Corocion Control Manual 5f6u5d

~-Io1-I MOLD BULKHEAD HOLE DIA.

ID

A

(IN.)

MOLD

MOLD

MOLD OD

(IN.)

DEPTH

(IN.)

(IN.)

THICKNESS

B

C

D 1/2

1/2-3/4

1-3/8

1-3/4

3/8

3/4-1

1-3/4

2-1/4

3/8

1/2

1-1

2

2-1/2

1/2

3/4

1-1/4-1-112

2-1/2

3

1/2

3/4

1-1/2-1-3/4

2-314

3-1/4

1/2

3/4

1-3/4-2

3

3-1/2

1/2

3/4

1/4

(IN.)

ALL DIMENSIONS +1/16 IN.

Standard Cup Molds

Figure

6

WIRE BUNDLE

HOLE IN CENTER

SEALANT FILLING HOLE

CUP MOLD

Cup Mold Preparation Figure 7

20-20-54 Page 6 Aug 31/84

o

COPYRIGHT, 1984 BY SABR ELINER CORPORATION

SR-76-023 CORROSION CONTROL MANUAL

NO SPOT TIES

WITHINBIN.OFTHE

n I

/U CONNECTOR SHELL

tt---

SEALING*REA

Sealinff Between Wires Fiffure 8

20-20-54 7

COPYRIGHT, 1984 BY SABRELINER CORPORATION

Aua ~1/84

SR-7(i-023 CORROSION CONTROL MANUAL

SEALANT INJECTION HOLE

5

DUST CAP MOLD

6 ii

CONNECTOR SHELL

WIRE BUNDLE

CONNECTOR SHELL MOLDS

HOLE CLAMP

SEALANT FILLING HOLE

MOLD

HOSE CLAMP WIRE BUNDLE

MOLD CAVITY

CATERPILLAR

GROMMET

BULKHEAD

BULKHEAD MOLDS

Typical Mold Installations Figure 9

20-20-54 Page 8 Aug 31/84

o

COPYRIGHT, 1984 BY SABRELINEA CORPORATION

SR-76-02~ CORROSI()N C()NTHOL MA~iUAL

SEALING ELECTRICAL WIRE BUNDLES ING THRU BULKHEADS (Continued) Injt´•ctina Sealant

into Mold

(Cont’d)

(:urinR may be accomplished at room temperature(7Ti to 80"F) for a period of 24 hours or in a circulating air oven for 1 hour at 130 to 1400F

under heat radiation from 30 minutes at 130 to 140"F. The usable work life of the material after mixing is 1-1/2 hours. The wire bundles must not be disturbed durinR the curing periotl. or

carefully regulated heat lamps for

After the sealant has cured,

carefully

remove

molds.

The dimensions of the final seal must conform to

figure

5.

The cured potting compound should be free from cracks and have a smooth, clean surface. Surface holes or bubbles smaller than 1/8 in. diameter are acceptable.

When bubbles andlor holes larger than 1/8 in. diameter present on the surface of the sealant, remove the top of the bubble with a knife or razor blade taking care not to cut the wire insulation. Fill the bubble openings and/or holes with sealing compound. Very large bubbles may be filled by making two holes in the bubble, injecting sealant into one hole and allowing the air to escape from the other. Corks may be necessary to plug the injection holes. are

The

compound should adhere firmly

to the

connector shell and to all wire insulation

Th e

com

pou nd

com

bulkhead

or

except Teflon.

pletely encases Teflon wi re i nsulation.

When small

a new wire is installed in a bulkhead seal, use a Phillips head screw driver of similar blunt tool for puncturing the seal to provide a hole for the wire. No atid i tion al seal i nR i s generally req u i red.

NOTE Luhricants should not be used on new wires installed in bulkhead seals. When

a sealed wire bundle leaks inside the bundle or an added wire fails to seal, it is necessary to reseal using a small tipped polyethylene nozzle to inject sealing compound between and around the wires where they exit from the origi nal seal. Spread the wires apart for this operation.

20-20-54 0


Page 9/10 Blank Aug 31/84

Sft-’lfi-Of?3 C()HH()SI()N (:()N’I’R()I, MAIVIIAI.

SEALING ELECTRIC TERMINATIONS SUBJECT TO TEMPERATURES UP TO 300"F (;ENERAI, ’I’his section

Sealant Mixing and Handling

the I,otti~lff compounds for´• From -65 lo:J00011’. covers

preparation and application of use in electrical terminations

MA’rERIALS

Nal,htha Ketf primer. Vulcabond

TT-N-SFi Stabond Corp.,

GHrdena, CA

vloz

I’ro-Tek 1Iand (:ream

nu Pont

(:onlpountl.. I’otting.

11R()120-0()6

~leclrical, (;eneral

Purpose EC~IIII’MENT Pressure (;un, No. 250 Cartridge, No. 250-C6 No~zle, No. 250-4-2

Semco Inc, Los Angeles, CA

Safc!ty Ol,sclrve safety precautions for the handlingof flammable anti tiangerous chemicals. Workers engaged i n the mixing or cleaning operations should be furnished with rubber gloves or i’ro-Tek Hand Cream.

A fter the solder I,ots inside the connector shell have been clhockctl to make certain that the wires ar´•c~ properly

r,lace and th;il no plastic tubing has been over thcnl (which would r´•csr~lt in a I,oor seal), r(tlnOVc;lll excess rosin from soldei ts with a small, sliTi brush using na,hthaa as a cleaning agent. Solder ts showing evidence of corrosion must be cleaned. soltlcrod irt

Remove antiseize

If the potting compound is to be cured at a temperature above 90"F, preheat the connectol´• assembl!´• immediately before potting for at least 10 minutes at a tempel’ature within 100F of the cure temperature. Position connector (plug or receptacle) in a suitable holding device or Jiff-board with the shell backskirt opening facing upward. Insert injection nozzle of the pressure gun between the wires near the lower central area of the wire bundle (just above the open i ng´• of the ~hell

I’r´•aration

shell threads with

When tl-ie compound is supplied premixed and flazen, allow the compound to warm at r´•oom temperature for 30-50 minutes before use. After the warmup period and before the compound is inserted in a pressure gun. \\ipe the outel´• surface of the tube of potting compound u.ith a clean, dry cloth. SEALING PROCEDURE:

INSTAI,I,ATION NOTES

C:onnec:tor

Use an air-driven mixing machine operated at 60 ~’l,nl or’ less (to prevent overheating and the introduction of air) for mixing. After mixing 10-16 minutes, visually inspect to make sure that no particles of acceleratol´• are left undispersed in the mixture. If hand mixing is make certain that the accelel´•atol´• is evenl~´• throughout the compound and that air is not introduced by rapid stirring or by a folding action. Hand mis fo~´• 15-20 minutes using a spatula. Only sn7all quantities should be mixed by hand.

backskirt). Fill the plastic mold or backshell slo\vl!´• n´•ith potting compound, taking care to avoid the enti´•ap~nent of air.

compountls or lubricants on the backnaphtha before wir´•es are installed in

the connectors.

a

min

Temperature (+50F) 70

(:lean assembled connectors by immersion in naphtha for 2 minutes. Agitate solvent during the immersion period, Drain excess naphtha from the connectors, and allow them to dry for 1T, minutes. For connectors with back-

shells, allow

A ftel´• the connectors are potted, they must be mai ntainetl in a vertical position to prevent leakage until the compound has cured. Cure potting compound by heating the potted connector at any one of the following temperature schedules:

drying period of

~O minutes.

Minimum ?‘ime 24 hrs

120

3 hl´•s

140

2 hrs

Ihr

160 200

30 minutes

270

15 minutes

Yl,ray or brush one coat of Vulcabond V-102 red primer the back surface of resilient inserts in electrical on co n nectors. Allow pr´•i mer to d ry at room tem perature for at least 30 m i nutes or force dry under a heat lamp or in an oven at a temperature of 120 to 1400F for at least Fi minutes.

20-20-56 0


Page 1 Aug 31/84


SEALING ELECTRIC TERMINATIONS SUBJECT TO TEMPERATURES UP TO 300"F (Continued)

SE:AIIIN(; PROCE:I)I~KE:

(C:ont’d)

The cured potting compound should be free from cracks, have a smooth clean surface, and adhere to the metal and plastic porti ons of the connector, backshell, and all wiring except MIL,-W-713Y wiring. The compound should completely enclose MIL-W-7139 wiring. Integral molds should have sufficient adhesion to add structural to the potting compound. Air bubbles along inner mold walls that do not project more than 1/16 in. into the potting compound are acceptable. The exterior surfaces of the connector shall be free from If bubbles

or

holes with

a

potting compound.

diameter of 118 in.

or more are

present on the surfaceofthesealant,removethetopofthe or hole with a knife or razor blade, taking care not the wire insulation. Fill openings with potting compound and cure.

bubble to cut

or bubbles greater than 1/8 in. diameter are present in the body of the potting compound, the connector must be reworked. Holes or bubbles 1/8 in. diameter or less in the body of the potting compound or large bubbles or holes in the surface that cannot be filled must also be

If holes

reworked i.

as

follows:

itemove the mold (by cutting away if necessary) backshell.

unsatisfactory material, taking damage the wire insulation.

Cut out the to

3.

Install

4.

Repotthe

a new

mold

or

care

or

not

backshell.

connector.

20-20-56 Paae Aug 31/84

o



SEALING ELECTRICAL TERMINATIONS SUBJECT TO A MAXIMUM TEMPERATURE BETWEEN 300 AND 400"F GENERAL

INSTALLATION NOTES

This section covers materials and procedures used in preparing and applying potting compound to protect electrical terminations from moisture, corrosion. and other damage caused by metal particles or liquids found in air´•cr´•aft.

Potting compound LB0120-007 is suitable for continuous operation throughout a temperature range of -65 to

MATERIALS

Work area

must be properly ventilated with adequate fi re prevention provisions.

Naphtha. Petroleum Aliphatic (;I´•ease. 4ir´•craft Instruments Compound; Potting, Electrical

TT-N-9,5 MIL-C;-X278

Mixing

or cleaning operations require rubber gloves or Pro-Tek hand cream to facilitate easy removal of compounds from hands and prevent the cleaners from causing

LB0120-007

dermatitis.

High Temperature Pro-Tek Hand Cream

DuPont Company

This Dotting compound is a one-component material. No curing agents or accelerators are added and no mixing is

EC~UIPMENT

required.

Sealant (;un. Model No. 250,

Semco Sales ce. Service, Inc. Semco Sales Sr, Service. Inc. Semco Sales ~ Service, Inc. Met-L-Chek

equivalent Cartricl~e. No. 250-6 or

Nozzle No. 420

P1´•ogellon Spr´•ayer,

+400"F. (FA2-54 and FA2-90 are used where max temperatures do not exceed 225 and ~OO"F respectively.)

or’

equivalent

Remove entrapped or, dissolved air and gases by applying a m in 89 in. of vacuum inegative 14 psi gage) to the potting co m pou nd for a m i n o f 2 hours. The i n itial vacuum should be applied slowly so that the compound does not froth over the edge of the container. The compound has a tendency to ex pand du ri ng vacuum ap p licatio n so it may be necessary to use half filled containers to ensure no overflow. At the entl of the vacuum application, allow atmospheric air to slowly enter the vacuum chamber to prevent a turbulent

Western Co.

oo NOT GREASE INTERNAL

CONNECTOR THREADS

7\

c APPLY MIL-G-3278-

DO NOT GREASE

GREASE TO EXTEANAL

"C" RING SEALING

CONNECTORTHREADS

SURFACEOFCONNECTOR

Assembling Connector Figure 1

20-20-58 0


Page 1 k;, :7/84

SR-76-0 CORKOSION CONTROL IMANUAL

SEALING ELECTRICAL TERMINATIONS SUBJECT TO A MAXIMUM TEMPERATURE BETWEEN 300 AND 400"F (Continued) INSTALLATION NOTES (Cont’d)

grease from coating the connector. (See figure i.)

mixing of compound and incoming air. Store vacuum processed potting compound in tightly sealed friction lid containers prior to use.

O-ring sealing surface of the

Cured potting compound is free from cracks and has a smooth, clean surface. Surface holes or bubbles smaller than 1/8 in, diameter are not cause far rejection.

Tht´• stor´•age I ife of potti ng com pound LB0120-007 at room temperature is a max of 9 months. The storage life at +~F;"F is in excess of 1 year. The compound should be stol´•ecl in a cool place away from direct sunlight, ovens, and other sources of heat.

The compound should adhere to metal and plastic portions of the connector and backshell and completely enclose the wires. Lack of adhesion to the outer edges of the shell back skirt or backshell is not cause for rejection.

The storage I i fe of primer at room tem perature is a max of 4 months. The storage life at +~50F is a max of 8 months. The primer should be stored in tightly capped containers at a tempel.ature of O to 400F to obtain max storage life.

SUPPO’t

Exterior surfaces of the connector must be free of potting

A fte I´• the

al,pl!´•

a

potti nff o peration has bee n com p leted. carefu lly thi n coating of grease to the external

connectol´•

threads with

a

Integral molds have sufficient adhesion to add structural to the potting compound. Air bubbles along inner mold walls which do not project more than approximately 1/16 in. into the potting compound are not cause for ’ejection. compound. If holes or bubbles greater than 1/8 in, in diameter present, reject the connector.

stiff bristle brush. Prevent

are

’r

´•(5’.* t~ ´•C´•´•´•´•~.´•L,´•.

MAXIMUM ALLOWABLE

EXCESSIVE SPONGING

SPONGING

Connector Potting Figure 2

20-20-58 Page 3 Aug 17/~1

o

COPYRIGHT, 1984

BY SABRELINER CORPORATION


SEALING ELECTRICAL TERMINATIONS SUBJECT TO A MAXIMUM TEMPERATURE BETWEEN 300 AND 400"F (Continued) INSTALLATION NOTES (Cont’d) If excessive

indicated by

sponging of the compound has occurred, as numerous small holes greater than 1/16 in. sealant overlflow in figure 2, reject the

Bubbles and/or holes larger than 1/8 in. diameter on the surface of the sealant may be reworked by removing the top of the bubble with a knife or razor blade, taking care not to cut the wire insulation, Fill the bubble openings and/or holes with sealing compound and cure. If excessive

opening

sponging

or

large holes

occur, or

if

hole

a

or

is present which cannot be

filled, the connector shou Id be reworked accordi ng to the fol low i ng procedure: Remove the mold or backshell (by cutting away, if necessary) and cut out the unsatisfactory material, taking not to clamaae the wire insulation. Install t,ackshell and repot the connector,

care or

a new

mold

15 minutes. For connectors with backshells. allow 30

minutes min

drying period.

An alternate method of removing solder resin and of cleaning the connector is to use a solvent spl´•ay gun adjusted to give a stream of naphtha under a pressure of 40 ~10 psi. After solvent spray cleaning, allow excess naphtha to dry for 15 minutes. For connectors with backshells, the minimum drying period is 30 minutes. P’imer Application

Apply primer with a Propellon or other sprayer which produces a fine, narrow-spread, mist-type spray. Hold nozzle of the spray applicator within one and one-half inches ofthe backshell or wires during primer application to ensure complete coverage. Apply primer to the shell back skirt walls, to the solder pots, and to the ends of the wires for´• a distance of 1 in. from the solder pots. Take care to prevent primer from leaking through connector and coating electrical pins and sockets in the front skirt.

SE~LIN(; PROCEDURES Connector Preparation Check connector solder pots inside the shell to make certain that the wires are properly soldered in place and that no plastic tubing has been installed over them. An inferior seal will result if plastic tubing is allowed to remain over the solder pots. The depth of potting compound over the ends of the wire insulation extends a minimum of X;~f in. Remove ull e~cess reuin From solder ts with ~ciff bristle brush and naphtha.

in connector. After connector assembly, clean connector by immersing in agitated naphtha for two minutes. Drain excess naphtha from the connectors and allow to dry for

a

small,

Se"ling

Connector

Immediately prior assembly for

a

min

of "7Fi~lO"F.

to potting, preheat the connector period of 10 minutes at a temperature

Place connector (plug or receptacle), ~iith shellback skirt opening positioned up, in a suitable holding device or jig-board.

Place the injection nozzle of the pressure gun between the wires near the lower central area of the wire bundle. (See

Clean any solder ts showing evidence of corrosion, Remove any anti-seize compound or lubricant present on backshell threads with naphtha prior to installing wires

figure 3.)

PLASTIC MOLD

Sealant Injection

Figure

3

20-20-58 0

COPYRIGHT, 1984 BY SP SRFLINER CORPORATION

Page 3 Aug 17/84

CORROSION CONTROL MANUAL

SEALING ELECTRICAL TERMINATIONS SUBJECT TO A MAXIMUM TEMPERATURE BETWEEN 300 AND 400"F (Continwed) Sealing Connector (Cont’d)

Slowly fill the plastic mold or backshell with potting compound. Avoid air entrapment. The spot tie nearest the connector should be installed after potting compound application and before curing occurs. Sealant Cure After connector is to

potted, maintain in

a

vertical

position

prevent leakage until the compound has cured. Cure

potting compound

at 275 +100F for 1 ~0.1 hours.

20-20-58 Page 4 Aug 17/84

o

COPYRIGHT, 19a4 BY SABRELINER CORPORATION


APPLICATION OF SEALANT TO ELECTRICAL WIRE BUNDLES ING THROUGH BULKHEADS FOR MAXIMUM SERVICE TEMPERATURES FROM 350 TO 500"F

GENERAL This section covers the materials and process to be used for application of sealant to bundles of electrical wires ing through bulkheads and s. The sealing m ate ria I is su itable fo r conti n uous operation th roughout a mas

temperature range of:~50

to

Fj000F.

A minimum Shore A hardness evidence of cure.

reading

of 85 shall be

If it is necessary to disassemble any component part which was previously sealed, or for any other reason, to rework damaged sealant, clean off all sealant, touch up damaged finishes and coating, reassemble. reprime, and seal.

MATERIAL LB()120-0:51

Areas to which sealant has been applied shall be protected from stress or´• contamination until sufficiently cured to resist normal assembly environment.

Elastomeric Fire Wall Sealant

INSTALLATION NOTES A reas to be sealed shall be clean, dry, and free of foreign material which can reduce the adhesion of the sealing compuntl. Immediately before priming, all areas to be

shall be cleaned by wiping with a suitable hydrocut´•t-,on or halogenated hydrocarbon solvent, which will not adversely affect tl;e other materials. Solvents containing halogens shall not be used on titanium

The dimensions of the applied sealant shall conform to figure 1 or 2 as applicable. a

A reas to be sealed shall have

a

thin film

(approximately

().()()I in.) of primer applied to all surfaces, T he I, r i me r´• shall be allowed to air cu re for one hour before application of the sealing compound. I~oom

Wire bundles ing through bulkheads shall be protectecl prior to sealant application to prevent damage to the wire insulation.

