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TASK 72-58-40-300-808
1 . Thermal Spray Repair of the Center Vent Duct Mating Surfaces.
A.This procedure gives instructions to repair the mid fan shaft (shaft) by thermal spraying the center vent duct mating surfaces (diameter EP and surface EQ). 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.
(q)Do an inspection of the center vent duct mating surface (surface EQ) for:
2Nicks, dents, or scratches:
Maximum repairable limit:
Any amount, if dimension ER is not more than 1.7578 inches (44.65 mm) after the removal of the surface defect.
3Contact mark:
Maximum repairable limit:
Any amount, if dimension ER is not more than 1.7578 inches (44.65 mm) after the removal of the surface defect.
4Fretting or corrosion pits:
Maximum repairable limit:
Any amount, if dimension ER is not more than 1.7578 inches (44.65 mm) after the removal of the surface defect.
(q).A.Do an inspection of the center vent duct mating surface (diameter EP) for:
2Nicks, dents, or scratches on diameter EP:
Maximum repairable limit:
Any amount, if diameter EP is not more than 3.43011 inches (87.125 mm) after the removal of the surface defect.
3Contact mark:
Maximum repairable limit:
Any amount, if diameter EP is not more than 3.43011 inches (87.125 mm) after the removal of the surface defect.
4Fretting or corrosion pits:
Maximum repairable limit:
Any amount, if diameter EP is not more than 3.43011 inches (87.125 mm) after the removal of the surface defect.
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)
 
2331M20G03  
2332M81G03  
2332M81G04  
2332M81G05  
 
2440M20G05  
2440M91G05  
2440M91G06  
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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
 
C04-271
Shot, Peening, Cast Steel (AMS 2431/2 ASH), Cast Steel Shot, High Hardness (55-62 HRc) (high hardness cast steel shot)
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
 
70-31-06
Machined Features Shop-Run Tolerances
 
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
 
70-49-21
Thermal Spraying Nickel-Chromium/Aluminum Composite (Powder)
 
72-58-40
Inspection 001
D.Expendable Parts. None.
E.SPD Information.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. Refer to TASK 70-49-21-340-022 (THERMAL SPRAYING NICKEL-CHROMIUM/ALUMINUM COMPOSITE (POWDER)) .
3 . Dimensional Information.
Subtask 72-58-40-220-110
A.Refer to Figure 901 for specified dimensions and locations.
NOTE:
The dimensional data identified within this procedure was designed using millimeters as the base unit of measurement for dimensional values. The conversion to inches is rounded to two additional decimal digits than millimeters. 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 inches to millimeters.
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 EP
3.41438 in. (86.725 mm)
3.43011 in. (87.125 mm)
3.40453 in. (86.475 mm)
3.40649 in. (86.525 mm)
--
 
