* * * FOR ALL
TASK 72-58-45-300-802
1 . Repair of the Rabbet Diameter B.
A.This procedure gives instructions to repair the No. 4 bearing aft rotating seal (aft rotating seal) by thermal spraying the rabbet diameter B. 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 72-58-45, Inspection 001, refer to TASK 72-58-45-200-801 (72-58-45, INSPECTION 001) .
(5)Dimensional Inspection.
(d)Do an inspection of the aft rotating seal for:
1Diameter B (free state):
Maximum repairable limit:
11.801 inches (299.75 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)
 
2301M66P02  
--
--
--
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
 
Machining Fixture
902
B.Consumable Materials.
 
Code No.
Description
 
C04-271
Shot, Peening, Cast Steel (AMS 2431/2 ASH), Cast Steel Shot, High Hardness (55-62 HRc) (S110 steel shot)
 
C10-012
Tape, Masking, High Temperature (masking tape)
 
C10-021
Tape, Plastic
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
 
70-24-00
Etching Procedures for Fluorescent-Penetrant Inspection
 
70-24-01
Swab Etching Procedure
 
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
 
70-49-32
Thermal Spraying Inconel 718 (Powder)
 
72-58-45
Inspection 001
D.Expendable Parts. None.
E.SPD Information.
(1)Locally Manufactured SPD. None.
F.Special Solutions. None.
G.Test Specimens. Refer to TASK 70-49-32-340-033 (THERMAL SPRAYING INCONEL 718 (POWDER)) .
3 . Dimensional Information.
Subtask 72-58-45-220-027
A.Refer to Figure 901 and Figure 905 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 B
11.801 in. (299.75 mm)
11.802 in. (299.77 mm)
11.810 in. (299.98 mm)
11.812 in. (300.02 mm)
--
4 . Setup Information.
Subtask 72-58-45-350-009
A.Set-up the aft rotating seal for machining. Refer to Figure 903 and as follows:
Subtask 72-58-45-930-002
(1)If necessary, make the machining fixture. Refer to Figure 902.
Subtask 72-58-45-350-010
(2)Put the machining fixture on the rotating machine table as follows:
Subtask 72-58-45-220-034
(a)Surface FC must be perpendicular to 0.001 inch (0.02 mm) or less to the machine axis of rotation.
(b)The runout of diameter FD must be 0.001 inch (0.02 mm) or less, full indicator reading (FIR) to the machine axis of rotation.
Subtask 72-58-45-350-016
(3)Attach the machining fixture to the rotating machine table with socket head cap screws.
(4)Attach the aft rotating seal on the machining fixture/rotating machine table assembly as follows:
Subtask 72-58-45-220-035
(a)Surface A must be perpendicular to 0.001 inch (0.02 mm) or less to the machine axis of rotation.
(b)The runout of diameter AF must be 0.001 inch (0.02 mm) or less, FIR to the machine axis of rotation.
Subtask 72-58-45-350-017
(5)Attach the aft rotating seal to the machining fixture with round head bolts.
NOTE:
The round head bolts let you access all of the repair area.
5 . Procedure.
Subtask 72-58-45-220-028
A.Do a visual inspection of the aft rotating seal diameter B for Inconel 718 plasma spray coating or parent material. Refer to Figure 901 and as follows:
(1)If there is Inconel 718 plasma spray coating on the surface of diameter B, go to Subtask 72-58-45-330-003 (paragraph 5.B.).
(2)If there is no Inconel 718 plasma spray coating on the surface of diameter B, go to Subtask 72-58-45-320-005 (paragraph 5.D.), to prepare the aft rotating seal for thermal spraying.
Subtask 72-58-45-330-003
B.Alternative Procedure Available. Remove the Inconel 718 plasma spray coating from the aft rotating seal diameter B. Refer to TASK 70-23-00-100-001 (STRIPPING PROCEDURES), TASK 70-23-23-330-008 (REMOVAL OF COATINGS BY HIGH PRESSURE WATER STRIPPING), Figure 901, and as follows:
