* * * FOR ALL
TASK 72-53-43-300-801
1 . Thermal Spray Repair of the Seal Teeth Coating.
A.This procedure gives instructions to repair the HPT rotor interstage seal (seal) by removing and replacing the thermal spray coating on the seal teeth. 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 72-53-43, Inspection 001, refer to TASK 72-53-43-200-801 (72-53-43, INSPECTION 001, CONFIG 01) or TASK 72-53-43-200-806 (72-53-43, INSPECTION 001, CONFIG 02) .
(5)Dimensional Inspection.
(b)Do an inspection of the seal serrations (AW1, AW2, AW3, AW4) as follows:
1Diameter AW1:
Maximum repairable limit:
24.558 inches (623.77 mm).
2Diameter AW2:
Maximum repairable limit:
24.438 inches (620.72 mm).
3Diameter AW3:
Maximum repairable limit:
24.318 inches (617.67 mm).
4Diameter AW4:
Maximum repairable limit:
24.198 inches (614.62 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)
 
2352M63P01  
2352M63P02  
2445M71P01  
2445M71P02  
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.
 
Description
Figure
 
Holding Fixture
902
B.Consumable Materials.
 
Code No.
Description
 
C04-166
Shot, peening, conditioned cut wire (CCW14 shot)
 
C10-012
Tape, Masking, High Temperature (masking tape)
 
C10-021
Tape, Plastic (duct tape)
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
 
70-23-00
Stripping Procedures
 
70-23-23
Removal of Coatings by High Pressure Water Stripping
 
70-23-28
Stripping Thermal Sprayed Aluminum Oxide/Nickel Chrome Aluminum Yttrium Thermal Spray Seal Teeth Coating On Rene 88DT Parts
 
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
 
70-47-01
Shotpeening
 
70-49-00
Thermal Spraying
 
70-49-02
Thermal Spraying Aluminum Oxide - Alumina (Powder)
 
70-49-35
Thermal Barrier Coating System - Yttrium Oxide Stabilized Zirconium Oxide (8% Yttrium Oxide) Over Nickel Chromium Aluminum Yttrium Bondcoat
 
72-53-43
Inspection 001 - Configuration 01
 
72-53-43
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 70-49-02-340-003 (THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER)) and TASK 70-49-35-340-037 (THERMAL BARRIER COATING SYSTEM - YTTRIUM OXIDE STABILIZED ZIRCONIUM OXIDE (8% YTTRIUM OXIDE) OVER NICKEL CHROMIUM ALUMINUM YTTRIUM BONDCOAT) .
3 . Dimensional Information.
Subtask 72-53-43-220-049
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.
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 AW1
24.558 in. (623.78 mm)
--
24.592 in. (624.64 mm)
24.596 in. (624.73 mm)
--
 
Dia AW2
24.438 in. (620.73 mm)
--
24.472 in. (621.59 mm)
24.476 in. (621.69 mm)
--
 
Dia AW3
24.318 in. (617.68 mm)
--
24.352 in. (618.55 mm)
24.356 in. (618.64 mm)
--
 
Dia AW4
24.198 in. (614.63 mm)
--
24.232 in. (615.50 mm)
24.236 in. (615.59 mm)
--
 
Dia U
--
--
--
--
22.296 in. (566.32 mm)
 
