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TASK 72-58-40-300-809
1 . Thermal Spray Repair On The Aft Pilot Outer Diameter.
A.This procedure gives instructions to repair the mid fan shaft (shaft) by thermal spraying the aft pilot outer diameter. 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.
(i)Do an inspection of the aft pilot outer diameter for:
2Nicks, dents, and scratches:
Maximum repairable limit:
Any amount 0.011 inch (0.27 mm) in depth.
3Wear or galling:
Maximum repairable limit:
Any amount 0.011 inch (0.27 mm) in depth.
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
 
70-16-00
Marking Practices
 
70-16-08
Dot Peen Marking for Optical Character Recognition
 
70-21-00
Chemical Cleaning
 
70-21-03
Cleaning Method No. 3 - Steam Cleaning
 
70-21-23
Cleaning Method No. 23 - Hand-Wipe Degreasing
 
70-31-06
Machined Features Shop-Run Tolerances
 
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)
 
72-58-00
Storage 001
 
72-58-40
Cleaning 001
 
72-58-40
Inspection 001
 
72-58-40
Repair 001
 
72-58-40
Repair 002
 
72-58-40
Repair 003
 
72-58-40
Repair 013
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 72-58-40-220-120
A.Refer to Figure 901, Figure 902, Figure 903, and Figure 905 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 A
5.5961 in. (142.14 mm)
5.6106 in. (142.51 mm)
5.6189 in. (142.72 mm )
5.6196 in. (142.74 mm)
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Dia B
--
--
--
--
5.1799 in. (131.57 mm)
 