(1)Make sure to remove all the Inconel 718 plasma spray coating from diameter B.
Subtask 72-58-45-220-032
(2)Do a visual inspection of diameter B for parent metal wear after removal of Inconel 718 plasma spray coating as follows:
(a)If diameter B has parent metal wear, go to Subtask 72-58-45-320-005 (paragraph 5.D.).
(b)If diameter B does not have parent metal wear, go to Subtask 72-58-45-220-033 (paragraph 5.C.).
Subtask 72-58-45-320-004
CAUTION:
REMOVE ONLY THE MINIMUM QUANTITY OF MATERIAL NECESSARY OR DAMAGE TO THE AFT ROTATING SEAL CAN OCCUR.
B.A.Alternative Procedure. Machine the aft rotating seal diameter B to remove the previous Inconel 718 plasma spray coating and prepare it for thermal spraying. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-58-45-220-027 (paragraph 3.A.), Figure 901, and as follows:
(1)Go to Subtask 72-58-45-320-005 (paragraph 5.D.).
Subtask 72-58-45-220-033
C.Do a dimensional inspection of the aft rotating seal diameter B. Refer to Subtask 72-58-45-220-027 (paragraph 3.A.), Figure 901, and as follows:
(1)The average diameter B must agree with the in-process dimensions.
(2)Measure diameter B at eight locations with an equal distance between each location, around the aft rotating seal.
(3)Calculate the average of the eight dimensions.
(4)If diameter B agrees with the in-process dimensions, go to Subtask 72-58-45-160-008 (paragraph 5.E.), for thermal spraying.
(5)If diameter B is more than the in-process dimensions, go to Subtask 72-58-45-320-005 (paragraph 5.D.), to prepare diameter B for thermal spraying.
(6)If the average of diameter B is less than the minimum in-process, you cannot repair the aft rotating seal with this procedure.
Subtask 72-58-45-320-005
CAUTION:
MACHINE THE DIAMETER B CAREFULLY TO REMOVE THE MINIMUM QUANTITY OF PARENT MATERIAL NECESSARY FOR THE REPAIR. THIS WILL HELP TO NOT DECREASE THE NUMBER OF TIMES THE REPAIR CAN BE DONE AGAIN.
CAUTION:
REMOVE ONLY THE MINIMUM QUANTITY OF MATERIAL NECESSARY. DO NOT DECREASE THE WALL THICKNESS OF THE PARENT MATERIAL MORE THAN THE MINIMUM IN-PROCESS DIMENSIONS. DAMAGE TO THE AFT ROTATING SEAL CAN OCCUR AND WILL MAKE THE AFT ROTATING SEAL NOT REPAIRABLE BY THIS PROCEDURE.
D.Machine the aft rotating seal diameter B to remove wear or initial thermal spray coating and prepare it for thermal spraying. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-58-45-220-027 (paragraph 3.A.), Figure 901, and as follows:
Subtask 72-58-45-350-013
(1)Set-up the aft rotating seal for machining. Refer to Subtask 72-58-45-350-009 (paragraph 4.A.).
Subtask 72-58-45-320-006
(2)Machine diameter B to remove parent metal wear or all signs of remaining thermal spray coating as follows:
(a)Make sure that you remove sufficient material to get a minimum coating thickness of 0.004 inch (0.11 mm) after final machining.
(b)Deleted.
(3)Make sure that you remove all the parent metal wear from diameter B and as follows:
(a)If you cannot remove the parent metal wear from diameter B to agree with the minimum in-process dimensions, you cannot repair the aft rotating seal with this procedure.
Subtask 72-58-45-350-014
(4)If necessary, blend the machined diameter B of the aft rotating seal. Refer to TASK 70-42-00-350-002 (BLENDING AND REMOVAL OF HIGH METAL PROCEDURES) and as follows:
(a)Remove all high metal and rolled edges.
(5)Remove the aft rotating seal from the machining fixture.
Subtask 72-58-45-160-008
E.Clean the aft rotating 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 72-58-45-110-015
F.Etch the aft rotating seal diameter B. 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.
Subtask 72-58-45-230-004