The c:ured se;tlA.nt shall be free of cracks and shall have smooth, clean surface. Sur´•face holes or bubbles greater than 1/8 in. diameter are not permitted and should be removed during sealant application.

Ytr~uctures.

.~t

SEALING PROCEDURES

tempernti.ire, the ~ealant shall be

appiiecl

The sealant shall adhere firmly to the bulkhead and connector shell and to all wire insulation.

~vithin

ir~ \.~´•ol´•!e life.

BULKHEAD

NONPRESSURIZEDSIDE --cl

PRESSURIZED BAY SEALANT SCALANT

BbOT

(Typlcal)

111 WIRE BUNDLE

DIA0.12

IN. MIN.

1/32 IN. NOMINAL

SEALANT BUILDUP

A´•0.251N. MIN. TO 0.35 IN. MAX. AVG.

DETAIL B

DETAIL A

Booted Sealing Bulkhead Feedthroughs

Figure 0


1

20-20-60 Page 1 Aug 17/84


NON-PRESSURE SIDE ~I

~e EMP SHIELDED PRESSURIZED BAR

SPLIT FITTING ASSY.

60% WIRE BUNDLE

1/2~1/81N.

A

COVERED WITH HALAR SLEEVING

TY-WRAP LB0120-031 SEALANT I

LB0120-031 SEALANT

FLUOROSILICONE LB0120-031’ SEALANT

I

I

POTTING DAMS

SEALANT ENTRV HOLE

A

0.12 IN. MIN

0.12 IN. MIN

A

0.25 IN. MIN TO

A

0.35 IN. MAX AVG

0.35 IN. MAX AVG

DETAIL B

DETAIL A

20-20-60

0.25 IN. MIN TO

Sealing Split-Fit~ing Bulkhead Feedthroughs Figure 2

Page 2~

Aug 17/84

o

COPYRIGHT, 1984 B’r SABRELINER CORPORATION


ORGANIC BASE AND FINISH COATING MAINTENANCE PRACTICES Non-woven, Non-metallic Abrasive Mats, Type I,

APPLICATION OF POLYURETHANE INTEGRAL FUEL TANK COATING

application of pol~u´•rethane ´•integral

The

fuel tank coating involves materials and operations that are haxardous, Thefollowing ccczltions should be observed:

PolUurethalre components contain flalnmnhle solvents and should 6e mized and applied only in well ventilated areas where there

are no

openflames,

Personnel 7nizing or applying polyurethaneshould wear chemical cartridge respiratorv and protective clothing.

ilir´•plunes r´•ecei~uiny yolqlllrethane should static b.U.ild-1L~ be Qr´•o´•u´•ndecl to spraying operations, no

not

allow

polyu~r´•etha7Le

to

come

in

eyes. In, case of skin , wash with soap and U)ater. -Jn´• case con.taet witk skin

of

or

irnmediatel~y wash eyes for then get medical attention.

eye ,

15

Wusk hands befo´•re eating

or

smoking.

Polurethane integral fuel tank coating is a two comI,c,nent catalyzing material that is fuel resistant and

inhibiting.

3M Co.

Class Z or 2, Grade A or Finer, Scotchbrite MIL-A-9962 Turco Products

Cleaning Compound, Aircraft Surface Alkaline Waterbase (Air Tech No. 19) Neutral Paint Remover. No. Tj,Fj1 Paint Straining Funnels Cheesecloth Tack Rags, No. GR-99 or

equivalent Rubber Cloves (Rubber Base

Turco Products

Commercial Commercial Bostik Div., UMX Corp. Commercial

or

Nylon) 400 Grit

Commercial

Wet-or-Dry

Abrasive Paper

Tape, Masking (:3M No. or Mystik No, 62:!0 or equivalent,

2Fj0

~M Co.

or

Mystik Co.

Commercial

Chemical Cartridge

Respirator (Wiison Model No. 1200 with No. R21

Cartridges) Glasses. Goggles or Face‘ Shields. Safety Fiber Brushes or Tampico

Commercial Commercial

Brushes

SIate,´•ials Surface

Pnlvurethane Coatings for Integral Fuel Tanks, No. 132’i2<376 (Kit) Trichloroethane, i, i, i, Technical. Inhibited,

DeSoto Chemical Co.

Commercial

~[t´•thvl 1~thvl Retone

Commercial

~solve. Etch Solvent. No. ()20-~38 Naptha. Type II. TT-N-96 Lacclue,´•. Thinner. TT-B-266 ?-:ler, K1´•aft. Untreated Wrapping, UU-P-268

DeSoto Chemical Co.

Preparation

Integral fuel tank coating shall be applied over surfaces that have been properly surface treated. All surfaces to be coated shall be free of foreign material. If necessary, surfaces shall be wiped with a clean cloth dam pened with MEK. then wiped dry. Surfaces shall be coated within "4 hours and must be suitably protected from dust anti handling until they can be coated. Mixing of Polyurethane Integral Fuel Tank Coating

Commercial Commercial Commercial

Polvurethane integral fuel tank coating is a consisting of a base material and

ponent system

two coma

catalyst.

NOTE Do not intermiz product components of one ´•manufacturer with product components of another muanufacturer. Tile components will stot intermiz.

20-30-00 0

COPVC)JGHT, 1984 BY SABRELINER CORPORATION

Page 201 Aug 17/84


MAINTENANCE PRACTICES (Continwed) Mixing of Polyurethane Integral Fuel Tank Coating (Cont’d)

Strain material.

Coating

mixture

NOTES Use ofthinners other than those speci~fied by manufacturer may result in poor adhesion qualities.

1.

Temperature of the components 600F(160C) before *rL´•iz´•ing.

Pressure circulating system with material hose not to

2.

When nzizing, ´•u.re the batch of the base material and catalyst supplied as a kit, IVever suhstitzcte the catal7JstSrom another hatch,

requires continuous agitation to mainThis requirement can be accomplished

exceed 5 ft.

Agitation

pressure pot with material hose not to

exceed 5 ft, Pressure cup or suction shall be kept under agitation by hand or mechanical stirrrin~.

must be

NOTE

above

Mix the components as follows: agitate the base component while slowly adding the catalyst. Mix quantities less than complete kits by weight only. Spray application mixinK ratios are as follows:

When painting has ceasedfor more than 10 minutes it is mandatory to bleed out the material in the line. Mat pot l´•i~Lfe of spray material is 7 hours at temperatures of 7riOF. Discard any unused catal7Jxed

Product

material.

Component

Volume

Weight

Base ~Material No. Y2’iX~S6

1 parts

Catalyst No.

Ipart

100.0 parts 22.5 parts

010-702

Allow ix material to

chemically

react

Coating Application

for 30 minutes,

then add:

Thinnet´• No. 020-707

´•1 parts

0:3.7 parts

The application of polyuretiLane integral fuel tank coating involves materials and operations that are haxardous, Thefolloao-

ing cautions should be obsermed: NOTES

PolyzLrethane components contain fla~-

;If%P)’ C’hela.jL’(Lb I’RCLCtjl).n and th´•inn´•ing, ,´•esti,´•

mahle solvents and should he m´•izecl clrcd in well ventilated al´•ens where there art! no open~larnes.

applied o´•nly

use.

C:YF oS th.i.YL.YLe7’R othel´• than those spec´•i~iacl bl NLa´•n~uJ’acturer ma~l/ result in poor adhesion gualit´•ies.

Brush application mixing ratios Product

Component

are as

Thinnel´• No. 0$0-7017

follows:

Volume

Base Material No. 82’iIi:376

(I’:ltal!´•st No. 911)-702

Personnel miz´•ing 07´• appl:l/ing poly´•urethane should wear chemical cartridge ~respirators and protective clothing,

parts 1 part 1 part

Airplanes receiving polyurethane should be grounded to prevent static build-up during spray´•iny operations.

Weight 100.0 pal,ts 22.s parts Iti.l) pat´•ts

Do

allobo

polllureth.nnt,

to

come

in

eyes. IrL case of Nki~vL leash wz’th soap and ´•wcctel´•. In case or

, eye , immediately luauh eyes for 15 minutes then get medical attention.

NOTES .-lllo´•lo nclm´•ilr: to Fhelnicnll?j react ~rL´•I´•rL´•utes. Stir ´•Nlaterial before

1Lot

with Sk.in

of for

SO

Wash hands befo7´•e eating

C’se of thilzne´•rs other than those by mnazufacturer may result in poor adhesion ryualitiea

or

smoking,

Spray apply light wet single coats (1-2) to eChievd an optimum total dry film thickness of 0.23-1.5 (+0.5, -0.3)

20-30-00 Page 202 Aug 17/84

o

COPYRIGHT,

1984 BY SABRELINER CORPORATI(J;V

SR-76-023 CORROSION CONTROL IMANUAL

MAINTENANCE PRACTICES (Continued) APPLICATION OF EPOXY-POLYAMIDE PRIMER

Coating Application (Cont’d) Mils. Runs, sags. and grit are not acceptable on finished surface. Drying or curing time at 600F, relative humidity 40-800~ is 20 hours min in a well ventilated room, or air dry for 20 minutes, then use a hot-air type ground heater and bake at 120 to 1450F for a min of 1 hour. The ultimate cure at air dry, relative humidity 50-80% is 14 days. When touch-up applied by brush, apply one uniform wet coat,

The application of epox´•1/-polyamide primer involves materials and operations which are haxardous. The following precautions sho2Lld be ohselved:

Apply epozy-pol´•yamide primer only vhen adec)uate ´•clentilation is available.

Adhesion Test

Wet Adhesion

Tape Test

cnmei´•nwith

The applied coating shall be capable of ing the wet adhesion tape test after ultimate cure or at the timetempel´•ature conditions specified for exposure to fuel or traffic in table 201. Coating Cure Schedule.

shin and eyes. IrL case of shin , wash with soap and water. In case of eye , immediately wash eyesfor 2 .5 minutes then get medical attention.

Solvent Wipe Test

Donotingestorinhale vapors, Wash hands before eating or smolcing. NOTE

Surface Preparation Surfaces to be primed must be thor´•oughly cleaned before application of primer coat. In instances where primer is being applied to bare metal (chemical conversion coating or anodized coating damaged,’, the bare metal must be treated with the applicable chemical conversion coating. All areas/parts to be primed must be thoroughly dried after cleaning and/or chemical conversion treatment. Parts or areas shall be primed within 24 hours and must be suitably protected from dust and handling until they can be pr´•imecl.

This test rrLall be performed on process co´•rLt´•rol s cleaned and coated in, conw´•ith detailed parts. An adhesion cure test shall be made using the solvent wipe test after the applied catalyzed coating has reached ultimate cure in accordance with table 201. Saturate a p iece of cheese cloth with ME K. Wipe a selected area with at least 50 double strokes using moderate hand pressure. If coati ng material is dissolved or removed from substrate. coating is considered as failed and unacceptable. A slight Jtai n evident on cheese cloth will not be cause for rejection. Table 201.

Coating Cure Schedule

EXPOSURE

TEMPERATURE

"F

Ultimate Cure

air Dry

50-80

For´•ce Cul´•e 120-145 plus ~ir Dry

~O-dO

;Days

.50-80

7

RELATIVE HUMIDITY

Ambient Cure 60 (Min)

Days Hours

1 Hour

Force Cure 250 Fuel or Traffic

14

2

Force Cure I"" ~v-;vv

plus Air Dry

TIME MINIMUM

Days

30 Minutes 40-80

20 Hours

Force Cu;´•e 90-115

6 Hours

Force Cure 120-145

1 Hour

20-30-00 0


Page 203 Aug 17/84


MAINTENANCE PRACTICES (Continued) Mixing Epoxy-Polyamide Primer The

epoxy-polyamide primer is a two-part system consistiny of a primer base and a catalyst; along with a specific reducer/thinner which is applicable to a particular manufacturer’s

product.

the materials to enter into chemical reaction. The epoxypolyamide primer should only be mixed in the amount that can be used in an 8-hour shift. Discard, regardless of appearance, all material that is 8 hours old.

Spraying Epoxy-Polyamide Primer

5mBliRB

NOTE

ElanszJ-pol?Jamide primer base material and/or catalyst from one manufacturer

The temperature of the mixed primer and the surface of the area/part to he primed should be between 60 to griOF. (1 6 to 5.50C).

mlust not he 7n´•ized luith the base material

and/or catalyst from another rrLanufactu´•rel´•. The 7naterials

are

not

compatible.

After the mixed epoxy-polyamicle primer has been allowed to stand for the reyuir´•ed 1 hour´•s, spray a box coat (spray Run es at 9()0 to each other) to a dry film thickness of 0.6-0.9 mils. Allow the primer to airdry for at least 1 hour before handlingor stacking. If a second coatof primer is to be applied, allow 1-2 hours between coats. Ifa top coating is to be applied over the primer coat, allow the primer to air-dry for a min of 3 hours before application of the top coat. Primed surfaces requiring touch-up must be cleaned using MEK prior to the recoatina of the damaged or bare area.

Establ´•ished 7~izing ratios must be followed closel~y; otherwise the primer will ezhih´•it zcnuatisSactor7J film properties, such as poor adhesion, poor chemical

resistance,

or

´•inadeguate drying. NOTE

Tenr~e´•ruture of components shall be u IrLb7L~inzuns of 6()"F (16’OC7) before mizi´•ng. primer is mized in the ratio of 1 volume qfprimer base to I volume ofp´•m’nzer catalyst, then thinned by ap´•prozi~rLatel;l! I uolu´•m~e of manuSacturer’s

Application

.rpuc´•i~ied reducer!thinner.

Thoroughly stir the primer base material until the piymunts are completely clispersetl. ~Ieasure and pour the t’rtl II i retl amount of the stirred primer base material into a clean container capable of holding at least ii times the voiume of the primer base material. To the primer base add an equal amount, by volume, of thoroughly mixed pri mer catalyst while constantly stirring the primer base material.

of Zinc Chromate Primer iTT-P-17G7)

Zinc chromate primer is a.singie component, quick drying primer that can be applied by either spray or brush. Because the pigment in zinc chromate primer is heavy and settles rapidly, the primer must be agitated continually during application. The surface to be primed must be thoroughly cleaned or chemically treated, then tho’’oughly dried prior to the application of the zinc chromate primer. Partsisurfaceu which are not to be primed immediately after cleaning should be protected from dust or other contaminants.

Prepare zinc chromate primer by thoroughly mixing the primer in the original container until the pigment is thoroughly dispersed. For spray application, add 2-2 1/2 parts by volume of toluene (TT-T-Ej´•L8) to i part by volunle of zinc chromate primer. Spraying viscosity shoultl be

NOTE Pr´•ilr~er´• catalyst must always he added to fhr C’-’’~."L".’’ bose nrcte´•r´•ial. TILis ´•pl´•ocecl?cre he! ,´•everRed.

between 15-"1 seconds ~vhen checlteci with 3 No. Za.hn areas or touch-up, zinc chromate primer can be brushed. Thin zinc chromate primer by adding 1-1 1/2 parts by volume of toluene or xyiene to 1 part by volume of primer jxylene will provide a better wet edge cup. For small

To the mi~ted materials, add volume of the manufacturer’s

approximately 1 part by specified reducer~thinner

provide a spraying viscosity of between 113-21 seconds when checked with a No. 2 Zahn cup. Stir the thinner primer and strain through two paint straining fi!nnels or or 3 layers of lint-free cheesecloth. Allow the mixed pr´•imer to stand at room temperature under agitation for a min of 1 hour before using to allow

to

Pete"tion).

Spray zinc chromate primer on surface to be primed in a single wet coat followed in about 30-45 minutes by a second

20-30-00 Page 204 Aug 17/84

o



MAINTENANCE PRACTICES (Continued) Application of Zinc Chromate Primer (TT-P-1757) (Cont’d)

"Sources of Commercial

approved polyurethane top

coat which should

bring the total dry film thickness to between 0.6-1.2 mils, allow second coat to dry for at least 30 minutes before handling, If a top coating is to be applied over the primer coat, allow the primer to air dry for’2-6 hours before application of the top coat,

Products" for a listing of finishing materials.

coat

NOTES

Polyurethanetop coatmaterialsfromone manufacturer must not be mixed with mater:alsfrom another ´•manufactzcrer; the materials will not intermix,

APPLICATION OF POLYURETHANE TOP COAT

Polyurethane top coatings aree mixed ´•in the ratio of i part 62J volume of base material to 1 part of volume of catalyst. The! application ofpol2luretha7Le top coat involves materials and operations which are haxalzlous. The following precautions should be observed,

Pol´•yurethane top coat components contain flam7nable solvents and should he mixed and applied only in well ventilated areas lohers there are no open flames, Pel:sonnel m´•ixi´•ng or applying pol~yurethane top coat should wear chemical cartridye respirators and protective clothing,

Airplanes receiving polyurethane top should be ~rounded up

to

prevent static build-

no ILot allow pol2lurethane top coat to come in with skin or eyes, In case of skin . luash zu´•ith soap and luater. In case oS e~e , immediately ´•u~ash eyes So,´• 15 ,n~in?Ltes then get medical attention.

hefore eating

o´•r

smolci´•ny.

Surface Preparation Primer

coating imperfections such as imbedded dirt, ,aised nibs shall be smoothed using No. 400 grit abrasive paper before applying the polyurethane top coat. Immediately prior to the application of the top coat, liwhtlv wipe the area with a tack rag. Do not allow the tack to lie c,n the sul´•face to be top coated, dust,

Thoroughly stir the polyurethane top coat base material until the pigment is thoroughly dispersed. Pour the required amount of the stirred top coat base material into a container capable of holding at least 3 times the volume of the base material, To base material, add an equal part by volume of polyurethane top coat catalyst and mi?e thoroughly. NOTES

coat

du´•ring spraying operations,

~ctsh hands

Temperatureoftop coatmaterials~mustbe before mixing,

above 60"F (I 60C)

o

Top catalyst must always he added to the top coat base! ´•material; the pr´•ocedul´•e shall not be reversed, coat

Pot life of the mixed polllurethane top coat is 8 hours. Materials that are over 8 hours old should be discarded. The mixed polyurethane top coat materials may be thinned for spraying by adding the necessary amount of the manufacturer’s approved thinnerjreducer to adjust the viscosity of the top coat to approximately 18-20 Seco"ds when measured with a No. 2 Zahn cup.

ol´•

~iIixing Polyurethane Top Coat top coat is a two part system consisting of a Iriate~´•iai anci a cRtalvst. along with a.specific thinnei´• apl,licabie to the manufacturer’s product. Refer to

Pol!urethane hR,c-

20-30-00 0


Page 205 Aug 17/84


MAINTENANCE PRACTICES (Continued) Spraying Polyurethane Top Coat

Preparation." Touch-up of damaged areas or scratches is restricted to that which can be repaired using a brush. Overspray from a spray gun cannot be removed from the top coat. If the damaged area cannot be touched up with a brush, it will be necessary to mask off the area at skin breaks or laps and the damaged area stripped and refinished.