Dim. ER
1.7540 in. (44.55 mm)
1.7578 in. (44.65 mm)
1.7304 in. (43.95 mm)
1.7500 in. (44.45 mm)
--
4 . Setup Information.
Subtask 72-58-40-350-038
A.Set-up the shaft for machining. Refer to Figure 901 and as follows:
Subtask 72-58-40-220-111
(1)Make sure that diameter G runout is 0.0011 inch (0.03 mm) or less.
(2)Make sure that diameter B runout is 0.0011 inch (0.03 mm) or less.
5 . Procedure.
Subtask 72-58-40-160-004
A.If necessary, clean the shaft. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-58-40-320-006
B.Machine the shaft diameter EP/surface EQ. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-58-40-220-110 (paragraph 3.A.), Figure 901, Figure 902, and as follows:
Subtask 72-58-40-220-115
(1)For tolerances and general instructions, which include visual inspection after machining. Refer to TASK 70-31-06-220-001 (MACHINED FEATURES SHOP-RUN TOLERANCES).
Subtask 72-58-40-350-039
(1)Set-up the shaft for machining. Refer to Subtask 72-58-40-350-038 (paragraph 4.A.).
Subtask 72-58-40-320-007
(1)Machine diameter EP/surface EQ to the in-process dimensions to remove all damage/remaining thermal spray coating.
(2)Break the machined edges and sharp corners to 0.00500-0.01500 inch (0.127-0.381 mm).
Subtask 72-58-40-350-040
C.If necessary, blend the shaft machined area. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), Figure 902, and as follows:
(1)Remove burrs and rolled edges from the shaft.
Subtask 72-58-40-220-112
D.Do a dimensional inspection of the shaft diameter EP/surface EQ. Refer to Subtask 72-58-40-220-110 (paragraph 3.A.), Figure 901, and as follows:
(1)If diameter EP/surface EQ does not agree with the in-process dimensions, you cannot repair the shaft with this procedure.
Subtask 72-58-40-240-004
E.Alternative Procedure Available. Do a magnetic-particle inspection of the shaft machined areas. Refer to TASK 72-58-40-200-801 (72-58-40, INSPECTION 001), and Figure 902, and as follows:
(1)Indications are not permitted.
Subtask 72-58-40-220-113
E.A.Alternative Procedure. Do an inspection of the shaft machined areas. Refer to Figure 902 and as follows:
Subtask 72-58-40-110-010
(1)Etch the shaft machined 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:
(a)Use Class C etchant.
Subtask 72-58-40-230-001
(2)Do an inspection of the shaft 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:
(a)Use Class G penetrant.
(b)Indications are not permitted.
Subtask 72-58-40-380-016
F.Peen the shaft machined areas. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 901, Figure 902, and as follows:
(1)Use S170 maximum C04-271  high hardness cast steel shot.
(2)Intensity must be 0.010 to 0.015A.
(3)Use a simulative fixture.
(4)Shotpeen overspray is permitted but not on the threaded or coated areas.
(5)Minimum of 100 percent coverage is required.
Subtask 72-58-40-340-001
G.Thermal-spray the shaft machined areas and the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-21-340-022 (THERMAL SPRAYING NICKEL-CHROMIUM/ALUMINUM COMPOSITE (POWDER)), Figure 903, and as follows:
(1)Maximum as sprayed coating thickness must not be more than 0.039 inch (1.0 mm).
Subtask 72-58-40-320-008
H.Machine the shaft to the finish dimensions. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-58-40-220-110 (paragraph 3.A.), Figure 901, Figure 904, and as follows:
(1)For tolerances, refer to TASK 70-31-06-220-001 (MACHINED FEATURES SHOP-RUN TOLERANCES).
Subtask 72-58-40-350-041
(2)Set-up the shaft for machining. Refer to Subtask 72-58-40-350-038 (paragraph 4.A.).
Subtask 72-58-40-320-009
(3)Machine diameter EP/surface EQ to the finish dimensions.
(4)For part number 2331M20G03   , break sharp edges to 0.004-0.019 inch (0.1-0.5 mm).
(5)For part number 2332M81G03   and part number 2332M81G04   , break sharp edges to 0.0100 inch (0.254 mm) maximum.
Subtask 72-58-40-350-042
CAUTION:
DO NOT ETCH AND SHOTPEEN THE SHAFT REPAIRED AREA AFTER THE BLENDING PROCEDURE. DAMAGE TO THE THERMAL SPRAY COATING CAN OCCUR.
I.Blend the shaft. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES), Figure 903, Figure 904, and as follows:
NOTE:
An FPI on the repaired area after the blending procedure is not necessary.
(1)Make a smooth contour of the thermal sprayed area with the adjacent surface.
(2)Maximum blend depth of base metal at overspray coating removal is 0.00098 inch (0.025 mm).
Subtask 72-58-40-220-114
J.Do a visual inspection of the shaft repaired area as follows:
(1)Spalling, chipping, cracking, or separation of the thermal spray coating is not permitted.
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Figure 901   Mid Fan Shaft - Dimensional Information
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Figure 902   Mid Fan Shaft - In-Process Dimensions
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Figure 903   (Sheet 1 ) Mid Fan Shaft - Thermal Spray Requirements
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Figure 903   (Sheet 2 ) Mid Fan Shaft - Thermal Spray Requirements
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Figure 904   Mid Fan Shaft - Finish Dimensions