G.Do an inspection of the aft rotating seal diameter B. 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 72-58-45-200-801 (72-58-45, INSPECTION 001) for the fluorescent penetrant inspection limits.
Subtask 72-58-45-160-009
H.Clean the aft rotating 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 72-58-45-380-001
I.Peen the aft rotating seal. Refer to TASK 70-47-01-380-016 (SHOTPEENING), Figure 904, and as follows:
(1)Make sure to apply C10-021  plastic tape to all the surfaces adjacent to diameter B that you will not peen.
(2)Use C04-271  S110 steel shot.
(3)The peening intensity must be 0.006-0.012N in the repair area.
(4)The minimum coverage must be 125 percent.
(5)Remove the masking tape from the aft rotating seal.
Subtask 72-58-45-160-007
J.Clean the aft rotating 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 72-58-45-340-007
K.Thermal-spray the aft rotating seal and the test specimens. Refer to TASK 70-49-00-340-001 (THERMAL SPRAYING), TASK 70-49-32-340-033 (THERMAL SPRAYING INCONEL 718 (POWDER)), Subtask 72-58-45-220-027 (paragraph 3.A.), Figure 904, and as follows:
NOTE:
Overspray is not permitted out of diameter B.
(1)Make sure to apply C10-012  masking tape to all the surfaces adjacent to diameter B that you will not thermal spray.
(2)Make sure that you do the preliminary operations specified in TASK 70-49-00-340-001 (THERMAL SPRAYING).
(a)Use the surface roughness limits for the nickel base material.
(3)Thermal-spray the aft rotating seal repair area and the test specimens as follows:
(a)Apply a sufficient quantity of thermal spray coating to permit you to machine to get the finish dimensional limits.
(b)The maximum as-sprayed coating thickness must be 0.015 inch (0.38 mm).
(c)Apply thermal spray coating to the test specimens and to diameter B at the same time, same spray angle, and to the same thickness.
(d)The minimum coating thickness after final machining must be 0.004 inch (0.11 mm).
(4)Remove the masking tape from the aft rotating seal.
(5)Do a tensile bond test and a metallographic examination of the coating on the test specimens.
Subtask 72-58-45-320-003
L.Machine the aft rotating seal diameter B to the finish dimensions. Refer to TASK 70-00-03-800-004 (MACHINING DATA), Subtask 72-58-45-220-027 (paragraph 3.A.), Figure 901, Figure 905, and as follows:
Subtask 72-58-45-350-015
(1)Set-up the aft rotating seal for machining. Refer to Subtask 72-58-45-350-009 (paragraph 4.A.).
Subtask 72-58-45-320-007
(2)Machine diameter B and the chamfer to the finish dimensions. Make sure that the minimum coating thickness after final machining is 0.004 inch (0.11 mm).
(3)The surface finish of diameter B must be 63 microinches (1.6 micrometers) or smoother.
(4)Remove the aft rotating seal from the machining fixture.
Subtask 72-58-45-220-031
M.Do a visual inspection of the thermal spray coating on the aft rotating seal diameter B as follows:
(1)Chipping, flaking, and separated coating are not permitted.
(2)The thermal spray coating must have equal and full coverage in the thermal sprayed areas.
Subtask 72-58-45-160-006
N.Clean the aft rotating seal. Refer to TASK 70-21-00-110-051 (CHEMICAL CLEANING) and TASK 70-21-03-160-001 (CLEANING METHOD NO. 3 - STEAM CLEANING).
* * * FOR ALL
Figure 901   (Sheet 1 ) No. 4 Bearing Aft Rotating Seal - Repair Area
* * * FOR ALL
Figure 901   (Sheet 2 ) No. 4 Bearing Aft Rotating Seal - Repair Area
* * * FOR ALL
Figure 902   (Sheet 1 ) Locally Manufactured Machining Fixture
* * * FOR ALL
Figure 902   (Sheet 2 ) Locally Manufactured Machining Fixture
* * * FOR ALL
Figure 903   Setup for Machining
* * * FOR ALL
Figure 904   Masking for Shotpeening and Thermal Spraying
* * * FOR ALL
Figure 905   Final Machining Requirements