NOTES The lool´•llurethane top coat is applied to surfaces which have previously been coated with epozy-polllamide primer and allowed to air dryfor at least 3-4 hours.

APPLICATION OF IMPACT RESISTANT POLYURETHANE TOP-COAT

If the primer has dried for ~4 hours or primed surface must be lightly

more, the

sanded and then cleaned as described in "Surface Preparation." When the surface is thoroughly cleaned, spray the surface with a light coat ofepolcy polyamide primer and allow to air dry for I-d hours before

application of polyurethane top

Impact resistant polyurethane top-coating is a two component system, formulated for areas which are subject to gravel/debris impingement during take-offs and landings. The impact resistant coating is also extremely resistant to humidity, fuel, oil, hydraulic fluids, and extended exposure to the atmosphere.

coat.

Apply a thin coat of polyurethane top coat to primed surfaces. Allow to air dry for between 15-.10 minutes, then apply a full wet cross coat on top coat to provide a total top coat thickness of between 3.0-3.5 mils. NOTE

Thefirst coat ofpolyurethane top coat will not dry sufficiently to be touched or handled. Care must be taken 90 that air iicij.eu do not touch the top coated surfaces between

thefirst and second to?,

coats.

Large areas to be top coated such as the top surfaces of wings or fuselages which must be walked an to properly apply the top coat, may have. the top coating applied in 1 ~et box coat (spray gun es at 900 to each other) to achieve the required dry film thickness of 3.0-3.5 mils. Areas of the top coating which will be overcoated by another color should have the edges of the second coat "feathered" to reduce the total film thickness. If the basic top coat dries for over 24 hours before being overcoated with another color, the surface must be lightly sanded with 400 grit abrasive paper, then wiped down with a tack rag before the color is applied.

Drying curing time for the polyurethane top coat is a max of 12 hours to the "dry hard" condition. Spray equipment and tools should be cleaned using MEK or equivalent thinner immediately after the application of the top coat material. Cleanliness must be exercised since the top coat materials, once cured, are extremely hard to dissolve. Surfaces requiring touch-up must first be cleaned using MEK. Contamination of any kind will cause poor adhesion, cratering, and pl-e;nature film failure. Damaged areas where the paint has been scratched or abraded to the bare metal must be treated as described in "Surface

Surface Preparation

Impact resistant polyurethane top-coat may be applied to freshly primed chem-film treated aluminum alloys, filled and freshly primed reinforced plastics, or over existing epoxy polyamide primed surfaces which have been thoroughly abraded with Scotch bright pads, Type Alter equivalent), then reprimed with epoxy polyamide primer (MIL-P-23377C). Immediately prior to the application of the impact resistant top coat, the areas to be painted should be wiped with a tack rag. Mixing Impact Resistant Polyurethane Top-Coat The impact resistant coating is a two component system which is purchased as a kit. Mix the two component (catalyst base material) plus the manufacturers recommended thinner in the following proportions: 2 parts by volume of base material (821)[398) Color 6011 1 part by volume of catalyst (910X152)

1/2 part by volume of thinner (020X722) NOTES Use only catalystwhich ´•is indicatedforuse with base material.

or

Viscositl/ should be 16-18 seconds when measured with a No. 2 Zahn cup. After mixing the base material with the catalyst, allow a 5 minute chemical reaction time before spraying the catalyzed material. Pot life of the catalyzed top coat in a closed container is 4 hours. If the container is allowed to stand open, the pot life will be shortened considerably.

20-30-00 Page 206 Aug17/84

o

COPYRIG~T, 1984 BY SABRELINER CORPORATION


MAINTENANCE PRACTICES (Continued) or all of the followign components there ´•is any possibility of paint remover : Ae~lic windows, rubber hoses, fiberglass or plastic parts, tires, and wires or wiring bundles,

Spraying Impact Resistant Polyurethane Top-Coat

any

Impact resistant polyurethane top-coat may be applied cvith conventional spray equipment using between 55-6.5 psi of regulated air. Agitate catalyzed mixture before and during use. Spray a full‘wet cross coat of top-coat material to a dry film thickness of approximately 1..5-2..5 mile. ~llow first coat to dry for 1 hour and then apply a second

Mask or protect all sealant in paint removal area. Paint remover will soften and destroy the integrity of sealant,

cross coat. Total dry film thickness of top-coat should be between 5.0-4.5 mile. Allow coating to air dry at ambient air temperature far a min of 6 hours before hantlling. Drying time may be expedited by allowing the top-coat to air dry for 1 hour, then exposing to an elevated temperature of 170-180"F for 30 minutes.

wet

NOTE Whenever possible, paint ´•v´•emovcLI p7´•ocedu´•res should be accomplished outdoors and in a shaded area. If indoor paint removal is absolutely necessary, make certain that adeguate ventilation ´•is assured.

REMOVING PAINT/PRIMER FTNISHES The removal of damaged or deteriorated paint/primer films from an airplane surface may be accomplished by either mechanical or chemical methods. The mechanical method is limited to removing paint/primer films from small ar´•eas using a motor driven abrasive brush or by hant-l sanding to "feather out" the edges of the damaged area.’ro remove damaged paint/primer films from large areas of the airplane. the chemical method of paint I´•emoval should be used. Refer to "Sources of Commercial Products" for an approved paint remover and proceed as Follows:

Chemical paint remover~ are tozic and to both sli~n cn,l´•tn´•in ingl.edients am.cl c´•~es and should be 1Lsud luith caution. R,Lhhel´• gloves, face 8h´•ields and protective clath´•lrLy must he luorrL tohile ´•using paint re~rLo2ler. I~ paint remover gets 071 the skin, wash ´•luith large cluantities of Loater. ildd soap to the water soap is rinse available. aJE~cted Freely readily with a mizture of 1 part isopropyl a.bcoh´•ob mized ´•2uith 4 parts of zuater. The speed 4f removal of remover from skin is c;x´•tre´•nLely important. Do not apply salves o´•r´• oint~LerLts. If gets into e´•lle.r, i´•narr~ed´•inteby flood eyes utith large q?ca?Ltitles 4f Luater and obtain medical aid as area

soo´•r~ as

remover to areas where paint is to be removed. Use spray or brush and apply sufficient remover to cover surface.

1.

Apply paint

2.

Allow

remover

to remain

on

surface for sufficient

length of time to wrinkle and lift the paint. This may require from 10 minutes to hours. depending upon the temperature and type of paint being removed. :3.

wet paint remover with a fiber brush saturated with remover to further loosen any paint that may be still adhering to surface.

ii.

Reapply paint remover and scrub areas where paint still adheres to surface or whe,´•e the r´•emover´• has dried on the sur´•face.

6.

Remove loosened paint and residual paint 1´•emover´• by washing and scrubbing surface with fresh watel´•. If water spray is available, use a stream of high pressure water applied directly to the surface while it is being scrubbed with a fiber brush.

6.

Use non-metallic scrapers or abrasive pads to remove any small spots of paint that the r´•emover did

Agitate

not remove.

Lis i ng c lean water., fl us h all fsyi ng surf aces and gaps where paint remover could have penetrated until it is a certainty that all paint remover and paint residue have been eliminated.

possible. 8.

Dry

area

with clean dry cloths.

1Mask allfa´•lling surface ~ts and edges that tuill come in Luith paint

prevent removerfrom entering joilzts or crevices; damage to inter´•iol´• surfaces and parts could result. Also, mask remover, to

into

20-30-00 0

COPYRIGHT, 1984 BY SABRELINER CORPOFi.’TION

Page 201 Aug 17/84

SR-76-023 C()RROSION CONTROL IMANUAL

MAINTENANCE PRACTICES (Continued) CORROSION REMOVAL/PAINT TOUCH-UP KIT

NOTE

A corrosion removal and

paint touch-up kit may be obtained from most Sabreliner Service Facilities. The kit con tai ~1R all materials and equipment necessary to remove corrosion and apply a protective finish to corrosion damaged areas of the airplane. The following procedures should be used in conjunction with the corrosion removal :Incl paint touch-up kit. i.

contained in the kit have a pot l~fe of4 hours after being activated and must be used within this time span or be discarded.

cans

10.

Determine extent and depth of corrosion deposits and/or damaged finish,

Strip all paint from the corroded or damaged finish area using a neutral stripper such as Turco 5R51 (or eyuivalent). Abrade the entire damaged pad from touch-up kit. 4.

The contents of both the eloozll poll/anride primer avid the polyurethane top coat spra?/

area

using

an

abrasive

if corr´•osion has been detected, continue scrubbing with the abrasive Dad or use the aluminum brush from the touch-up kit until all corrosion has been r´•emovetl.

Use an abrasive pad to lightly sand the primed area and to remove any nubs, dirt, etc. Be careful not to sand through the primer, If the primer is sanded

through, 11.

a new coat

of primer

must

be applied.

Remove all sanding residue by lightly wiping with or a clean, dry soft cloth.

12’

Activate spray

can

coat and

2 coats to the

apply

containing the polyurethane top primed area, allowing

15 minutes between coats.

Do not c´•zceed corrosion removal ii;n´•ite g ;i;rr iiiJCi’(l.rLb ~´•:s mrLrLs~ccl.

U~ t~UCiL upplicab ie ciLapter in

Feather out the edges of the painted ing the damaged areas. ii.

tiin~e the abraded

1V i pe the abraded i~ith ,LIEI(. 8.

area

ai´•ea

~vith clean

~vith

a

areas

surround-

~vater

and

dry

clean cloth moisteneti

if bare metal has been exposed during the abrading apply a thin coating of a chemical convel´•sion coating (Alodine 1200, or equivalent) to an all bare metal using a soft bristle brush. Allow conversion coating to remain c,, the surface for;: minl.ltes. then rinse the area with clean water. Wipe 111´•´•´• cle~n soft cloths. process,

I,.

the uan

con tents

and

~llan´• I,t´•imer

apply to

I

of the epos~

poi´•amide primer

the affected air rlr´•v for I-~ hou2´•s. cross coat

to

ar´•ea.

20-30-00 Page 2OL) Aug 17/84

a

a

tac-rag

COPYRIGHT,

1984 BY SABRELINER CORPORATION


CATI-COAT PRIMER APPLICATION GENERAL

Application

l’his section covers the application of Cati-Coat primer to the interior surfaces of aluminum integral fuel tanks

Spray a light tack coat to edges in ordel´• to insure adhesion of subsequent coats. On relatively flat surfaces, spray 2 wet box coats of primer. On surfaces with raised

MA’I’ERIAI,S

lands or com pie x be applied.

Arro (:ati-Coat Primer, 13uff

E42 N P3 Sherwin-Williams

Aero Cati-Coat

VfiG K P46 Serwin-Williams

Company Catalyst-Reducer

Company Aero Cati-Coat Reducer

R7 K P36 Sherwin-Williams

Company Wash Primer Butyl Alcohol Toluene

Naphtha, Aliphatic Cheese Cloth

Masking Tape Tack Rags Abrasive Paper (wet or dry) 320-360 grit Abrasive Pads

MIL-C-8514 TT-B-846 TT-T-548 TT-N-95 Commercial No. 250 3 M Company Commercial Commercial

3M Company

INSTAI,I,ATION NOTES

Dry coated parts by

Prior

parts ment.

Preparation

to painting, interior aluminum tank surfaces and must be anodized or given a chemical film treatSurfaces should be free of all foreign material. with a clean cloth dampened with naphtha, then

Wipe wipe dry.

During stripping for anodize or chemical film treatment, areas that require electrical bonding may be stripped to the bare metal or masked during processing. Touch up these

areas.

fiau rations, 4 one

of the

wet

I,ar´•allel

c´•oRts

rn

ay

following methods:

approximately

i.

Air dry in well ventilated 70"F for 24 hours.

2.

Air dry for 20 minutes then bake at 140 to 1500F for a min of 30 minutes.

3.

Air dry for 20 minutes then bake at 180 to 2000F for a min of 15 minutes.

room

at

The dry film finished coating thickness should be 0.0013 in, min and 0.0023 in, max measured by Model E.C.

Permascope

or

equivalent,

The finished coating should be uniform, smooth, and free from blisters, runs, alligatoring, and other visible defects. Particles larger than 1/4 in, diameter or 1/32 in, long must be removed and the surface repaired by touching up.

Touch Up

Injection sealing grooves, spot faces in the seal i ng grooves, and fastener holes do not require touch up. Repair all other areas where the coating has been damaged or metal is

Surface

con

exposed

as

follows:

Sand the area lightly to insure adhesion of the touch up coating. Clean by wiping with a clean cloth dampened with naphtha and wipe dry. Except for counter bores cut during tank assembly, apply Type I chemical film and wash primer to all exposed metal.

Nutplates and protruding screws should be cleaned and coated with wash primer prior to close out. Faying surfaces which are touched up should be air dried for at least 30 minutes before ing. Wash primer applied for touch up should be 0.0004 in, min and 0.0007 in, max.

Mixing and Handling Stir or shake primer until all pigment is dispersed. While stirring, slowly add an equal amount of Catalyst-Reducer. If additional thinning is required, add small amounts of Cati-Coat Reducer. The 1:1 ratio of primer to Catalyst Reducer must be maintained. Discard unused catalyzed

Cati-Coat.

20-30-05 a



SR-76-023 CORROSION CONTROL MANI!AI,

WASH PRIMER APPLICATION Liquid Ounces

GENERAL Th is section covers the application of wash primer used to promote adhesion of zinc chromate primer and other organic finishes to metal´• surfaces.

MATERIALS

l’i-linner, Dope and Ilaccluer, Cellulose

TT-T-266

Nitrate

Thinner, Cellulose-NitrateDope, Plush Retarding Coating Compound, Metal

MIL-T-6095

MIL-C-8514

Pre-treatment, Resin-Acid

Parts By Volume

To Make

Component

1

4

Isopropylalcohol

2

8

Butyl alcohol

1

´•I

Table Acid

1

Quart

While stirring, slowly add the thinned acid to an equal amount of resin. If necessary, the amount of alcohol may be varied but the 2:1 ratio of isopropyl to butyl alcohol shall not be changed unless high relative humidity conditions exist. The 1:1 ratio of resin to thinned acid shall not be

changed.

Mixing Kits

Solvent, Dry Cleaning ("Stoddard Solvent") Butyl Alcohol

P-D-Ci80

IsopropylAlcohol,

CommercialGrade

TT-B-846

99% Grade

One pint of resin is packaged in a quart can, allowing. ample space for adding the acid-thinner mixture and achieving the proper 1:1 ratio. Redisperse any settled pigment by stirring and shaking until all lumps are dissolved. While stirring add the acid-thinner mix to the resin.

EQUIPMENT NOT~

Spray (;un, De Vilbiss M.R.C. or equivalent Number 30 or 36 nozzle and size FJ needle and tip or

equivalent

INSTALLATION NOTES Surface Preparation All surfaces to be wash primed should be clean and completely free of other finishes.

Never odd the resin to the ac~id-thinner m~x.

Dry Film Finish The dry wash primer coating is smooth, uniform and free from runs, sags, blush and other visible defect. Dry film adhesion is such that it resists removal when scraped with the thumbnail. Dry film thickness is 0.0002 in. min and 0.0003 in,

max.

local area of wash primer by removing the defective coating and recoat. No other treatment is required. Refinish

a

damaged Mixing and Handling

primer issupplied in two forms; as a two-component product which requires mixing and thinning and as a kit which requires mixing only. Wash

Immediately after mixing, all wash primer should be The time clearly labeled "Not to be used after entered shall be 4 hours after mixing. At the end of that limcl any unused material shall he discarded.

Mixing Two-Component Product

Agitate the resin on a mechanical shaker until the pig ment is completely dispersed. Shake the acid thoroughly then mix with isopropyl and butyl alcohols in the following proportions.

or

Clean-Up Because wash primer con\erts chemically in the absence of air, all equipment used far its application must be thoroughly cleaned aftel´• ever´•y 8 hours of use. Cleaning may be accomplished with either isopropyl alcohol or methyl ctl´•iyl ketone (MEK).

Installation i’rocedur´•e

Spray a th i n, single, wet coat of wash pri mer. Viscosity of wash I,rimer for spraying is between 29 and 34 seconds Zahn 2 at 770F. Do not attempt to achieve a thin film by spraying from too great a distance. Do not attempt to get complete hiding of the surface. Both will result in poor adhesion. Each mixture described will usually provide a blush free film.

20-30-10 0


Page 1 Aug ~1/84


WASH PRIMER APPLICATION

(Continued)

Installation Procedure (Cont’d) If blushing

discontinue painting. If the blushing 20 minutes and the film resists scratching with the thumbnail, top coating may proceed. If the blushing does not disappear within 20 minutes, the coating must be stripped. The chart below shows relative humidit)l values which, if exceeded, may cause blushing. When blushing occurs the condition can be corrected by increasing the temperature, dehumidifying the air or by using a thinning mixture composed of equal amounts of isopl´•opq´•l and butyl alcohols. Do not paint at temperatu res lou~ei´• than 65"F. occurs

disappears within

Maximum Relative

Tempel´•ature

OF

65

80

70 75 80 85

7,7

F)O

95 100

Wash

Humidity

primer drying time

75 74

73 72 71 70

is 15 minutes min and 4 hours

ma~.

20-30-10 Page

2

Aug 31/84

o



MOISTURE AND FUNGUS RESISTANT COATING APPLICATION 4.

~:ENERAI, ’I’his section covers the impregnation and c´•oatinK of materials and electrical parts and assemblies with a moisture and fungus resistant varnish conforming to MII,-V-173. MATERIALS Varnish Moisture-and-

MIL-V-173

Component parts such as cable with C,lastic insulation wher´•e al,plication of coating matel’ial rrtluc´•cs insulation resistance below acceptable valut~s: capacitors (variable. air, ceramic. or mica dielrctricl types); ceramic insulators subject to 600 volts operating where danger of flash-over exists; waveguides; and materials when used for their specific are-resistant properties and classified as "are resistant."