Dia Y
--
--
--
--
22.604 in. (574.14 mm)
4 . Setup Information.
Subtask 72-53-43-350-005
A.Set-up the seal to machine the seal teeth as follows:
Subtask 72-53-43-930-001
(1)If necessary, make the holding fixture. Refer to Figure 902.
Subtask 72-53-43-350-008
(2)Put the holding fixture on the machine turntable as follows:
(a)Surface FA of the holding fixture must be flat to a maximum of 0.001 inch (0.02 mm) FIR.
(b)Attach the holding fixture to the machine turntable.
(3)Install the seal on the holding fixture. Refer to Figure 903 and as follows:
(a)Diameter U must be concentric to the machine turntable centerline to a maximum of 0.001 inch (0.02 mm).
(b)Surface A must be parallel to the machine turntable face to a maximum of 0.001 inch (0.02 mm).
5 . Procedure.
Subtask 72-53-43-110-010
A.Remove the thermal spray coating on the seal teeth. Refer to TASK 70-23-00-100-001 (STRIPPING PROCEDURES) and as follows:
(1)Alternative Procedure Available. Refer to TASK 70-23-28-110-801 (STRIPPING THERMAL SPRAYED ALUMINUM OXIDE/NICKEL CHROME ALUMINUM YTTRIUM THERMAL SPRAY SEAL TEETH COATING ON RENE 88DT PARTS).
Subtask 72-53-43-350-007
(a)Apply C10-012  masking tape or C10-021  duct tape to the seal teeth areas that you will not grit-blast. Refer to Figure 904.
Subtask 72-53-43-140-001
(b)Grit-blast the seal teeth to remove the top coating.
NOTE:
This procedure is to remove the top coating only.
Subtask 72-53-43-350-009
(c)Remove the tape from the seal.
(d)Remove the bond coating with the stripping solution.
Subtask 72-53-43-330-001
(4).A.Alternative Procedure. Refer to TASK 70-23-23-330-008 (REMOVAL OF COATINGS BY HIGH PRESSURE WATER STRIPPING).
Subtask 72-53-43-110-005
B.Etch the seal teeth. 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 72-53-43-230-005
C.Alternate Procedure Available. Do an inspection of the seal teeth. 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)Refer to TASK 72-53-43-200-801 (72-53-43, INSPECTION 001, CONFIG 01) or TASK 72-53-43-200-806 (72-53-43, INSPECTION 001, CONFIG 02) for the fluorescent-penetrant inspection limits.
Subtask 72-53-43-230-006
C.A.Alternative Procedure. Do an inspection of the seal teeth. 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)Refer to TASK 72-53-43-200-801 (72-53-43, INSPECTION 001, CONFIG 01) or TASK 72-53-43-200-806 (72-53-43, INSPECTION 001, CONFIG 02) for the fluorescent-penetrant inspection limits.
Subtask 72-53-43-160-005
D.Clean the seal. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-53-43-220-050
E.Do a dimensional inspection of the seal diameter AW1, diameter AW2, diameter AW3, and diameter AW4. Refer to Subtask 72-53-43-220-049 (paragraph 3.A.), Figure 901, and as follows:
(1)If diameter AW1, diameter AW2, diameter AW3, and/or diameter AW4 are less than the minimum in-process dimensions specified in Subtask 72-53-43-220-049 (paragraph 3.A.), you cannot repair the seal with this procedure.
Subtask 72-53-43-380-003
F.Peen the area AG of the seal. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 904, and do as follows:
(1)Apply C10-021  plastic tape to areas that have thermal spray coating.
(2)Use C04-166  CCW14 shot.
(3)Peen to an intensity of 0.006-0.0012 N.
(4)Direct impingement required.
(5)Overspray is permitted.
(6)The coverage must be a minimum of 125 percent.
(7)Intensity verification is required by using a simulative fixture.
(8)Remove all plastic tape from the part.
Subtask 72-53-43-340-001
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.
G.Thermal-spray the seal teeth and the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-35-340-037 (THERMAL BARRIER COATING SYSTEM - YTTRIUM OXIDE STABILIZED ZIRCONIUM OXIDE (8% YTTRIUM OXIDE) OVER NICKEL CHROMIUM ALUMINUM YTTRIUM BONDCOAT), Figure 904, and as follows:
(1)Apply C10-012  masking tape to the seal areas that you will not thermal-spray.
(2)Prepare the seal teeth and the test specimens for thermal spraying as specified in TASK 70-49-00-340-001 (THERMAL SPRAYING) and as follows:
(a)Overspray is permitted in area BS.
(3)If necessary, apply C10-012  masking tape again to the seal areas that you will not thermal-spray.
(4)Apply the bond coating to the seal teeth 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 seal teeth.
(b)Overspray is permitted in area BS.
(c)Bond coating in area AL must be 0.002-0.006 inch (0.06-0.15 mm) in thickness.
(d)Bond coating in area AM must be 0.0015-0.0060 inch (0.039-0.152 mm) in thickness.