Dia G
--
--
--
--
5.512 in. (140.0 mm)
4 . Setup Information.
Subtask 72-58-40-350-043
A.Set-up the shaft for machining. Refer to Figure 901 and do as follows:
Subtask 72-58-40-220-121
(1)Set diameter G to a maximum of 0.00019 inch (0.005 mm) and diameter B to a maximum of 0.00039 inch (0.010 mm) concentric with machine axis.
5 . Procedure.
Subtask 72-58-40-160-005
CAUTION:
COMPLETE THIS PROCEDURE AND RE-APPLY THE PROTECTIVE COATING IN LESS THAN 24 HOURS OF AFTER YOU REMOVED THE PROTECTIVE COATING FOR REPAIR, OR THE SHAFT CAN CORRODE. IF YOU CANNOT APPLY THE PAINT IN 24 HOURS OR LESS, APPLY PRESERVATIVE OIL. REFER TO TASK 72-58-00-550-801 (72-58-00, STORAGE 001).
A.If necessary, clean the shaft. Refer to TASK 72-58-40-100-801 (72-58-40, CLEANING 001).
Subtask 72-58-40-320-010
CAUTION:
REMOVE ONLY THE MINIMUM QUANTITY OF MATERIAL NECESSARY OR DAMAGE TO THE SHAFT CAN OCCUR.
B.Machine the shaft diameter A. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-58-40-220-120 (paragraph 3.A.), Figure 901, Figure 902, and as follows:
(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).
(2)Set-up the shaft for machining. Refer to Subtask 72-58-40-350-043 (paragraph 4.A.).
(3)Machine the shaft diameter A to the in-process dimensions to remove all damage/remaining thermal spray coating.
(4)Break all sharp edges to 0.00500-0.01500 inch (0.127-0.381 mm).
Subtask 72-58-40-220-126
C.Do a dimensional inspection of the shaft machined area. Refer to Subtask 72-58-40-220-120 (paragraph 3.A.), Figure 902, and as follows:
(1)If diameter A does not agree with the in-process dimensions, you cannot repair the shaft with this procedure.
Subtask 72-58-40-160-006
D.Clean the shaft machined area. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
Subtask 72-58-40-240-006
E.Do a magnetic-particle inspection of the shaft machined area. Refer to TASK 72-58-40-200-801 (72-58-40, INSPECTION 001) and as follows:
(1)Indications are not permitted.
Subtask 72-58-40-380-018
F.Peen the shaft machined area. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 903 and as follows:
(1)If necessary, clean the shaft machined area. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-23-110-053 (CLEANING METHOD NO. 23 - HAND-WIPE DEGREASING).
(2)Use S170 maximum C04-271  high hardness cast steel shot.
(3)Shot media hardness must be 55-65 HRc.
(4)Intensity must be 0.010-0.015A.
(5)Use a scrap or simulative fixture.
(6)Shotpeen overspray is permitted but not on the diameter G, splines, threaded or coated areas.
(7)Minimum of 100 percent coverage is required.
Subtask 72-58-40-340-002
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 904, and as follows:
(1)Maximum as sprayed coating thickness must not be more than 0.039 inch (1.0 mm).
Subtask 72-58-40-320-012
H.Machine the shaft to the finish dimensions. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-58-40-220-120 (paragraph 3.A.), Figure 901, Figure 905, and as follows:
(1)For tolerances, refer to TASK 70-31-06-220-001 (MACHINED FEATURES SHOP-RUN TOLERANCES).
(2)Set-up the shaft for machining. Refer to Subtask 72-58-40-350-043 (paragraph 4.A.).
(3)Machine diameter A to the finish dimensions.
(4)The repair area surface finish must be 32 microinches (0.8 micrometers) or better.
(5)Remove the sharp edges as necessary.
Subtask 72-58-40-350-047
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 905, and do as follows:
NOTE:
An FPI on the repaired area after the blending procedure is not necessary.
(1)Make sure that you remove all burrs and sharp edges from the repaired area.
(2)Make a smooth contour of the thermal sprayed area with the adjacent surface.
(3)Maximum blend depth of base metal at overspray coating removal is 0.00098 inch (0.025 mm).
Subtask 72-58-40-220-127
J.Do a dimensional inspection of the shaft repaired area. Refer to Subtask 72-58-40-220-120 (paragraph 3.A.) and Figure 905.
Subtask 72-58-40-220-125
K.Do a visual inspection of the shaft repaired area as follows:
(1)Spalling, chipping, cracking, or separation of the thermal spray coating or oversprayed coating is not permitted.
(2)If you find defects, do Subtask 72-58-40-320-010 (paragraph 5.B.) thru Subtask 72-58-40-220-125 (paragraph 5.K.) again.
Subtask 72-58-40-220-128
L.Measure the runout of the shaft. Refer to Figure 901 and do as follows:
(1)Measure the runout of surface D with respect to diameter A and diameter B.
(2)If the position of the lowest measured runout point is different from the position of the mark L on surface DE, do Subtask 72-58-40-350-048 (paragraph 5.M.).
(3)If the position of the lowest measured runout point is the same position of the mark L on surface DE, refer to Subtask 72-58-40-350-049 (paragraph 5.N.).
Subtask 72-58-40-350-048
M.If necessary, put a mark on the shaft. Refer to TASK 70-16-00-350-001 (MARKING PRACTICES), TASK 70-16-08-350-001 (DOT PEEN MARKING FOR OPTICAL CHARACTER RECOGNITION), and as follows:
NOTE:
The shaft is a life-limited part.
(1)Use Method 1 or Method 2 as follows:
(a)Character height is 0.0603-0.1200 inch (1.53-3.05 mm).
(2)Put a line through the mark L on the mounting flange outer diameter of surface DE.
(3)Put a mark L on surface DE at the lowest runout point of surface D that you recently measured.
Subtask 72-58-40-350-049
N.Complete all the necessary repairs for the shaft.
Subtask 72-58-40-350-050
O.Do a balance inspection of the shaft and correct imbalance as necessary. Refer to TASK 72-58-40-300-801 (72-58-40, REPAIR 001).
NOTE:
Balance inspection can be performed after you apply the protective paint to the shaft.
Subtask 72-58-40-350-051
P.Apply protective paint to the shaft, as follows:
(1)For part numbers 2331M20G03   , 2332M81G03   , and 2332M81G04   , apply protective paint to the shaft. Refer to TASK 72-58-40-300-803 (72-58-40, REPAIR 002).
(2)For part numbers 2332M81G05   , 2440M20G05   , 2440M91G05   , and 2440M91G06   , apply protective paint and seal coat to the shaft. Refer to TASK 72-58-40-300-812 (72-58-40, REPAIR 013).
Subtask 72-58-40-350-052
Q.Apply solid film lubricant to the shaft. Refer to TASK 72-58-40-300-804 (72-58-40, REPAIR 003).
Subtask 72-58-40-350-053
R.Apply oil to the shaft surface where solid dry film lubricant or aluminum protective paint is not applied. Refer to TASK 72-58-00-550-801 (72-58-00, STORAGE 001) for approved oils.
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Figure 901   (Sheet 1 ) Mid Fan Shaft - Dimensional Information
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Figure 901   (Sheet 2 ) Mid Fan Shaft - Dimensional Information
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Figure 902   Mid Fan Shaft - In - Process Dimensions
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Figure 903   Mid Fan Shaft - Shotpeening Area
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Figure 904   Mid Fan Shaft - Thermal Spraying Area
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Figure 905   Mid Fan Shaft - Finish Dimensions