Fungus-Resistant (for the treatment of communica-

Cleaning

tions,electronic,and

All parts and assemblies to be coated with varnish should be thoroughly cleaned as follows:

associated electrical

equipment) Thinner; Synthetic Besin

TT-T-306

Wipe parts or

2.

Remove rosin flux r´•esidues by scraping wherever feasible or by vigorous brushing with denatured alcohol, using a natural bristle brush.

3.

Z,ightly scuff sand glossy plastic parts

Cleaning Solvents

cleaning solvent should be following. The

i.

Toluene, commercial grade

2.

Approximately

one

or

more

of the

500/0 by volume isopropyl alcohol, commercial grade, 99.9%, and either naphtha per TT-N-95 or petroleum solvent

3.

Naphtha,typeI, TT-N-95

4.

Fetroleumsolvent, Stoddardsolventtype

5.

Denatured alcohol, solventgrade

I~ng´•lazed ceramic materials used in electrical applications, unless enclosed in hermetically sealed assemblies should be coated with varnish after fabrication and any firing operation. All nonmetallic materials should be coated with varnish unless enclosed in hermetically sealed assemblies or specifically excluded. Precautions, such as masking, must; be taken so that the coating is not I.

following:

portion of binding posts, connectors, fuses,

jacks, keys, plugs, relays, sockets, switches, points, and variable capacitors. 2.

Before the varnish is applied, wipe cleaned items with clean cheesecloth. No indication of residual soils, stains, or other contaminants should show.

Store varnish in a closed, airtight container when not in Discard when it becomes thickened, skinned, or otherwise affected by evaporation, oxidation, or contamination. When thinning is ,´•equired, use toluene, cOMMercial grade, or thinner, TT-T-306. use.

Applications and Limitations

to the

test

Handle parts throughout impregnation and dipping by of wires, clamps, or other suitable methods to prevent parts from ing each other or ing possible contaminants. Coated parts shall be protected against damage or contamination during transfer and means

storage. Varnish should not be sprayed when the relative humidity at a particular ambient air temperature exceeds the following values:

Surfaces which each other for electrical or magnet such as those in bearings, fingers, potentiometers, shafts; shields, variable

autotransformers, and relays. 3.

to be coated.

Mixing and Handling

INSTALLATION NOTES

applied

areas requiring cleaning with a clean cloth moistened with cleaning solvent. Dry with a clean, dry cloth. Parts may also be cleaned by immersion in, rinsing with, or spraying cleaning solvent.

1.

Enamel

Mechanical parts such as all bearing surfaces, gear teeth and gear trains or assemblies, screw threads and screw adjustments; springs except at base of pileup; surfaces whose operating temperature exceeds 3020F or will cause carbonization or smoking; transparent plastic parts, windows, and

Air

Temperature OF 90 85 80 75

70 65 60

Maximum Relative

Humidity 63 67 70 73 77 80 85

lenses.

20-30-15 o


Page 1 Aug 3 1/84


MOIST’I~RE AND FUNGUS RESISTANT %OATING APPLICATION

(Continued)

Mixing and Handling (Cont’ct)

coatings should have a dried film thickness of at least coatings should be free of bubbles, wrinkles, filan~ents, sags, runs, and overspl´•ay when dry. Continuity of the applied varnish coating can be determined by inspection under ultraviolet light, A similar uncoated article may be exposed at the same time to the ultraviolet light for comparison. Fluorescence indicates the presence All

4.

0.00% in. The

of coating. Mark each subassembly that has been moisture and fungus I,rotected "MFI’" and the month and year of treatment.

performed properly. Vacuum

~’arnish is

or

vacuum

applied bg brushing, dipping, spraying, impregnation. The coating may be applied parts after assembly.

to

1´•

spl´•aying,, the vai´•nish shall have a %ahn No. 2 cup reading of 22-29 seconds, which may be achieved by adtling 1 part toluene to 2-3 parts varnish. A spray gun u´•ith the tip regu lated to give a wet spray is recommended. For small compact equipment, a pencil spray tip regulated to clive a narrow wet spl.ay is I´•ecommended. The part shall be sprayed from as many angles as necessary to insul~e complete col´•el‘age with a wet coat. When the part configuration permits, 2 box coats of varnish shall be apl,lied by spraying, nrith a drying time of 15-60 minutes betn´•ecn coats. Each box coat normally provides 1 mil of dried film thickness,

3~

Remove part from varnish, drain, remove excless drops of varnish from bottom edges or part, and allow part, to dry for 25-30 minutes at room

Fill and Drain

Rigid metal electrical conduit that will be temperatures of 300"F

provide a dried-film dip part in varnish

I:sing varnish thinned

to ~,rovide a total dried film Ih ic´•kncss between 0.002 and 0.00~ in., dip part in the va!´•nish and remove immediately.

ice

Plug

2.

Remove stopper and allow varnish to drain into a suitable container for reuse. Allow coating to tlrain from conduit for at least 30 minutes while in a vertical position. Excess varnish may be removed from the draining end of the conduit by carefully wiping exterior area with a clean cloth saturated with toluene,

lower end with any suitable stopper, place conduit in a vertical position, and completely fill with as-received varnish.

After drai nincr has been com pleted, direct a flow of air thru the coated conduit for at least 1 hour. 4.

Bake the coated conduit in a vented, circulating-air oven at a temperature of 150 to 1800F for´• at least 2 hours and then cooled to room temperature. (Wil´•cs may be coated with talc to facilitate insertion in the coated conduit.)

5.

Thickness of dry coating applied by using steps 1 thru 4 is normally 3-6 mile. If a thicker coating is needed, repeat steps 1 thru 4 until the desirctl coating thickness is obtained.

thickness of less than 0.0015 in., and 1´•emove immediately.

I)1´•ain part, remove excess drol,s of varnish fr´•om bottom of part. and allow it to air dry at room tcm I,erature fol´• 25-30 minutes. W,´•inklinff in following tlip operation may occur if air dry is more than :3() minutes.

serv

or

1´•

When dip pl.ocess is usetl, the coating thickness should ~,e i,rt wclcn 0.002 and O.OOX in. The coating is ;tl,plied as rollo\r~s: to

used at

less is coated, after bond ing an rl cleaning, by the following method:

Dil,PinR

3.

at 120 +100F for 2 +0.26 hours and cool to

temperature.

temperature.

For

d.

follows:

Immerse part in diluted varnish at room temperature and subject immersed part to v;lcuum for 5-fi minutes. (Excessive foaming will occur if the vacuiini exceeds 2X.6 in, of Hg.)

SP,’ayjnK

I!sing \-arnish thinned

Dry part

as

2.

employed.

i.

impregnate

room

RrrlshinR MThcn brushed on, the varnish normally is applied as receiveti, thinned if necessary to reduce consistency for brushing. No more than 10’b by volume of thinner shall be

Impregnation

When the vacuum impregnation pr´•ocess is used, the thickness of the dry coating should be between 0.002 anti 0.00tl in. The varnish is thinned with 1 volume of toluenc´• to 2 volumes of varnish. Vacuum

Application Procedure

detail

Drain the part, remove excess drops of varnish from bottom edges of part, and allow to air dry for 14-1Ci hours. In lieu of air drying, part may be oven dried at 110 to 1300F for 2-2-1/2 hours. Wrinkling at this stage indicates that previous steps were not

20-30-15 Parrtr 2

Aug 31/(34

o


SR-76-083 COKROSIO~ CONTROL MAN17AL

PAINTING METAL SURFACES WITH EPOXY POLYAMIDE PRIMER OR ZINC CHROMATE PRIMER Foil, Aluminum. 0.005 in, min

(;ENERAL ’I’his section covers the general procedures to be followed in al,ply i ng two types of primer coatings to metal su rfaces.

MATEKIALS

I~laxy Primer, Filiform

Str.iping- Brushes Tape, 3M Co., No.

TT-M-261 TT-T-266

Toluene

TT-T-fi48 TT-P-1757

The spray

MIL-T-6095

The spray

Sensitivity

Dope, Blush Retarding Non-Woven, Non-Metallic

MIL-A-9962

Abrasive Mats iReqnire Type I, Class I or TI, C;rade A or Finer, Scotch nrite (RM (:o.) or equivalent)

Toluene-Methyl Isobutyl

MIIl-’r-19fi88

Ketone

Pr´•imel´•, (:oatinff, E:poxy-Poly-

MII,-T-23~77C

amide, Chemical and Solvent Ilesistant (Class II Air Non-Polluting) (:leaning Solvent (Stoddard Solvent Type) Primer (MI~1-P-23377C) Thinner. Non-Photochemically Iteactive and Compatible with Primer Paint Straining Funnels Aluminum Foil Fabric Tape

(:heesecloth

Visqueen Polyethylene Film No. C;R-99 Tack Ilags Bostik Div. USM Corp., Middleton, MA, or equivalent Itubber Cloves (Rubber Base o~´• Nylon) (;love l’owder (Talc) 400 (;rit Wet-ctr-Dry Abrasive Paper Tape, Masking (3M Co., No. 250 or Mystik No. Ci2XO or equivalent) Boots, Treat Cloth

or

Rubber

Coveralls, IJint-Free

C:al,s,

Painter

Type

(:lasses, (;nggles or Face Shieltfs, Safety

Commel´•cial

EQUI[PMENT

Corrosion Inhibitor

l’hinner, Cellulose-Nitrate-

(CFM)

SH0125-024

Mc!thyl Ethyl Ketone (MEK) Thinner. Dope and Ilacquer Primer C:oating, Zinc Chromate, Low Moisture

670

Fiber Brushes or Tampico Brushes Tape. 3M Co., No. 202

Commercial Commercial Commercial Commercial

ST0210GB0003

Commercial

Paint

Spray Room should be well illuminated (a min of 50

room

ft-candles), using vapor and explosion-proof lights, and floor lighting equipment. when necessary. floors should be kept clean. and free of other debris. Hose floors down at the and rags, paper beginning of each shift. Additional floor wetting may be required to keep the overspray and other dust contained on the floor. room

Tem perature and hum id i tS´• i ndicators shou Id be instal I etl and in proper oper´•ation dur´•inlS the time of paintinR and drying. The temperature of the spray room should be in the range of 60 to 950F Ifi to 450C) during spray painting these paint systems. The relative humidity should be in the range of 25-750/0 during this same time period. Whenever the temperature and humidity cannot be main-

tained within these limits, discontinue painting.

Spray

Guns and Hoses

The spray guns and accessories used should conform nith table 1 requirements or be equivalent.

Commercial Commercial Commercial Commercial Commercial

Commercial

Fluid lines should have a min ID of S/8 in. from tank shall not exceed 75 ft in length.

High pressure air hoses leading to regulator or tank should have a min ID of 7/16 in., and a mar; length of 150 ft. Air hoses from tank to gun should have a min ID of 6i 16 in., and a max length of 75 ft. Recommended pressure settings for fluid tank, I´•egulator. and spray guns are given in table 8. The following

Commercial (:ommercial

to

gun, and

precautions should

be observed while sl,ray

painting.

Commercial

Dusting

or

rippling

will be caused

by

too

high

an

air

pressure. sags will result when the air pressure the fluid pressure is too high. Both the epoxy primer and the zinc chromate primel´• build up in thickness very rapidly.

Orange peel and is too low


or

20-30-20 o


Page 1 Aug 31/84

(:OHROSION (:ONTROI, MANuAL

PAINTING METAL SURFACES WITH EPOXY POLYAMIDE PRIMER

OR ZINC CHROMATE PRIMER

(;uns and Hoses

Spr´•aS

(Cont’d)

Thoroughly dry all parts after cleaning and/or chemical

I

surface treatment.

equipment, guns, lines and pressure pots thoroughly both before and immediately after use \~´•ith toluene (zinc chromate primer) or MEK(epoxy). \~Then MEK is not available use the thinner comm ere ially available from pri mer supplier and compat(’lean spray

ible with the epoxy

Parts should be primed within 24 hours after cleaning, chemical surface treatment, anodizing, or plating, and should be suitably protected from dust and handling until

they

primer.

air line out at least twice each day or oftcllcl´•, if’ necessary, when painlina details, or assenlblies, to purge lines of any oil or water´•. As a further precaution, all air lines should contain an air filter and water separator that is cleaned or changed at least once a month. nlou´•

areas

tape, plugs,

or

adequate ventilaingest.

Do not inhale\´•apors. WASH HANDS REFORE EATING OK SM()KINc. of liquid or vapor with eyes may cause sevel´•e irritation. In clase of skin , wash with sclal, and natel´•. In case of eye , immediately wash eve~ for at least 1.5 minutes; get medical attention.

NOTE The No. maskang tapu ac´•rl/li.e surfaees. 2.

Preparation

Thoroughly clean surfaces prior

to the

The visqueen protective! covering and/or Protex ZOV die cuts initially installed on window for physical protection may be used as the fir´•st mask with the addition of an edge seal i ng´• usi ng 3M No. 670 (C F‘M

tape.

with the skin and eyes. Do not

Sur´•face

not to be primed with masking pal,er, other suitable masking materials.

All acrylic and glass transparencies must be double masked prior to solvent cleaning of adjacent surfaces as fol lows:

Safet~´• with

primed.

Protect any

i.

Al,y1!´• these coating systems only

are

Acrylic and (:lass Transparencies

INS’I’ALI,ATION N()TES

tion.

(Continued)

m´•usl not touch

A second masking is applied using aluminum foil 0.005 in. min thickness and 3M No. 202 masking

tape.

application of

finishing materials. Alun-l inum, steel, and magnesium surfaces must be given the I,ropel’ chemical treatment prior to application of the finishinR materials.

l’ahlt´• i.

Spray Guns and Accessories TANK GUN

TYPE GUN

I

FLUIDTIP

De\’ilbiss JC;A or´• TKA Model 502

Table 8.

FF

02´•

E’X

AIR CAP

NEEDLE FF

or

FX

FLUID TIP F,X

705

or

E’X

AIR CAP

NEEDLE EX

or

FX

1

30

PressureSettings FINISHING MATERIAL

FLUID TANK SETTING

Primer %ine (rhromate PI´•imer

O

CUP GUN

i~tf d I 1 I, of fl u ill I,l´•essu I´•e fol´• each ft of a~,ove the fluid tank level. for normal

AIR RE~ULATOR SETTING

AIR PRE8SUKE AT SPRAY (;UN

8-12

psi

60

psi

45

psi

8-12

I.,si

56

psi

40

psi

height of the Run operation.

Frequent checks should be made with determ ine ai r pressure at the gu n.

a

t.cst aaugc´• to

20-30-20 f’affe

2

Aug 31/84

o

%OPYRIGHT, 1984 BY SABRELINER CORPORATION

SR-7fi-023 (:()RK()SI()N (:()NTK()I, MAN1IAI,

PRIMER PAINTING METAL SURFACES WITH EPOXY POLYAMIDE OR ZINC CHROMATE PRIMER (Continued)

~t;poxy-Polyamide

Class 2)

Primer

I until pigments are thoroughly mixed. Ited I)evil shaker or equivalent method.) Reduction of Com ponent I (pigmented solution) with Component Il solution)is 1 volume to 1 volume. Temperature of

(:amponent

Stir

(Nlix

on

(clear

components

is a day. Where no such agitation cans, it is hand or in cans such gun as spray provided, essential that the primer be well mixed to redisperse all solids before the primer is sprayed. 24 hours

agitated

Mixing and Handling

must be above 600F

(16"C) before mixing,

Component I into an empty container allowing II atlequate time for complete drainage. Pour Component slowly into Component I with constant stirring. Allow

Thin primer by adding 2-8-1/2 volumes of toluene (’r’l’-’T548) to 1 volume of the zinc chromate primer. The spraying viscosity should have the range of 15-21 seconds when checked with a No. 2 Zahn cup (8-12 seconds with a No. 4 Ford cup). The primer is ready for use when thinned.

Pour

II. Each container of proper drai nage time for Component Components I and IT may be rinsed with the non-photo-

chemically reactive solvent type thinner. Component II is not always added to Component I,and this procedure must he reversed.

NOTE

Yellow zinc chromate

priming is required it should be applied as soon as possible to give protection against corrosion during shop

When

handling

a

completion of the after mixing waiting period, the ired and thinned epoxy primer should be sprayed with one wet cross coat to

preliminary

chemical reaction and is necessary fol´• the following reasons:

Iteduces

cratering.

a

dry film thickness of 0.6-0.9 mil.

NOTE The

primed 80

to he betwee~n hr should pl´•imsl´•

temperature of the surface and the

and g.5"F.

No. 2 Zahn cup.

The thinned paint should be stirred thoroughly, strained through 2 paint straining funnels or 2-3 layers of lint-free cheesecloth, and allowed to stand at room temperature for 1 hour before using. The standing period for primer is a period for the components to enter into

2.

storage in stock.

or

After

spraying

Shortensdryina time.

Application

Primer

Thin 2 volumes of the Class 2 ired primer for spraying by adding approximately 1-1/2 volumes of nonphotochemically reactive thinner which is compatible with alags 2 primer as specified in manufacturer’s directions.’I’he viscosity should have a range of from

I.

For

Epoxy Polyamide Primer

Never mix epoxy primer from one vendor with primer from another vendor. Com?30nents also are not interchangeable.

18-21 seconds when checked with

primer (TT-P-1757) can be used primed surfaces.

touch-up of jet skin and epoxy

Epoxy Polyamide

Primer

Drying Time

Allow primer to air dry 2-4 hours at air temperature of 78 +Fi"F prior to top coating. Allow to air´•

dry for

at least 1 houl´•

prior

to

handling

ol´•

stacking. ’I’he primed sur´•face may be force cured by allowing a Ir,-minute flash off periotl followed by a i hour hake at 18() -fT,o F’. Zinc Chromate Primer

Allows any bubbles

(formed by mixing)

to escape.

Epoxy primer should be ired only in that amount that life of the ired epoxy can be used in one shift. The pot material must be 8 After hours, hours. is 8 I,rimer discarded regardless of appearance.

single coat of zinc chromate primer and for 30-4Fj minutes. Apply a second coat fol´• allow to air dry mils. Allow second coat to 8 d,y film thickness of O.fi-1.2 then apply top coat. air dry for 2-6 hours,

Spray

on a

wet

Hollow Zinc Chromate Primer

(TT-F-1757)

This is a single component primer but the paint must be well mixed in the original container before being thinned. The pigment is heavy and will settle rapidly in both the unthinned and thinned state. To prevent this settling, it is essential that all such paints being used in mixing tanks, circulating lines, pressure pots, hoses and wherever mechanical agitation is practicable, be kept constantly

Hollow (i.e. tubes), ~hich remain open in service and require pl´•iming by the fill and drain method, should be accomplished by using zinc chromate primer (TT-P-1757). Fill and drain with the specified primer until the entire surface is covered.