(e)There must be visual indication of thermal spray coating coverage in area AK.
(f)Record the as-sprayed bond coating dimensions of each seal tooth.
(5)Do all the quality assurance testing for bond coating only specified in TASK 70-49-35-340-037 (THERMAL BARRIER COATING SYSTEM - YTTRIUM OXIDE STABILIZED ZIRCONIUM OXIDE (8% YTTRIUM OXIDE) OVER NICKEL CHROMIUM ALUMINUM YTTRIUM BONDCOAT).
Subtask 72-53-43-340-002
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.
CAUTION:
MAKE SURE THAT YOU DO NOT GRIT-BLAST THE SEAL TEETH AGAIN. DAMAGE TO THE BOND COATING CAN OCCUR.
H.Thermal-spray the seal teeth and the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-02-340-003 (THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER)), Figure 904, and as follows:
(1)If necessary, apply C10-012  masking tape again to the seal areas that you will not thermal-spray.
(2)Apply the top coating to the seal teeth 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 seal teeth.
(b)Overspray is permitted in area BS.
(c)Top coating in area AL and area AM must be 0.003-0.013 inch (0.08-0.33 mm) in thickness.
(d)There must be visual indication of thermal spray coating coverage in area AK.
(3)Remove the masking from the seal.
(4)Do all the quality assurance testing specified in TASK 70-49-02-340-003 (THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER)) and as follows:
(a)Voiding and porosity must not be more than condition V-4 shown in GE Photo No. 8603003.
(b)Voiding in area AK must not be more than the condition shown in GE Photo No. D33998.
Subtask 72-53-43-320-001
I.Machine the seal teeth to the finish dimensions. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-53-43-220-049 (paragraph 3.A.), Figure 901, and as follows:
(1)Set-up the seal to machine the seal teeth. Refer to Subtask 72-53-43-350-005 (paragraph 4.A.).
(2)Make sure diameter AW1, diameter AW2, diameter AW3, and diameter AW4 agree with the finish dimensions.
(3)Remove the seal from the holding fixture.
Subtask 72-53-43-220-051
J.From the as-sprayed bond coating dimensions of the seal teeth that you recorded, get the top coating thickness measurement after final machining of diameter AW1, diameter AW2, diameter AW3, diameter AW4, and as follows:
(1)If you find that the top coating thickness is less than 0.003 inch (0.08 mm) for a seal tooth, the seal is not serviceable and you must do this repair procedure again.
Subtask 72-53-43-220-052
K.Do a visual inspection of the thermal spray coating on the seal teeth. Refer to Figure 904 and as follows:
(1)Spalling or lifting is not permitted.
(2)Chipping or missing thermal spray coating is permitted as follows:
(a)A maximum of 0.30 inch (7.6 mm) in length of missing or chipped thermal spray coating is permitted on each seal tooth.
(b)A total maximum of 1.50 inches (38.1 mm) in length of missing or chipped thermal spray coating is permitted on each seal tooth.
(c)The minimum distance between areas with missing thermal spray coating must be 1.00 inch (25.4 mm).
(3)Overspray is permitted in area BS.
Subtask 72-53-43-220-109
L.Do a dimensional inspection of the seal teeth. Refer to TASK 72-53-43-200-801 (72-53-43, INSPECTION 001, CONFIG 01) or TASK 72-53-43-200-806 (72-53-43, INSPECTION 001, CONFIG 02).
* * * FOR ALL
Figure 901   (Sheet 1 ) High Pressure Turbine Rotor Interstage Seal - Dimensional Information
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Figure 901   (Sheet 2 ) High Pressure Turbine Rotor Interstage Seal - Dimensional Information
* * * FOR ALL
Figure 901   (Sheet 3 ) High Pressure Turbine Rotor Interstage Seal - Dimensional Information
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Figure 901   (Sheet 4 ) High Pressure Turbine Rotor Interstage Seal - Dimensional Information
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Figure 901   (Sheet 5 ) High Pressure Turbine Rotor Interstage Seal - Dimensional Information
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Figure 902   Holding Fixture
* * * FOR ALL
Figure 903   Seal Setup in the Holding Fixture
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Figure 904   (Sheet 1 ) Thermal Spray Coating and Masking Locations
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Figure 904   (Sheet 2 ) Thermal Spray Coating and Masking Locations
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Figure 904   (Sheet 3 ) Thermal Spray Coating and Masking Locations