nicks, dents, and scratches:
Maximum repairable limit:
10 percent of the contact area, 0.003 inch (0.08 mm) in depth.
Repair method:
Blend with a minimum radius of 0.50 inch (12.7 mm).
(m)Do an inspection of the spline surfaces for:
4Nicks, dents, or scratches on the end faces, refer to Figure 902:
Maximum repairable limit:
Not more than 0.003 inch (0.08 mm) in depth after the removal of high metal. Damage is not permitted in the root radii.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm).
(n)Do an inspection of the coupling nut mate face for:
1Galling:
Maximum repairable limit:
15 percent of coupling nut mate face area, not more than 0.002 inch (0.05 mm) in depth, after high metal is removed and blended.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm).
(o)Do an inspection of all other areas of the aft shaft:
1Nicks, dents, and scratches:
Maximum repairable limit:
Except for no blending zones, not more than 0.003 inch (0.08 mm) after you blend.
Repair method:
Blend with a minimum radius of 0.25 inch (6.4 mm). Blend radius in area AA must be a minimum of 0.040 inch (1.02 mm).
(q)Do an inspection of the air hole cone forward outer corner:
1Nicks, dents, and scratches:
Maximum repairable limit:
0.030 inch (0.76 mm) in depth, after blend. Removal of material into the air hole break edge is not permitted.
Repair method:
Blend with a minimum radius of 0.50 inch (12.7 mm).
(s)Do an inspection of area D for:
1Nicks, dents, and scratches:
Maximum repairable limit:
Not more than 0.007 inch (0.18 mm) in depth after blending.
Repair method:
Blend with a minimum radius of 0.250 inch (6.35 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)
 
2300M84P02  
2383M86P02  
2445M92P01  
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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)
 
C10-010
Abrasive Cloth
 
C10-021
Tape, Plastic
 
C10-205
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
 
72-53-41
Inspection 001
D.Expendable Parts. None.
E.SPD Information. None.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. None.
3 . Dimensional Information.
Subtask 72-53-41-220-054
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 reconvert from millimeters to inches.
4 . Setup Information.
None.
5 . Procedure.
Subtask 72-53-41-100-001
A.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 72-53-41-200-001
B.Do a visual inspection of the disk. Refer to TASK 72-53-41-200-801 (72-53-41, INSPECTION 001).
Subtask 72-53-41-350-003
C.Blend the disk. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), Figure 902, and as follows:
(1)Blend in the area AV, area AW, area AX, and area AY, except as noted not to blend.
(2)For area CX only, blending must not be more than 0.002 inch (0.05 mm) in depth and with a blend radius of 2.00 inches (50.8 mm).
(3)For the blending limits refer to TASK 72-53-41-200-801 (72-53-41, INSPECTION 001).
Subtask 72-53-41-100-002
D.Clean the repaired 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 72-53-41-110-004
E.Etch the repaired 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 72-53-41-200-002
F.Alternative Procedure Available. Do an inspection of the repaired areas. Refer to TASK 70-32-00-200-002 (INDIRECT INSPECTION METHODS), TASK 70-32-02-230-001 (FLUORESCENT PENETRANT INSPECTION), as follows:
(1)Use Class G penetrant.
(2)Indications more than 0.015 inch (0.38 mm) are not permitted.
(3)Indications which cross corners are not permitted.
(4)Linear indications are not permitted.
NOTE:
Linear indications are indications that are at least four times longer that they are wide.
Subtask 72-53-41-200-003
F.A.Alternative Procedure. Do an inspection of the repaired areas. Refer to TASK 70-32-00-200-002 (INDIRECT INSPECTION METHODS), TASK 70-32-03-230-002 (SPOT-FLUORESCENT-PENETRANT INSPECTION), as follows:
(1)Use Class G penetrant.
(2)Indications more than 0.015 inch (0.38 mm) are not permitted.
(3)Indications which cross corners are not permitted.
(4)Linear indications are not permitted.
NOTE:
Linear indications are indications that are at least four times longer that they are wide.
Subtask 72-53-41-350-001
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.
G.Polish the disk to remove the effects of the swab etching procedure as follows:
(1)Use C10-010  abrasive cloth.
Subtask 72-53-41-380-001
H.Peen the repaired areas. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 903, and as follows:
(1)Apply a mask using C10-021  plastic tape to all areas you will not peen.
(2)Use C04-166  CCW14 steel shot.
(3)Peen to an intensity of 0.006N-0.012N.
(4)Use simulative fixture for intensity verification.
(5)Ricochet peening is permitted in area BB, area CG, hole AT and hole BU.
(6)Overspray is permitted in area AL.
Subtask 72-53-41-220-055
(7)Do an inspection of the intensity in all the disk repaired areas with C10-205  almen test strips and an almen test strip holder.
Subtask 72-53-41-350-002
(8)Remove all masking from the part.
Subtask 72-53-41-100-003
I.Clean the repaired 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 72-53-41-200-004
J.Do a final inspection of the disk. Refer to TASK 72-53-41-200-801 (72-53-41, INSPECTION 001) and as follows:
(1)Burrs or rollover edges are not permitted.
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Figure 901   (Sheet 1 ) Stage 2 Disk
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Figure 901   (Sheet 2 ) Stage 2 Disk
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Figure 901   (Sheet 3 ) Stage 2 Disk
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Figure 901   (Sheet 4 ) Stage 2 Disk
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Figure 901   (Sheet 5 ) Stage 2 Disk
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Figure 902   (Sheet 1 ) Blending Areas
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Figure 902   (Sheet 2 ) Blending Areas
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Figure 902   (Sheet 3 ) Blending Areas
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Figure 903   Shotpeening