20-30-20 o


Page 3 Aug 31/84

SR-76-023 CORROSION CONTROL MANUAI,

PAINTING METAL SURFACES WTH EPOXY POLYAMIDE PRIMER OR ZINC CRROMATE PRIMER (Continued) l’ouclh

lip of Damaged Primer

tions. Such swrfat:es

ar´•e not su itable for touch-ul, subsequent top coats even if solvent wiping is attempted, because adhesion will not be atlequate.

i

Where the initially applied primer coat is to be the only be touched up to eliminate all bare areas caused bg shop handling, drilling, cutting, filing, or form i nff operations. Before su rface treatment and touch up´• Feather etlges of the primer adjacent to the bare area using No. 300 abrasive paper to prevent ridges in the

or

coat it must

coating. Surfaces reyu iring touch-up must be cleaned (using M EK fo,´• epoxy or toluene fol~ zinc chromate primer) since conlamination of any kind will cause poor adhesion, cratering~, and premature film failure. Any paint areas scr´•atched or abraded to the bare metal must be t;ouched up´•

Primer (’oat Preparation For Finish Coat

F’inish (’olor Coats Over I)r´•imers One coat of epoxy

primer or 2 coats of zinc chromate pri171el’ al’C’ applied to surfaces to be subsequently paintetl. l’his I,rimcl´• coating must not be removed prior to application of additional finish coats unless the primer is in pool´• condition and would not provide a suitable base for su bsequent finishing. Polyamide Primei

Epoxy

Stripping of

Primers

Mask off all

plastics, rubber, fabric, ts, parts, and plated areas that might be damaged by paint strippers or water using tape (aluminum foil or fabric) and polyethylene film.

Apply paint stripper

to

remove

primer´•

or.

paint.

Remove loosened paint and contaminants with a bristle brush and water spray or wipe off with water moistened clean cloths. Dry surface, An alternate method of removing paint is by lightly scouring the paint area with abrasive pad (MIT,-A-9962), Gratle A or´• finer, moistt!nctl with a 1:1 mixture of MF:K and lacquer thinner´•. Wipe stripped area clean with a sufficient number of solvent moistened clean cloths to assure adhesion of sut,secloent paint films.

Cure/Baking In general, primers usetl c~n detai Is and assemblic!s ail, tlry satisfactorily and do not require baking; however, primel´•s for certain parts may be baked for increased abr´•asion anc’ chemical resistance. Baking temperatures shall not exceed 200"F and time shall not exceed 2 hours.

Before

applyingepoxy polyamide finish coats, wipe cured primel´• \I´•ith a MEK moistened, clean cloth to remove soil and contamination, Lightly abrade with No. 400 abrasive papel´• and wipe again with MF,K moistened, clean cloth to remove

the dust.

Finish

Inspect painted surface for freedom from dust particles, lint, and any foreign matter. The surface should be free of surface irregularities such as too much paint, runs, sags,

Zinc Chromate Primer

and overspray,

To

Primer Test

good adhesion, zinc chromate primed surfaces given a finish coat as the next operation after priming must be cleaned of oil and other soil before applying additional paint coats. Any contamination such as dirt, grease, and oil must be removed by wiping with Stotldal´•d solventol´• lacquer thinner prior to application of assure

to be

an!,

top coat.

Paint,

coatings falling within the classification noted in I,ar;taral,hs (I) and (2) below must be removed (refer to StriPPinR ()f Primers below) before application of reqrl i red fi nal primer or pal nt coatings. (1)

Shop aged primer´•

coats on exterior skins of assembled aire raft, and primer on pair;t coats i n an unsatisfactory condition.

Stl.il, and rcl,rirne ;111 zinc´• ch romate primed sur facts which are intentionally oiled, greased, or othcru~ ise contam i natetl

;Is an

aid to form ing ol,era

Inspect primer coating for adhesion after it has been allowed to dry for the full curing period. Apply a 1 in. wide strip of masking tape (No. 250, 3M Co.) pressed down using 2 es of a 4-1/2 Ib rubber roller or by firm pressure with the hand. Remove the tape in one abrupt motion 90" to surface. F:xamine the tested ar´•ea for any paint damage, such as removal of one of thr! layers ol´• removal of the entire system from the metallic surface. Any such removal is unsatisfactory and the primer must. be stripped, the surface pr.epared again, and reprinletl. Shelf Life of

Coating Materials

The unmixed primers may be stored unopened for a max periad of 1 year stored at temperatures within t.he I´•angr of 36 to 950F (2 to ~50C). After th is storage l,erio(-l of 1 yeal´•, the coating materials ma!, be tested far anothe,´• storage period of 6 months by m i x i ng and apply i ng sam pie coats to scrap material. Precatltions must be taken during storage and handli nff of the pal nts ant´•l thinnt!r´•s lo I,rev~,r, water contaniination.

20-30-20 I’aae

/1

Aug 31/84

o

~OPYRIGHT, 1984 BY SABRELINER CORPORATION

SR-76-023 COKROSION CONTROL MANUAL

CONVERSION TYPE COATINGS APPLICATION (;ENERAI,

After spraying operations are conipleted, equipment such spray Runs ;Intf pots may l,e c´•ltl;lncld by thinner, T’I’-’l’-B(iti. as

l’his section covers Ihe application of convel´•sion type finishes lo metal surfaces,

INSTALLATI()N PR()CE:DIIRES M~TEKIALS P:namel:

Epoxy, Conversion

’I’y I,e Aliphatic Naphtha Toluene Thinner

Apply catalyi~etl mixture t,y spl´•aying at a pressu,.c~ or’ psi. ()ne full coat will produce a film thickness of approximately 0.75-1.0 mi I. Parts that have been sprayed are cured for 16-18 hours at 1400F or for 7 days at 720F in

LB()125-006

25-XO

Commercial Grade Commercial Grade TT-T-266

a

APPLICATION N<)TES

Cleaning

dust-free environment.

Parts on which a conversion film has been applied should be examined visually. The applied finish should have a uniform appearance free from pinholes, blistel´•s, 1´•uns, alligatoring, or other imperfections such as drying irreffu larities noted below:

Surfaces must be clean and free from all dirt, grease, rust, scale, chips, or other contamination before finishes are

1.

Films remain

applied.

2.

Films remain soft drying for 7 days.

Metallic parts, except titanium, that are to be painted must be solvent vapor degreased. Titanium parts must be cleaned in accordance with applicable titanium cleaning procedures. Parts that are thoroughly clean, such as those that have just been anodized, chromodized, phosphatetreated, or given a chemical film treatment, will require further treatment before application of finishes, no Finffermarks, smudges, and smear´•s may be removed from large surfaces by wiping with aliphatic naphtha.

tacky for to

24 hours

thumbnail

or

longer.

scratching after

ail´•

If the applied conversion finish shows poor adhesion, surface irregularities, or drying irregularities, the conversion film must be stripped, the surfaces recleaned, and the conversion film re-appplied.

Conversion type coatings may be applied to surfaces primed with zinc chromate if the surfaces are clean and intact and the primer has dried at least 16 hours. Dirty or im properly applied zinc chromate primer films must be stripped and reprimed before applying the conversion finish coats. If a conversion type finish will be applied over a wash pr´•imer, I,repare the surface and apply the wash primer normally, except that the drying period for the wash primer´• must be at least 1 hour.

Conversion coating may be applied directly to surfaces that have been previously coated with conversion coatings, except that such surfaces must have been cleaned by wiping with clean, toluene-soaked cloths before the conversion coating is applied.

Mixing and Hannlinng The conversion finish is supplied in the form of a resi n and catalyst. Mix the catalyst and resin in the proportions recom m ended by th e m an u factu re r. The catalyst m ust be adtled to the resin with constant stirring until a smooth uniform mix is obtained. The catalyzed mixture must be used within 24 hours after mixing. Discard mixtures more than 24 hours old.

20-30-25 0

COPYRIGHT, 1984 BY SABRELINER CORPORAIION



POLYURETHANE FINISH SYSTEM FOR SABRELINER AIRCRAFT EXTERIOR SURFACES (;ENERAI, This section covers the materials, procedures, and requirements for the application of an epoxy polyamide primer

and polyurethane topcoat finishing system to the exterior of aircraft. Procedures are in accordance with the applicable sections of the Military Specifications MIL-F-18264. All surfaces,

including well areas normally exposed to the

external environment during flight or

on

the ground,

are

MATERIALS Technical Inhibited Methyl Ethyl Ketone (MEK)

Naphtha Lacquer Thinner Paper, Kraft, Untreated Wrapping Non-Slip Walkway Compound Chemical Conversion Coatings on Aluminum and Aluminum Alloys Nan-woven, Non-metallic Abrasive Mats, Require Type I, Class 1 or 2, Grade A or Finer, Scotchbrite

(3M Co.)

or

TT-M-261 TT-N-95 (Type TT-T-266 UU-P-268 MIL-W-5044 MIL-C-5541 MIL-A-9962

Non-Polluting) Cleaning Compound, Aircraft

MIL-P-23377C

MIL-C-25769

Surface Alkaline Waterbase

(Turco Air Tech No. 19) Neutral Paint Remover, Turco No. 5351 Primer (MIL-P-23377C) Thinner, Non-Photochemically Reactive and Compatible with Primer Paint Straining Funnels Aluminum Foil or Fabric Tape

Cheesecloth

Visqueen Polyethylene Film No. GR-99 Bostik Tack Rags Div., UXM Corp., Middleton, MA or equivalent Scotchbrite Pads, Type A (3M Co.) Thymol Blue Indicator Paper (Van Waters and Rogers) Rubber Gloves (Rubber Base or

Commercial

Commercial Commercial Commercial Commercial Commercial Commercial Commercial Commel´•cial

(FJ.I. DuPont)

0-T-620

equivalent

Chemical and Solvent Resistant Epoxy Polyamide Primer Air Coating (Require Class 2

Shields, Safety Striping Brushes Fiber Brushes or Tampico Brushes Pressure Air/Water Guns Imron Polyurethane Enamel

considered exterior surfaces.

Trichloroethane, I, 1, 1,

Chemical Cartridge Respirator (Wilson Model No. 1200 with N,~ R21 Cartridges) Boots, Treat Cloth or Rubber Coveralls, Lint-free Caps, Painter Type Glasses, Goggles or Face

192 S Activator(E.I. DuPont) 8485 S Reducer (E.I. DuPont)

II)

Commercial

Commercial

EQUIPMENT Spray Guns and Hoses The spray guns and accessories used must conform with table 1 requirements or be equivalent.

Fluid line must have a min ID of 3/8 in, from tank to gun, and must not exceed 75 ft in length. High pressure air hoses leading to regulator or tank must have a min ID of 7/16 in., and a max length of 150 ft. Air hoses from tank to of gun must have a min ID of 5/16 in., and a max length 75 ft. Recommended pressure settings for fluid tank, regulator, and spray gun are given in table 2. Observe the following precautions while spray painting.

Dusting

Commercial

or

rippling will be caused by

too

high

an

air

pressure.

Commercial

Orange peel and sags will result when the air pressure is too low or the fluid pressure is too high. Both epoxy primer and the polyurethane topcoat build up in thickness very rapidly.


Clean spray equipment, guns, lines, and pressure pots thoroughly both before and immediately after use with MEK.

INSTALLATION NOTES Commercial Commercial

Commercial

Nylon) Glove Powder (Talc) 4()0 Grit Wet-or-Dry Abrasive


Paper Tape, Masking(3M Co., No. 250 or Mystik Na. 6280 or equivalent)

Commercial

Safety Precautions Polyurethane vehicle, thinner, and primer components contain flammable solvents so all ordinary precautions such as adequate ventilation and absence of open flames should be observed. Ground all aircraft as static charges can build up, especially when using spray equipment.

20-30-30 0


Page 1 Aug 31/84

SR-76-023 C()KROSION CONTROL MANUAL

POLYURETWANE FINISH SYSTEM FOR SABRELINER AIRCRAFT EXTERIOR SURFACES (Continued) Safety Precautions (Cont’d)

turbulence and excessive air currents and must at a min of 125 fpm at the exhaust in the painting area. Room air must be exhausted through an exhaust system immediately at one end of the aircraft or part being painted so that overspray does not drift into other areas of the room. to

Isolate painting procedure from exposure of nearby personnel. Only painters must be allowed in´•the spraypainting and adjacent areas. Spray painters must be fully clothed in coveralls and caps with collars buttoned and sleeves taped at the wrists.

Solvent-resistant gauntlet style gloves (natural rubber or neoprene) must be worn by personnel engaged in the mixing and application of polyurethane paint. Painters and others must wear a chemical cartridge respirator when mixing and spraying polyurethane paint.

Apply these coating systems only with adequate ventilation. Avoid with the skin and eyes. Do not ingest. Do not inhale vapors. WASH HANDS BEFORE EATING OR SMOKING. of liquid or vapor with eyes may cause severe irritation. In case of skin , wash with soap and water. In case of eye , immediately wash eyes for at least 15 minutes; get medical attention,

cause

be maintained

Floors The spray

floors must be kept clean, and free of rags, debris. The floors must be hosed down at the beginning of each shift and in the area of the aircraft approximately 1 hour before the beginning of the painting of the aircraft. Additional floor wetting may be required to keep the overspray and other dust contained on the floor. room

paper and other

Doors

Hangar doors (large) must not be opened for an hour before, during, and for at least 2 hours after the painting of an aircraft with the basic topcoat system. Personnel doors (small) shall be restricted,so thatonly 1 door to the outside shall be available to foot traffic during the same time period as the hangar doors.

Facility Requirements Lighting The spray room must be well illuminated (recommend a min of 50 ft-candles), using vapor and explosion-proof lights, and floor lighting equipment, when necessary. Air The paint spray room must use filtered air. The amount of air forced into the spray room must exceed the volume withdrawn. Air must be introduced in such manner as not Table 1.

Spray Guns

and Accessories

TANK GUN TYPE GUN

DeVilbiss JGA or TEA Model 502

FLUID TIP FF

Binks Model 7

Table 2.

FX

NEEDLE FF

33B

or

AIR CAP

FX

FLUID TIP

765

33

EX

or

FX

NEEDLE EX

or

AIR CAP

FX

30

33 PM

Pressure Settings FINISHING MATERIAL

F~posy

O

or´•

CUP GUN

FLUID TANK SETTING

AIR REGULATOR SETTING

AIR PRESSURE AT SPRAY GUN

Primer

8-12

psi

60

psi

40-45

psi

Polyurethane Topcoat

8-12

psi

60

psi

50

psi

Add 1 Ib of fluid pressure for each ft of height of the gun above the fluid tank level, for normal operation.

P

Frequent checks should be made with determine air pressure at the gun.

a

test gauge to

20-30-30 Page 2 Aug 31/84

o


SR-76-023 CORROSION CONTROL MANIIAI,

POLYURETHANE FINISH SYSTEM FOR SABRELINER AIRCRAFT EXTERIOR SURFACES (Continued) Facility Requirements (Cont’d)

Thoroughly abr´•ade metal surfaces with abrasive nylon pads, ensure that the heads

Temperature and Humidity

fasteners have been abraded.

Thoroughly

NOTE

Re-abrade and rinse break free" surface.

in the top coat. When this condition is encountered topcoat should be reduced to Zahn cup 1 r.0 seconds measured with No. and allow a min dr2ling time of 1 ~Lour occur

single

and

plated

immediately. While still

wet, determine if a "water-break free" surface has been achieved. Refer to Water Break Test below.

Hish temperatures and high relative humidity can cause bubblinglblistering to

between each

spray water rinse

water

of all

as

necessary to

achieve

a

"water-

Rinse with high pressure water rinse while agitating to ensure removal of all sanding residues from abraded

surfaces,

spray coat.

gaps, seams, etc.

Temperature and humidity indicators must be installed and in proper operation during the time of painting and dry i nff. The temperature of the spray room must be in the range of 00 to 90"F 1 hour before, during, and for 4 hours after spray painting this paint system. The relative humidity must be in the range of 25-75%.

Water-Break Test

Pressurized Air Source

(without

day or oftener, if when painting an aircraft, to purge lines of any

Distribute a film of water on the bare metal surfaces. If th,,,t,, film gathers into discreet droplets with 25 seconds after application of water, the surface has exhibited a "water-break" and has failed the test. a continuous film of water sudden flashout or the forming of droplets) then the surface has ed the "water-break" test.

If the water film stays in a

nlow out air lines at least twice each necessary,

oil

or

water. As

a

precaution, all air lines contain separator. Change the filter and

further

air filter and water separator at least once a month and certify

an

Surface

same,

(:leaning and Stripping Remove strippable protective shop coatings as required. Mask off all plastics, rubber, fabric, ts, parts, and plated areas that might be damaged by paint strippers, chemical solutions or water by using aluminum foil or fabric tape and visqueen polyethylene film. to remove any

Aftel´• final rinse and while still wet, apply alodine by brush or spray. Refer to 20-40-30. The alodine surfaces must dry a min of 1 hour or until moisture free. Ensure removal of moisture from seams, gaps around fasteners, etc.

Preparation


Chemical Film (MIL-C-5541)

shop

coats of

The primer must be applied within 24 hours aftel´• aiodining, subject to the following conditions. Time After Alodining

paint.

Action Before

Priming

preparation \~.hen dry

1-4 hours

No further clean and

4-24 hours

Solvent clean

Refer to 20-10-45. Remove loosened paint and contaminants with aid of a bristle brush and high pressure water spray, then dry surface. Refer to 20-10-45. An alternate method of removing paint is by lightly scouring the paint area with abrasive pads (Scotchbrite), Grade A or finer, moistened

with MIEK. Final traces of organic residues must be removed by sol vent cleaning. Ensure complete removal of all residues from gaps, seams around fasteners, etc.

Abrading Unpainted metal surfaces must be abraded and a water break free surface must be achieved and then alodined.

Mixing and Handling Epoxy-Polyamide

Primer

(MIL-P-23:377

Class 2)

Stir Component I thoroughly until pigments are mir;ed. Mix on Red Devil shaker or equivalent. Reduction of Component I (pigmented solution) with Component II (clear solution) must be 1 volume to 1 volume. Temperature of components must be no lower than 600F (160C)

before mixing.

Component I into an empty container allowing adequate time for complete drainage. Slowly pour Component II into Component I while constantly stirring. Proper drainage time must be allowed for Component II. Pour

20-30-30 0


Page 3 Aug 31/84


POLYURETHANE FINISH SYSTEM FOR SABRELINER AIRCRAFT EXTERIOR SURFACES ´•(C/ontinued) Mixing and Handling (Cont’d)

Imron Polyurethane Enamel

Each container of Components I and II may be rinsed with the non-photochemically reactive solvent type thinner, Component II must always be added to Component I. Never reverse this procedure.

Stir Component I (Imron pigmented base material) thoroughly until pigments are mixed. Mix on a Red Devil shaker or equivalent. Add 1 volume of Component II (192 S Activator) to 3 volumes of Component I. Temperature of components must be a min of 60"F (16"C) before mixing.

First pour Component I into

Ne?,er mit epozy primer from one vendor with primer from another vendor. Components also are not interchangeable.

adequate time

for

an empty container with complete drainage.

NOTE Thin 2 volumes of the Class 2 ired

primer for spraying by adding approximately 1 volume of non-photochemically reactive thinner which is compatible with Class 2 primer as specified in MIL-P-23377 and manufactur´•er’s directions. The spraying viscosity must have a range

of from 17-19 seconds when checked with

a

No. 2

%a.hn cup.

Stir the thinned primer thoroughly, strain thru 2 paint strai n i ng fun nels or 2-3 layers of ii nt-free cheesecloth and allowed to stand at room temperature under agitation for 1 hour before using. The standing period for primer is necessary for the components to enter into chemical reaction, Mix epoxy primer only in that amount that can be used in 8-hour shift. Discard all material that is 8 hours old, regardless of appearance. an

Open Component II can carefully. niscard Component II if material is not clear or has turned dark. Pour Component II slowly into Component I with constant stirring. Allow proper drainage time for Component II. Each container of Components I and II may be ri nsed with 8485 S Reducer. Always add Component II to Component I; never the reverse. Never mix Polyurethane paint from one vendor with another vendor. Components of different colors from the same vendor may not be interchangeable. Check components and batch numbers to assure compatibility for proper curing. Viscosity must be 18-20 seconds when checked with a No. 2 Zahn cup. Stir the thinned paint thoroughly and strain through 2 paint straini?g funnels or 2-3 layers of lint-free cheesecloth before

paint from

Polyurethane Topcoat

spraying.

SB0125-025 Polyurethane Coating (Alumigrip)

Mix only the amount which can be used in one shift. Pbt life of the ired topcoat in a closed container is 8 hours. Discard the paint after 8 hours regardless of appearance.

Stir Mix

Component I thoroughly until pigments are mixed. Red Devil shaker or equivalent. Add 1 volume of Component II to 1 volume of Component I. Temperature of components shall be a min of 60"F (16"C) before on

mixing. First pour Component T into an empty container with adequate time for complete drainage.

NOTE

Open Component II can carefully. Discard Component mifmaterial is not clear or has turned dark.

Shelf Life of Coating Materials Unmixed materials (primer and topcoat) may be stored a max period of 1 year from date of acceptance when stored at temperatures within the range of 35 to 950F (2 to 35"C) and the peak air temperature must not exceed 115"F (460C). After this storage period of 1 year, the coating materials may be retested for acceptance for another storage period of 6 months. Precautions must be taken during the storage and handling of the paints and thinners to prevent water contamination.

unopened for

slowly pour Component II into Component I with stirring. Allow proper drainage time for Component II. Each container of Components I and II may be rinsed ~´•ith the non-photochemically reactive thinner. Always add Component II to Component I; never the

Then

constant

reverse.

20-30-30 Page 4 Aug 31/84

o

CO’$YRIGHT, 1984 BY SABRELINER CORPORAIION


POLYURETHANE FINISH SYSTEM FOR SABRELINER AIRCRAFT EXTERIOR SURFACES (Continued) Film

Adhesion C:heck

A tl ry adhesion Icst m list be eonductc!d on Ihe 8i I´•ylane kst. (see below) after the application of the top coat. If failu ~´•e occurs, dZuality Engineering shall be immediately further action may be taken. Basic topcoats must dry a min of 48 hours before dry tape test and 8 days for wet test. (Refer to adhesjBn test.) informed

magnification lens, there must be no evidence of microcracks, except that after flight tests, slight microcracks around highly stressed fasteners will not be cause for reject.ion. A slight surface orange peel effect. is not

6X

Adhesion, Thickness, and Finish

f,,

rejection.

Gloss

so

The white topcoat shall have the gloss value measured with a Gardener 60" gloss meter and the average measurement shall not be lower than 85%.

Test s

painting an aircraft use 4 3 x 5 in. aluminum test s (positioned vertically and placed in the vicinity of the aircraft). Finish in the same manner as the aircraft. Upon completion, measure the for primer thickness

Film Thickness Tests

When

and for total system thickness and adhesion test. The results should then be recorded in the inspection sign-off record. Record the aircraft number, date painted, and

system applied, including paint batch numbers.

Dry Tape Test

parallel scratches 2 in. long and 1 in. apart down Apply a strip of masking tape (3M Co., No. 250 or equivalent) horizontally across the test area, pressing down firmly by hand. Grasp the tape by one end and rapidly remove with one abrupt motion maintaining an angle of I)O"F. Examine the tested area for any paint

Make 2

to the bare metal.

damage (i.e., removal

or

damage of

any

portion

of the

paint system). Wet

Tape Test

Place a piece of cheesecloth or filter paper that is 3 in. min diameter and 1/8 in, thick and saturated with tap water onto the painted surface. Overlay with a piece of barrier material such as grease-proof paper with the coated side of the paper ing the wet ~ad. After 24 hours remove pad and wipe surface dry with a clean, soft cloth. Apply a strip of masking tape (3M Co., No. 250) across test surface and press down firmly by

Film thickness tests should be conducted on all painted surfaces. A random sampling technique should be employed. The locations measured and the thickness measured should be recorded and made part of the inspection sign-off record. The basic gloss white paint thickness measurements over 70% of the area must be within 2.3-3.2 mils total dry film thickness. Areas that have additional overcoats of International orange or flat black colors or insignia and markings must not exceed 4.5 mils total dry film paint thickness. Film thickness may be determined by use of a Dermitron or equivalent instrument.

Repairing Damaged Paint Area Stripping. of the Paint System polyurethane topcoat and epoxy primer stripped using neutral paint remover, Turco No. 5351. A small residue of the epoxy primer may be left on the stripped surface which may be removed by Scotchbrite pads and MEK. If necessary, the

may be

Balanced Control Surfaces

NOTE The pa´•int film thickness is critical balanced control surfaces.

on

touch-up balanced control surfaces unless damage repaired is minor and does not exceed approximately 1 square inch in area. If major repairs are required, completely strip and refinish the entire control surface. Do not

hand. Grasp tape by one end and rapidly remove with one abrupt motion maintaining an angle of 90"F to the surface. Examine test area for paint damage.

to be

Smoothness

Cleaning of Polyurethane Cured Paint Film

Visually inspect the epoxy primer surface for specks and bumps. There must be no seediness or roughness.

Removal of boot marks, bugs, etc. from cured painted surfaces can be accomplished by a MEK or watermoistened clean cloth. Do not use Bon Ami or other cleaners containing abrasives, chlorine or alkali

Appearance The final coatings must have a smooth, uniform appearance. The finish must be free of dried overspray, runs, with a sags, and blisters. In addition, when examined

c0mp0u"ds.

20-30-30 0


Page 5 Aug 31/84


POLYURETHANE FINISH SYSTEM FOR SABRELINER AIRCRAFT EXTERIOR SURFACES (Continued) Repairing Damaged Paint Area (Cont’d)

Touch-up of Damaged Paint

Topcoat Application

Film

NOTE

Surfaces requiring touch-up must be cleaned, using MEk, since contamination of any kind will cause poor adhesion, cratering, and premature film failure. Treat any paint areas scratched or abraded to the bare metal as outlined in

The first coat of polyurethane will not dry sufficiently to be touched or walked on 90

that

Abrading.

San d i ng the cured pal n t fi Im removes th e gloss and causes coating deterioration. The touch-up of any scratches or damaged areas is restricted to that which can be accomplished by brush. Overspray cannot be removed from the topcoat. If the damaged area cannot be touched up by brush, it is recommended that the surface be masked off at skin or part breaks and the damaged area stripped for

refinishing

as

specified originally.

Polyurethane System Application Operations Prior

to

Painting

Before application of epoxy primer, mask off areas not to be painted, such as radomes, canopies, intake duct leading edges, etc. Use Mystik No. 6230 masking tape or equivalent. It is mandatory that rubber or nylon gloves be used when touching the aircraft surfaces until the topcoat has been applied and dried.

must be taken not to lean

on the allow the hoses to touch it between the first and second topcoats. care

aircraft

or

Apply the polyurethane topcoat by spraying over epoxypalyamide primer, which has been allowed to dry 3-24 hours at 60 to 900F and a relative humidity of 25-75%. Apply a wet, thin coat of polyurethane, air-dry 30-45 mi"utes, then spray a full wet cross coat to a total dry film thickness of 1.7-2.3 mils. Large areas requiring the topcoat, such as the top surface of wings, fuselage, etc., which must be walked on to properly apply the topcoat, may have the topcoat applied by the cross coat technique to achieve the required dry film thickness in one application instead of the two-coat system above. Large areas of the aircraft that will be overcoated by colors other than gloss white, such as stripings, International orange or flat black, must be painted with only the fi rst coat Of the basic topcoat and the second coat should be "feathered" irl at the

edges

of these

areas

to reduce the total film thickness. If

the basic topcoat dries over 36 hours before the colors are applied, sand the surface with 400 grit abrasive paper and tack off before the colors

Primer

Application

are

applied.

NOTE NOTE

Spray

The temperature of the surface to be primed an.d the primer should be between 60 and 800F. After completion of the waiting period specified, spray the ired and thinned epoxy primer with 1 wet cross coat to a dry film thickness of 0.6-0.9 mil. Allow to air dry for a min of 3 hours before applying topcoat.

Walkway Areas Masking After application of the epoxy primer and before the application of the topcoat, mask off areas to be finished with walkway coating.

and other equi~ment should be cleaned using IMEK thinner as soon as the epoxy primer and polllurethane topcoat have been applied. Cleanliness must be ezercised sinCe both these materials, once eured, are most d~fficult to dissolve.

Drying or curing time for the polyurethane topcoat is specified as "dry hard" within a max time of 12 hours. The actual drying time depends on the temperature and humidity of the spray room. The higher either or both are, tire more rapid the curing of the topcoat.

Smoothing of Epoxy Primer Santl primel´• surfaces to

remove nibs, dirt and other prin~el´• coating imperfections before applying the polyurcthanr toy,roat. Acclomplish the smoothing by using Scot.chbl´•ite ol´• No. 400 grit abrasive paper. Immediately priol´• to applying the topcoat, air blow and tack off the aircl´•aft using tack rags. Wipe lightly with tack rags but do not allow tack rags to lay on the surfaces to be painted.

20-30-30 Page 6 Aug 31/84

o

1984 BY SA&RELINER CORPORATION


POLYURETHANE FINISH SYSTEM FOR SABRELINER AIRCRAFT EXTERIOR SURFACES (Continued) Polyurethane System Application (Cont’d) Z,eading F,dffe Coating The leading edge of engine ducts and cowling, wings, and stabilizers, except where in conflict with blueprint requirements of a different coating, must be primed and painted in the same manner as the aircraft. After the topcoat has cured (8 hours) areas adjacent to the leading

edge areas must be masked off and additional coats tallow at least 30 minutes of drying time between coats) of the polyurethane topcoat must be applied so that the total dry film thickness (primer plus topcoats) is built up to 3.5-4.5 mils. If drying time exceeds 36 hours between applications, sand surface with 400 grit abrasive paper and tacked off prior to application of additional coats.

NOTE Where topcoats have sharp leading edges exposed to the airstream, the coating should be feathered to produce aerodylzamically smooth surface to preclude coating erosion duringflight. An alternate method for the

application

of the additional

co;lting thickness on the leading edges is to free spray (without masking) the additional topcoats required at the time that the topcoating is being performed. (Refer Topcoat Application.)

same

to

Insignia and Marking Application Masking for insignia and marking may be begun after the coating has dried tack free, a min of 8 hours. If drying time exceeds 36 hou rs between applications, sand surface with 400 grit abrasive paper and tack off prior to application of additional coats.

Walkway Coating Application

Apply MI11-W-5044 Type II walkway coatings as specified in MIIJ-W-5050 except the walkway coating must be applied directly to surfaces primed with epoxy primer.

20-30-30 0




MIL-C-83286 POLYURETHANE ENAMEL APPLICATION

(;ENERAI, This section covers materials, procedures, and requirements for the application of an epoxy polyamide primer and polyurethane topcoat finishing system to the exterior of aircraft. to the external environ-

areas normally exposed during flight or on the ground,

All well ment

are

considered

exterior surfaces.

MATERIALS

Trichlaroethane, 1, 1, 1, Technical, Inhibited Methyl Ethyl Ketone (MEK)

Naphtha Lacquer Thinner Paper, Kraft, Untreated Wrapping Non-Slip Walkway Compound Chemical Conversion Coatings on Aluminum and Aluminum Alloys Non-woven, Non-metallic Abrasive Mat (Require Type I, Class 1 or 2, Grade A or Finer, Scotchbrite

(3M Co.)

or

0-T-620 TT-M-261 TT-N-95 (Type TT-T-266 UU-P-268 MIL-W-5044 MIL-C-5541

MIL-A-9962

equivalent) MIL-P-23377C

Chemical and Solvent Resistant Eltoxy Polyalnide Primer Air (:oating(Require Class 2

(SB0125-024)

Non-Polluting) Cleaning Compound, Aircraft

MIL-C-25769

Surface Alkaline Waterbase

(Turco Air Tech No. 19) Aliphatic Polyurethane Coating Thinner Coating Urethane, Aliphatic Isocyanate, for Aerospace Applications Primer (MIL-P-23377C) Thinner, Non-Photochemically Reactive and Compatible with Primer Paint Straining Funnels Aluminum Foil or Fabric Tape Cheesecloth

Visqueen Polyethylene Film Tack Rags

No. (;R-99 Bostik

MIL-T-81772 MIL-C-83286

Tape, Masking (:SM Co., No. 250 or Mystik No, 6230 or equivalent) Chemical Cartridge Respirator (Wilson Model No. 1200 with No. R21 Cartridges) Boots, Treat Cloth or Rubber Coveralls, Lint-free Caps, Painter Type Glasses, Goggles or Face Shields, Safety Striping Brushes Fiber Brushes or Tampico Brushes


Commercial

Commercial Commercial Commercial Commercial Commercial Commercial

EQUIPMENT II)

Spray Guns and

Hoses

The spray guns and accessories used must conform with table 1 requirements or equivalent. The fluid line must have a min ID of 3/8 in. from tank to gun, and not exceed 75 ft in length.

High pressure air hoses leading to regulator or tank must have a min ID of 7/16 in., and a max length of 150 ft. Air hoses from tank to gun must have a min ID of 5/16 in., and a max length of 75 ft. Recom mended pressure settings for flu id tank, re)Su latol., and spray gun are given in table 2.

INSTALLATION NOTES

Safety Precautions This process involves materials and operations which hazardous.

are

and primer compoall ordinary precautions such as adequate ventilation and absence of open flames should be observed. All aircraft should be grounded as static charges can build up, especially ~´•hen

The Commercial

Commercial

polyurethane vehicle, thinner,

nents contain flammable solvents

using

spray

so

equipment.

niv., USM Corp., Middleton, MA

or

equivalent

Blue Indicator Paper (Van Waters and Rogers) Rubber Gloves (Rubber Base or

Thymol

Commercial

Commercial

Nylon) Wet-or-Dry Abrasive Paper (3M Co.)

400 (;Fit

Commercial

20-30-35 0


Page 1 Aug 31/84


MIL-C-83286 POLYURETHANE

ENAR;ZEL APPLICATION (Continued)

Safety Precautions (Cont’d)

turbulence and excessive air currents and must be maintained at a min of 125 fpm at the exhaust in the painting area. Exhaust room air thru an exhaust system immediately at one end of the aircraft or part being painted so that overspray does not drift into other areas of the room.

isolate the painting

procedure from exposure of nearby personnel. Only painters must be allau~ed in the spraypain ting and adjacent areas. Spray painters must be fully clothed in coveralls and caps with collars buttoned and sleeves taped at the wrists.

Floors

Solvent-resistant gauntlet style gloves (natural rubber or neoprene) must be worn by personnel engaged in the mixing and application of polyurethane paint.

room floors must be kept clean, and free of rags, paper and other debris. Hose floors down at the beginning

Spray

Painters, and others, when mixing and spraying polurethane paint must wear a chemical cartridge

of each shift and in the area of the aircraft approx imately 1 hour before the beginning of the pal nting of the aircraft. Additional floor wetting may be required to keep the

respirator,

overspray and other dust contained

Apply these coating systems only with adequate ventilation. Avoid with the skin and eyes. Do not ingest. Do not inhale vapors. WASH HANDS BEFORE EATING OR SMOKING. of liquid or with eyes may cause severe irriation. In case of skin , wash with soap and water. In case of eye , immediately wash eyes for at least 15 minutes: get medical attention.

Doors

on

the floor.

Hangar doors must not be opened for an hour before, during, and for at least 2 hours after the painting of an aircraft with the basic topcoat system. Restrict personnel doors so that only 1 door to the outside is available to foot traffic

during this time period.

Facility Requirements Lighting The spray room must be well illuminated (recommend a min of 50 ft-candles), using vapor and explosion-proof lights, and floor lighting equipment, when necessary. Air

The paint spray room must use filtered air. The amountof air forced into the spray room must exceed the volume withdrawn. Introduce air in such manner as not to cause Table i.

Spray Guns

and Accessories

I

TANK GUN TYPE GUN

FLUID TIP

DeVilbiss JGA ol´• TEA Model

Table 2.

or

FX

FF

or

AIR CAP

FX

FLUID TIP EX

765

or

EX

NEEDLE EX

or

AIR CAP

EX

30

Pressure Settings FINISHING MATERIAL

O

FF

NEEDLE

CVP GUN

FLUID TANK SETTING

AIR REGULA’Z~OR SETTING

AIR PRESSUHE AT SPHAY (;UN m

EpoxJ’ Primer

8-12 psi

60

psi

45

psi

Polyul´•ethane Topcoat

8-12

65

psi

50

psi

psi

Add 1 Ib of fluid pressu I´•e fol´• each ft of heightof the gun above the fluid tank level, for normal operation.

G1

Frequent checks should be made with determine air pressure at the gun.

a

test gauge to

20-30-35 Page 2 Aug 31/84

o

COPYRIGHT, 1984


SR-76-023 COHKOSION CONTROL MANUAL

MIL-C-83286 POLYURETHANE ENAMEL APPLICATION Re-abrade and rinse break free" surface.

Facility Requirements (Cont’d)

l’emperature and I-lumidity Temperature and humidity indicators must be installed and in pr´•oper operation during the time of painting and dry i ng. The temperature of the spray room must be in the and ranae of 60 to 950F (16 to 350C) 1 hour before, during, for 4 hours after spray painting this paint system. The relative humidity must be in the range of 25-759/0, during this

same

time

period.

rressurized Air Source

are

cleaned

Surface

or

changed

at

regular intervals.

Preparation

Cleaning and Stripping

a

"water-

Rinse with high pressure water rinse while agitating to removal of all sanding residues from abl´•acied

surfaces,

gaps, seams, etc.

After final rinsing and while aircraft is still wet, check several scattered areas of the aircraft for neutrality. Touch Thymol Blue indicator paper to the wet surface. If the paper remains yellow in color the surface is neutral; if the paper turns blue, the surface is alkaline and must be rinsed again. Repeat rinsing and testing until the surfaces

neutral.

Chemical Film Treatment While surface is still wet, apply Brush Alodine 1200 treatment (or equal MIL-C-5541 treatment) to all unanodized exterior surfaces. Thoroughly rinse, removing all traces of Alodine 1200 and repeat water-break free test. Anodized surfaces may be given 1 treatment of Alodine 1200 where required. Where the anodized surface is scoured. the brush alodine system is mandatory.

Remove strippable protective shop coatings as required. Mask off all plastics, rubber, fabric, ts, parts, and plated areas that might be damaged by paint strippers, chemical solutions or water by using aluminum foil or fabric tape and visqueen polyethylene film.


necessary to achieve

ensure

are

Air´• lines must be blown out at least twice each day (oftener, if necessary) when painting an aircraft to purge lines of any oil or water. As a further precaution, all air lines mustcontain an air filter and water separator which

as

(Continued)

to remove any

shop

coats of

paint.

chemical film epoxy primer within 24 hours after treatment. All surfaces must be thoroughly "dry" before application of the epoxy primer.

Apply

Mixing and Handling

Epoxy-Polyamide

Primer

(MIL-P-23377 Class 2)

Itc~move the loosened paint and contaminants with aid of a bristle brush and high pressure water spray, then dry surface. An alternate method of removing paint is by I iff htly scouring the paint area with abrasive pads Scotchbrile), Grade A or finer, moistened with MEK.

Thoroughly stir Component I until pigments are mixed. (Use shaker or equivalent method.) Reduction of Component I(pigmented solution) with Component Il(clear solution) is 1 volume to 1 volume. Temperature of components must be above 600F (160C) before mixing.

Remove final traces of organic residues by solvent cleaning. Ensure complete removal of all residues from gaps,

Component I is first poured into an empty container with adequate time for complete drainage. Component II then is slowly poured into Component I with constant stirring. Proper drainage time must be allowed for Component II. Each container of Components I and II may be rinsed with

seams

around fasteners, etc.

Abrading

Unpainted metal surfaces

must be abraded and

a

water-

break free surface achieved.

Thoroughly abrade metal surfaces with water and abrasive nylon pads. Ensure that the heads of all plated fasteners have been abraded. Spray water rinse immediately. While still wet, determine if a "water-break free" surface has been achieved. If the water film gathers into discrete droplets within 25 seconds after application of water, the surface has failed the test. If the water film stays in a continuous film of water (without a sudden flashout or the forming of droplets) then the surface shall be considered as having

satisfactorily ed the "water-break"

test.

the

non-photochemically

reactive solvent type thinner.

Component II must always be added to Component I. and this procedure must not be reversed. Never mix epoxy primer from one vendor with primer from another vendor. Components are not inter-

changeable. Two volumes of the Class 2 ired primer are thinned for sprayng by adding 1 volume of non-photochemically reactive thinner which is compatible with Class 2 primer. The spraying viscosity must have a range of from 17-20 seconds when checked with a No. 2 Zahn cup. The thinned

paint must be stirred thoroughly, strained through paint

2-:3 layers of lint-free cheesecloth) and allowed to stand at room temperature for 1 hour before

straining funnels (or

20-30-35 0


Page 3 Aug 31/84


MIL-C-8328(i POLYURETHANE ENANEL APPLICATION (Continued) Mixing

and

Handling (Cont’d)

Shelf Life of Coating Materials

Epoxy-Polyamide Primer (MIL-P-23377 (Cont’d)

Class 2)

using. This period shortens drying time, reduces cratering, allows any bubbles (formed by mixing) to escape, and is a preliminary period for the components to enter into

handling of the paints

and thinners to prevent water

chemical reaction.

ca8tamination.

Epoxy primer should be ired only in that amount that be used in an 8-hour shift. Discard, regardless of

Film Adhesion, Thickness,

can

appear´•ance, all material that is 8 hours old.

and Finish

Adhesion Check

Pol!-urethane Topcoat

The

Thoroughly

topcoat system has been allowed

Component I until pigments are mixed, Mix on shaker or equivalent method. One volume of Component II is added to 1 volume of Component I. Temperature of components must be above 60"F (16"C) stir

before mixing, First poul´• Component 1 into an empty container with adequate time for complete drainage.

Open Component II

can

if material is not clear

carefully. Discard Component II

or

has turned dark.

Slowly pour Component II into Component I with constant stirring. Allow proper drainage time far Component II. Each container of Components I and II may be rinsed with the non-photochemically reactive solvent type thinner, MIL-T-81772. Component II must always be added to Component I, and this procedure must not be reversed, 4

The unmixed materials (primer and topcoat) may be stored unopened for a max period of 1 year when stored at temperatures within the range of 35 to 950F (2 to 35"C) and the peak air temperature must not exceed 115"F (46"C). Precautions must be taken during storage and

Never mix polyurethane paint from one vendor with paint from another vendor. Components of different colors from the same vendor may not be interchangeable. Check components and batch numbers to assure compatibility for proper curing. For spray application, thin the ixture with solvent conforming to MIL-T-81772 to a viscosity of approximately 18-20 seconds when checked with a No. 2 Zahn cup. The thinned paint must be stirred thoroughly and strained thru paint straining funnels (or 2-3 layers of lint-free cheesecloth) before spraying. Mix only the amount which can be used immediately The pot life of the ired topcoat in a closed container is 6 hours. Clean spl´•ay equipment, guns, lines, and pressure pots thol´•oughly both before and immediately after use with

MEK. When MEK is not available, conforms to MI1,-T-81778.

use

the thinner that

following adhesion

test may be conducted after to air-dry a min of 168

hoU’S.

Randomly select areas to be tape tested. If failure occurs, select, additional areas to determine extent of faulty adhesion. To check pal nt adhesion, a piece of cloth or sponge is taputl the area under test and the cloth or sponge kept soaked for a min of 24 hours with tap water. Immediately after removing the wet cloth or sponge and blotting the surface water, apply a 1 in. wide strip of masking tape (Code No. 250, 3M Co.; only newly manufactured tape shall be used) adhesive side down. The tape is pressed down using 2 es of a4-1/2 Ib rubber roller, or by firm pressure with the hand. Remove the tape in one abrupt upward motion (900 to surface) and examine the tested area for any paint damage such as removal of paint at one of the layers of the finish system or removal of the entire system from metal. on

Film Thickness Film thickness tests may be conducted on all painted surfaces. The basic gloss white paint thickness measurements over 70% of the area shall be within 2.3-3.2 mils total dry film thickness and the average thickness shall not be greater than 3.2 mils. Areas that have additional overcoats of color or markings must not exceed 4.5 mils total dry film paint thickness. Film thickness may be determihed by use of a Permascope or equivalent instrument. Film Finish

Check the epoxy primer surface for specks and bumps by drawing gloved finger tips across the finish. There must be no seediness or roughness.

The final coatings must have

a smooth, uniform appearfree of dried overspray, runs, sags, and blisters. When examined with a 6X magnification lens, there should be no microcracks. (After flight, slight microcracks around highly stressed fasteners are not cause for refinishing.) A slight surface orange peel effect is not cause for refinishing.

ance,

20-30-35 Page 4 Aug 31/84

O

C~PYRIGHT, 1984

BY

SA~RELINER CORPORATION


MIL-C-83286 POLYURETHANE ENAMEL APPLICATION Film Adhesion, Thickness, and Finish I’’ilm Finish

(Cont’d)

of 3 hours and

a max

(Continued)

of 4 hours I,efore applying tol,zoat.

NOTE

(Cont’d)

The temperature of the surface to be pri´•med and the primer should be between 60 and 90"F (2 6 a.nd 35"Cj).

NOTE or rippling is caused by too high air pressure. Orange peel and sags result when the air pressure is too low or the fluid pressure is too high. Both epozy primer and the polyurethane topcoat build up in thickness ve~ rapidly.

nustilzg an

The white topcoat gloss value can be measured with a Gard ner 600 gloss meter. The average measurement must not be lower than 80%.

Nibs, dirt, and other primer coating imperfections

must

be smoothed or repaired before applying the polyurethane topcoat. Smooth using No. 400 grit abrasive paper. Immediately prior to applying the topcoat, tack off the aircraft using the GR-99 or equivalent tack rags. Wipe lightly with tack rags and do not allow tack rags to lay on the surfaces to be painted.

Topcoat Application Repairing Damaged Paint Films Surfaces requiring touch-up must be cleaned, using ME:K, since contamination of any kind will cause poor adhesion, cratering and premature film failure. Any pal nt area scratched or abraded to the bare metal must be treated with chemical film treatment,

Sand ing the cured paint film removes the gloss and causes coating deterioration. The touch-up of any scratches or damaged areas is restricted to that which can be accompfished by brush. Overspray cannot be removed from the topeout. If the damaged area cannot be touched-up by brush, mask the surface off at skin or part breaks and area for refinishing. Epoxy primer residue left on the stripped surface may be removed by abrasive pads and MEK.

strip the damaged

Do not touch-up balanced control surfaces unless damage to be repaired is minor and does not exceed approximately 1 square inch in area. If major repairs are required, completely strip and refinish the entire control surface, The paint film thickness is critical on these surfaces.

POI,YURETHANE SYSTEM APPLICATION Before application of epoxy primer, mask off areas not to be painted with the basic topcoat, such as, radomes, canopies, intake duct leading edges, etc. Immediately prior to painting, wipe the aircraft down with lint-free cloths moistened with MF,k to remove dust and dirt. Follow i ng this cleaning operation, rubber or nylon gloves must be used when touching the aircraft surfaces until the topcoat has been applied and dried. Primer

The polyurethane topcoat is sprayed over epoxy-polyamide primer which has been allowed to air-dry 3-4 hours. Apply a wet, thin coat of polyurethane, allou~ to air-dry for 15-30 minutes, then spray a full wet cross coat to a total dry film thickness of 1.7-2.3 mils. Large areas requiring the topcoat, such as the top surface of wings. must be walked on to properly apply th, topcoat, may have the topcoat applied by the box coat technique to achieve the required dry film thickness in one application instead of the two-coat system above. Large areas of the aircraft that will be overcoated by colors other than gloss white must be painted with only the first coat of the basic topcoat and the second coat feathered in at the edges of these areas to reduce the total film thickness. If the basic topcoat dries over 24 hours before the colors are applied, the surface must be lightly sanded with 400 grit abrasive paper and tacked off before

fuselage, etc., which

the colors

are

applied.

The first coat of polyurethane will not dry sufficiently to be touched or walked on between the first and second topcoats. Do not lean on the aircraft or allow the hoses to touch it.

Drying or curing time far the polyurethane topcoat is "dry hard" within a max of 8 hours. Actual drying time depends on the temperature and humidity of the spray room. The higher either or both are, the more rapid the topcoat

cure.

Application

After completion of the waiting period, the ired and thinned epoxy primer must be sprayed with 1 box coat to a dry film thickness of 0.6-0.9 mil. Allow to air dry for a min

20-30-35 0


Page 5 Aug 31/84

SR-76-023 C()RROSION CONTROL MANUAI,

MIL-C-83286 POLYURETHANE ENAMEL APPLICATION

(Continued)

Topcoat Application (Cont’d) NOTE

Spray and other equipment should be cleaned using MEK or MIL-T-8lrr~ thinner as soon as the epoxy primer and pol2lurethane topcoat have been applied. ClcanbineRs must be ezarc´•1:ssd since both these ,rLatc!rials, ortc´•e eu.red, are dZfficult to d’l:SSO11)P.

Prime and paint leading edge of engine ducts, cowling, wings, and stabi liters in the same manner as the aircraft. After the topcoat has cured (8 hours), mask off areas adjacent to the leading edge areas and apply additional coats tallow at least 30 minutes of drying time between coats) of polyurethane topcoat so that the total dry film th ick ness (pri mer plus topcoats) is bu i It-up to 3.5-5.0 m i Is. tIf drying time exceeds 24 hours between applications, surf ace must be sanded with 400 grit abrasive paper and tacked off prior to application of additional coats.) An alternate method for the application of the additional coating thickness on the leading edges is to free spray (~´•ithout masking) the additional topcoats required at the same time that the topcoating is being applied.

Insignia and Marking Application M as k i nR for i nsign ia an d mark i ng m ay be beau n after the a min of 8 hours. If drying ti m e ex ceed s 24 hou rs between appl i cations, surface m ust be lightly sanded with 400 grit abrasive paper and tacked off prior´• to application of additional coats.

coating has dried tack free,

20-30-35 Page 6

Aug 31/84

o

COiPYRIGHT,



HIGH INIPACT POLYURETHANE COATING APPLICATION (;ENEK´•AL

Safety

l‘his section covers the materials and procedures for the application of a high impact polyurethane coating.

Solvents and coating materials are toxic and flammable. Observe fire, health, and safety precautions to pl´•eclude injury to personnel or damage to equipment and facilities.

MATERIALS

Mixing and Handling

TT-M-261

Methyl Ethyl Ketone (MEK) High Impact Polyurethane Topcoat, 821X398, Color

The topcoat is a two-part catalyzing material that is purchased and stocked as a kit. When mixing, use only the catalyst indicated for use with the applicable base

Commercial

component.

6011, DeSoto Chemical Co. High Impact Polyurethane Topcoat, Catalyst, 910X152,

Commercial

Mixing Ratios:

DeSoto Chemical Co.

DeSoto Chemical Co. Paint Straining Funnels Scotchbrite Pads, Type A (~M Co.), Aluminum Oxide 400 Grit,

2.0 parts 1.0 parts 0.5 parts

Commercial

High Impact Polyurethane Topcoat Thinner, 020X310,

with

No. 2 Zahn cup. a

5 minute chemical reaction time before

using the

The usable pot life of the catalyzed topcoat in a closed container is 4 hours. When left in an open container the work life will be shortened.

Brothers, I,.A., CA

EQUIPMENT Pressure

Thinner, 020X,310

catalyzed material.

Commercial

Wipers, Sandler

a

Allow

Commercial

Paper Select Cotton

Base Component, 82123398 Catalyst Component. 910?(152

Viscosity should be 16.0-18.0 seconds when measured


Wet-or-Dry Abrasive

by volume by volume by volume

Mix/agitate catalyzed material just before and during use.

Spray Gun

17se a DeVilbiss MBC Spray Gun with a FX needle and nazzle and a No. 765 air cap. Regulate air pressure as follows: 6-9

i.

Pressure feed tank air

2.

Atomization air at spray gun

Always strai n the catalyzed mate ri al th ru pal nt strai ni ng funnels, prior to filling spray gun containers.

prior

to

Air

psi. .55-65

psi.

coating to d ry per one of the follow ing schedules handling.

Allow the

a

Dry:

6 hours min at ambient temperature.

Force Cure: Allow to air dry 1 hour min, at ambient expose to a temperature of 170

temperature, and then

to 1800F for 30 minutes min.

Siphon Cup (;un IJ se a I)eVi Ibi ss M BC Spray Gun with an E needle, nozzle and No.:30 air cap. Regulate air pressure to 55-65 psi.

APPLICATION NOTES Paint

Surface Preparation Ensure all surfaces have been properly treated, as required below prior to coating application of high impact material:

Spray Reem Requirements

Aluminum chemical film treat

I,ighting The spray room must be well illuminated, and explosion-proof lights,

Reinforced

using

vapor

Floors

plastic laminates

or

anodize.

clean and fill surfaces.

epoxy primed parts: Thoroughly abrade primed surfaces using Scotchbrite Pads. Type A, and wipe with clean cotton wipers dampened with MFJK to

Previously

remove

all sanding residues.

Sl,r´•ay room floors must be clean and free of rags, paper and other debris. l’emperature and Humidity The temperature of the spray room must be in the range of 60 to 90"F 1 hour before, during, and for 4 hours after be spray painting this system. The relative humidity must in the range of 25-75’Yo.

20-30-40 0


Page 1 Aug 31/84


HIGH IMPACT POLYURETHANE COATING APPLICATION Finish

(Continued)

Requirements

The

coating system must be free of defects which affect its perfor´•mance such as bubbles, pin holes, craters. The specular gloss of the 85, when measured with

applied topcoat must be a min of a 600 gloss meter.

APPLICATION OF COATING Prime,´•

ilpply a coat of SB0125-024 epoxy polyamide primer to the sul´•faces which have been cleaned and prepared. Topcoat

SDray apply a full wet cross coat of material mixed to a dry film thickness of approximately 1.5-2.5 mils. Allow to air dr´•y 1 hour. then apply a second wet cross coat. The total dry film thickness of the topcoat system should be 3.0-4.5 mils.

20-30-40 Page 2 Aug 31/84

o

COPYRIGHT,


SR-76-023 CORR()SION C()N’I~ROL MANIIAI,

URETHANE FINISH SYSTEM FOR SABRELINER AIRCRAFT EXTERIOR SURFACES SURFACE PREPAHATION

(;ENI1:RAI, ’I’l-lis section establishes the recruirements for a paint finish system for the exterior surfaces of Sabreliner ai rcraft. This paint system is appl icable to the appropriate for each ai rcraft or ex ter ior´• pal nt and markings d rawings

The follow ing procedu re and precauti ons m u ~t be fc,l low ed to prel,l-lre the airc´•raft for final paint applications

motiel.

Before painting, metal surfaces must be properly cleaned and stripped, otherwise an unacceptable paint job will materials occur. Stripping must be accomplished using and procedures established in 20-30-25.

’rho primer to be used is material,

a

two-component urethane

7’he topcoat is a two-component urethane enamel.

aliphatic isocyanate

Cleaning and Stripping

Masking

including well areas external environment during flight or on the

All exterior surfaces of the aircraft,

exl,osed to ground must be finished.

Masking is required to prevent damage to windows, windshields, radome, deicer boots, and other exterior details of the aircraft that

are

not to be

painted.

MA’L~ERIALS

Removing Shop Coating

The materials itemized below are required in performing the process specified herein. Items identified by a specification number or a manufacturer’s name are known to be suitable.

In-process protective shop coatings, such as Turco 498~ of Fabrifilm, applied to the bare portions of subassemblies

Alumiffrip Urethane Primer Alumiffrip Urethane Enamel Alum~Rrip (:atalyst;

I~rethane Thinner T-7:32A Methyl Ethyl Ketone (MEK) Thymol Blue Indicator Paper Air´• ’I’ec. No. 19 (:hem ical (:onversion Coating MHskinR’l’;lpe No. 250

U.S. Paint AA-92-Y-43 U.S. Paint AA-92 T~.S. Paint AA-92-C-3I3 U.S. Paint Commercial Grade Van Waters Rogers Los Angeles, CA Turco Products, Inc. MIL-C-T,S/I1 3M Co.

INSTAI,LATION NOTES

Facility Requirements

priming and finish coating of the aircraft performed in a facility suitable for the purpose.

The

must be

Air´•

facility must be provided with a filtered forced air ventilating system capable of producing a dried paint film conforming to Adhesion and Finish below.

The

Temperature and Humidity Painting shall be done only at temperatures between 70 and 80"F and a relative humidity between 40 and 650/0.

must be removed in accordance with

Removing Sealant Residues and Markings Sealant and/or zinc chromate residues resulting from fastener applications and surfaces that show grease pencil marks or other obvious shop soils must be I´•emoved using

cleaning solvent

or

MEK.

Cleaning After completion of the above items, the aircrait must be cleaned with Air Tec No. 19. The cleaninR solution is mixed by adding 5 parts by volume of tap watel´• to 1 pal‘t by volume of Air Tec No. 19 concentrate.

All exterior surfaces of the aircraft are to be sprayed with the mixed cleaner and thoroughly scrubbed with tampico brushes. After rinsing, the surfaces should be abraded using Scotch-Brite, manually or with air driven ScotchBrite roller

pads.

Rinse the aircraft with tap water under line pressure. The rinsing shall be sufficient to ensure complete removal of cleaning solution and soils. Itepeat the wash. rinse. and abrade operations above to any area when the rinse watel´• "breaks" from the surface at a faster rate than the adjacent areas, indicating that all soils have not been

removed.

Pressurized Air Source air used for drying and spraying purposes filtered, dry and free from dirt and oil.

Compressed must he

supplier’s instructions.

After final rinsing and while aircraft is still wet, several scattered areas of the aircraft must be checked fot´• neutrality. Thymol nlue indicator paper must I,e touched to the wet su rface. If the pape r´• rem a i n s ye IloM~ th s 1 rf ace i, neutral; if the paper. tur.ns blue, the surface is alkalinc~ and the area must be rinsed again. Rinsing and testiny must be repeated until the surfaces are neutral.

20-30-45 0

CQPYRIGHT, 1984 BY SABRELINER CORPORATION

Page 1 Aug 31/84


URETHANE FINISH SYSTEM FOR SABRELINER AIRCRAFT EXTERIOR SURFACES (Continued) Chemical Film Treatment

PotLife

While the aircraft is still wet, apply chem-film solution (refer to 20-30-30), using a spray or mop, to the exterior areas of the aircraft. The surfaces shall be maintained wet with chem-film solution. After application time has expired, rinse the aircraft, blow excess water from seams and recesses using filtered, dry air. Move the aircraft to the spray area and allow to dry prior to paint application.

Both the

primer and topcoat are two component materiais. Mixing must be accomplished in accordance with manufacturer’s instructions. The proporation of catalyst to base material must not be varied or the curing or performance of the coating will be adversely affected,

2 Parts 1 Part

T-732A

Alumigrip Urethane Enamel has a 800F.

max

pot life of 8 hours

at

The urethane top coat prepared above must be applied at dry film thickness of 1.25-2.25 mils for colors and 1.5-2.5 mils for white. Total thickness of system is 1.75-3.20 mils. Less than this will result in lower gloss.

Maximum protection and film build is achieved by first a tack coat followed by a wet coat.

spraying

MIXING AND HANDLING

Primer

AA-92

i

Preparation AA-92-Y-43 AlumigripUrethane Primer AA-92-C-33 Alumigrip Urethane Catalyst Urethane Thinner as needed

Enamel topcoat should be allowed to air dry a min of 12 hours to obtain 70% hardness, or tape dry condition. Surfaces will normally be dust dry in 4-5 hours. If finished surface is to be recoated, lettered or a stencil enamel is used, this must be applied within a 36-hour period. A longer time will necessitate a light sanding to remove g.loss before recoating or lettering.

CLEAN-UP

T-732A, MEK or cellulose cleaning equipment.

Reduced spray viscosity 18-20 seconds, No. 2 Zahn cup. After mixing, allow mixture to stand ~O minutes before

acetate may be used

for

ADHESION AND FINISH

application. PotLife

AA-92

Alumigrip Primer has

Film Finish a max

The topcoatings must have a smooth uniform appearance.

pot life of 8 hours at 800F. PRIMER APPLICATION All bare and previously primed surfaces must be primed, using material prepared above to a dry film thickness of 0.5-0.7 mils.

Primer should be allowed to dry 4 hours before topcoat is

applied, Primer should be topcoated within 48 hours. Longer periods will necessitate a light sanding with 320- or 400grit abrasive cloth or paper and an additional light primer coat. ´•Tack rags must be used as required to remove dust after sanding: wipe gently, do not apply heavy pressure,

APPLICATION OF URETHANE TOP COAT

1 Part T-732A

GIoss

The topcoat must have a min gloss value of 75 when measured with a Gardner 600 Gloss Meter. Adhesion The applied coatings must the tape test described below. The test must be made directly on non-mold line surfaces of the aircraft. The test must be made on a sufficient number of areas to assure that adhesion requirements are met. The coatings must be allowed to air dry for min of 24 hours at room temperature before testing. Plastic laminates must not be selected for adhesion

testing.

Paint Preparation 1 F:lrt

The finish must be free from dried overspray, runs, sags, blisters, dirt, dust and lint. A slight orange peel effect is ch"racteristic of polyurethane coatings and is acceptable.

Alumigrip Urethane Enamel (color selected) Alumigrip Urethane Catalyst UrethaneThinner(as needed)

Adhesion tests (dry tape test) is performed below.

as

as

described

Scratch thru the coating with a scribe made from 6061-0 aluminum. The scratch should be approximately 3 in. long.

Reduced spray viscosity 18-22 seconds, No. 2 Zahn cup After mixing, allow mixture application.

to stand 30

minutes before

20-30-45 Page 2 Aug 31/84

o

COPYRIGHT,

1984 BY SA&RELINER CORPORATION


URETHANE FINISH SYSTEM FOR SABRELINER AIRCRAFT EXTERIOR SURFACES (Continued) Adhesion (Cont’d) a 1 in. wide strip of No. 250 masking tape (3M Co.) that the scribed area is completely covered. Use only newly manufactured tape. Press the tape firmly into place by rubbing with the thumb while exerting max pressure.

Apply

so

Kemove the tape in one abrupt motion while maintaining such as an angle of 90" and examine for any paint damage blistering or removal of one or more layers of paint.

Repair the scribed

area

with

a

brush

or

spray

coating.

Failure of the finish to meet the above adhesion test will 2 complete retests performed on the suspected of the retests, area of the aircraft. If the finish fails either the suspected area, section, or entire aircraft must be stripped and repainted. Failure is defined as removal of 25% or more of the -paint film under the tape.

require

NOTE Bare aluminum 4 by 8 in. %0~4 s (anodixed) taped to the cabin window areas (at least one on, each side of the aircraft) and processed with the aircraft, mall be

uged~for adhesion testing,

20-30-45 0




WRINKLE FINISH APPLICATION with spray

application.

(;ENERAL

1.

Clean surfaces

’I’h is section covers the application ofa baked-on enamel to mt´•t;lllic surfaces so as to produce a wrinkled finish,

2.

As appropriate, brush cleaned metal I,art.

3.

Apply enamel without reduction brushing or spraying.

4.

Allow enamel to dry, without forcing by heat sunlight, until the wrinkle pattern forms.

5.

Do not handle finished part until 14 hours have elapsed. Do not apply an additional Coat within 24

MA’I’ERIAI,S

Enamel; Wrinkle-Finish, for

MIL-E-5558

Aircraft Use Primer Coating, Zinc Chromate, Low-Moisture-

MI7,-P-8585

Sensitivity Xylene (For Use in Organic Coatings)

TT-X-916

INSTALLATION

Cleaning

same as

or

spray

primer in

coat

on

viscosity. I,y ol´•

hours. Finish Consistency The wrinkle pattern, gloss, color, and texture of finished parts should be consistent over entire surface regardless of application method.

Clean metal surfaces to be wrinkle finished using methods (contained in this chapter) appropriate to the metal surface. Final cleaning of the surface is with xylene TT-X916 and clean rags.

Priming After being cleaned, the metal surfaces are given 1 coat of MII1-I’-8rj85 primer. Wrinkle Enamel

Preparation

If the wrinkling agent and the baking enamel are packaged separately, mix the required quantity of with the enamel and stir thoroughly. If

wrinkling agent further thinning is required after mixing the wrinkling agent with the baking enamel, add xylene gradually while stirring the mixture until the desired spraying consistency is attained. Wrinkle EnamelApplication

Apply baking wrinkle enamel by spraying in one direction and then in a direction perpendicular to the first. The enameled parts must have a uniform wet-film thickness of 0.0(15-0.(308 in. Drying and Baking After spraying, air dry the enameled parts for 15 minutes and then bake for 2 hours at a temperature of 200 to 2500F.

Touchup and Non-Bake Application Inaccessible areas not easily reached by spraying and the paint is areas that cannot be cured by heat after applied may be finished with an air-drying wrinkle enamel as follows:

20-30-50 0




LAMINATED AND MOLDED PLASTIC PARTS FINISHING (;ENERAI,

Dry Sanding (Alternate)

’I’h is section covers the materials and pr´•ocedures used for filling minor imperfections antf pinholes in plastic laminalo surfaces Itrior to application of I,rimers and/or paint Finishes.

After preliminary solvent wash, dry sand using wet or’ dry carborundum paper, 240 grit or abr´•asive nylon ~,ads. medium grit, as necessary to clean and remove gloss from laminate surfaces and indentations. When sanding use circular motion. All areas must present a matte al>pearance. Do not sand thru the outer´• ply of cloth; hou~t´•ver. isolated local abrasion of the cloth is acceptable.

MATEKIALS

Ey,ibond 156, Surface Filler

Furane Plastics

Los

Use filtered air blast to

Angeles, CA

U.S. Paint

Sur´•facer 84-A28

Commercially

Scotch Rrite Pads, Medium (;rit ~ar´•borundum Paper, wet dry ((;rit size 180-400) nenatured Alcohol

available 3M Co. or

MIXING AND HANDLING

Mixing Surface Filler

3M Co.

Using a clean metal, glass, or polyethylene container, thoroughly m ix the 2 components of the applicable surf ace

Commercially

filler.

available Sandler Brothers Los Angeles, CA

(:lean select cotton wipers

?’richloroethane, 0-T-620 i, i, 1, Technical, Inhibited

all sanding residues.

Wash surface with clean cotton wipers saturated with MEK. Wipe dry.

Lacquer Co.

Methyl Ethyl Ketone (MF;K)

remove

Measure in the following proportions:

Epibond

Commercially available

156

100 parts by weight No. 156 surface filler 6 parts by weight No. 956 hardener

INS1’ALLATION N~)TES

Surfacer 84-A-28

Preparation

Surface

Prior to manufacture andlor fabrication of plastic parts, mold release or parting agents are applied to tools to fac´• ilitate removal of parts after cure. During this process, the releasing agent transfers to the ing surfaces and may be tyansparent, translucent, or opaque in form. Thr!se affellts must be completely removed in order to

obtain subsequent adhesion of

applied fillers and/or

paints. Wet Sanding

(Preferred)

When surfaces remove

are

severely contaminated,

solvents to

ul, the

wipers and

a

stiff

reduce

approximately

25% with T816

Work Life of Catalyzed Filler

Epibond 156 exhibits exothel´•mic reaction (temperature rise) as it cures. This temperature rise during mixing and before application reduces work life. To prevent shortening work life due to internal heat build up, the Epibond 156 may be spread in a thin layer on an aluminum sheet. only the amount of filler that can be used during wol´•k life listed below: 30 minutes 4 hour´•s

156:

Surfacer 84-h-28:

residuals with clean wil>er´•s while surface is

SURFACE FINISH

Water. sand, using wet

or

dry carborundum

paper, 180-

grit.

Thoroughly rinse with clean tap water, observe water break. (An acceptable part will momentarily an unbroken film of water for 30 seconds). Remove water

spraying

reducer.

F,pibond

still wet.

400

For

Mix

heavy deposits.

Scrub repeatedly with clean cotton bristle brush, saturated with MEK.

Wil,e

use

9 pal.ts by volume No. 84-A-28 surfacer 1 part by volume No. 84-C-13 catalyst

by wiping dry with clean

cotton

After filler has cured, sand off all excess fillel´• using No. 240rit carborundum abrasive paper followed by a final sanding using No. 400 grit carborundum paper. Remove all sanding residues using clean cotton wipers.

Apply primers and/or top

coats

as

applicable.

wipers.

Wash the surface at least twice with denatured alcohol and wil,e tlry.

20-30-55 COPYRIGHT,

t 984 BY SABRELINER CORPORATION

Page 1 Auff.31/84

CORROSION CONTROL MANUAL

LAMINATED AND MOLDED PLASTIC PARTS FINISHING

(Continued)

FILLER APPLICATION

Apply Epibond lli6 using a plastic squeege os glazing knife. Force filler well into the minor imperfections and pinholes. Remove all excess filler with squeege or knife to prevent excessive buildup and subsequent unnecessary sanding.

Spray apply uniform wet cross coats of Surfacer 84´•A-28 required to ensure total coverage.

as

Allow the

applied catalyzed filler

to

cure

per

one

of the

following schedules: Epibond 156

Air

cure

Surfacer 84-A-28

Air

dry for

for 12 hours at 770F OR Force cure for 1-3 hours at 1500F 1 hour at 77"F

20-30-55 Page Aug ~1/84

o

CaPvRiaHT, 1984

BY

$ABRELINER CORPORATION

SR-76-023 CORR()SION CONTROL MAN1’AL

ABRASION RESISTANT COATING APPLICATION GENERAL ’l’h is section

(:oating"

to

covers

the

application of "Abrasion

Resistant

aluminum, aluminum alloys, magnesium

alloys, steel, and corrosion resistant steel. MATERIALS Wash Primer Abrasion Resistant

Coating

MIL-C-8514 LB0125-011

INSTALLATION NOTES Surface

Preparation

All surfaces to be coated must be free of oxides, scale, oil, steel surfaces must grease and other contaminants. CRES be primed with MIL-C-8514 wash primer.

Mixing and Handling The coating is mixed in accordance with the manufacturer’s instructions. Usually the mixed material is of the correct consistency for spray or brush application. If additional thinning is necessary, no more than 5% (by volume) of thinner recommended by the manufacturer.

APPLICATION, CURE, AND FINISH

Coating Application The coating may be applied by conventional

spraying and

brushing techniques. Apply 2.5-3 mils of the coating al lowing a min of 10 minutes air dry between coats. If over 3 mils of coating are required, the dry time between coats is a min of 1/2 hour. Cure

applied coating must be fully cured using following methods before placing in service:

The

i.

Air

cure

2.

Air

dry for 1 1/2 hour.

for

at

room

one

of the

temperature for 7 days.

hour followed by baking at 250 ~1O"F

Finish The cu red coating must be smooth, continuous, and free of scratches, seeds, and other visible defects. Cured coating must be of sufficient hardness that no intlention is visible after scratching with the fingernail. (~n cured coating, apply a piece of 1 in. masking tape (3M Co., No. 250). Rub with the thumb to insure good . Remove the tape in one abrupt motion. No coating must be removed.

Touchup scratched or abraded coating. Coating exhibiting poor adhesion must be

stripped

and

reapplied.

20-30-60 0




RAIN EROSION RESISTANT COATINGS APPLICATION (;ENEKAL covers the matel´•ials and procedures for the of a rain erosion resistant coating to glass applicalion Fa,ric resin laminates,

’I’his sect.ion

Sul´•faces to be coated generally consist of glass fabrilastic resin laminates. The coaling, basically neoprene rub~,er, is intended to pr´•otect such parts from rain erosion dur´•ing high speed flight and is primarily applicable to ail´•c´•raft leading edges. The coating provides protection only if it is of adequate thickness, even in thickness, well bonded, blemish free, and completely ed. Blemishes and areas ed by a pitted surface erode very rapidly, while poorly bonded areas blister under rain

impact. ()nce the coating has been completely penetrated, bseq uent water droplets, along with the ai rstream, peel the coating from the laminate surface. This exposes the laminate to rapid el-osion by direct impact.

su

MATERIALS (;aco N-79 Radome Coating Kit Consisting of: Gaco N-18 Primer (;aco N-7()0-9 Top Coat

Top Coat Accelerator No. lfi6 Surface Filler and No. 956 Hardener

Gates Engineering Co. New Castle, DE

~ac´•tt N-:S00-9

(;aco N-4.50-9 Diluent

Methyl I~thyl Ketone (MEK) Toluene

Xylone

obtain a shelf storage life of 8 months from date of manufacture without deteriol´•ation. If the I, ri mcl´• i s stor´•ed at room temperature the storage life is r´•t´•ducetl to’) months. Matel´•ial showing evidence of gelation must not be used.

Catalyze

the N-700-9

hours after catalv7,ation. Both the Craco N-18 primer and the Gaco top coat material N-´•150may be thinned to spraying consistency with Craco 9 diluent or a 50:50 mixture of MEK and toluene or xylene. For best results thin 1 pint of catalyzed N-700-9 to 1 quart of N-450-9 thinner. The top coat thickness in the fully cured condition must be 0.0085 +0.002 in. Obtain this thickness by spraying a calculated quantity of the material evenly over the surf ace of the part. This "calcuiated quantity" for each part being coated is determined as follows:

(Area of Part)X (K)= Wt. of Spray Material As Received where K is a factor dependent upon the desired coating thickness, the solids content of the coating material, and the density of the finished coating. K is determined

F’ur´•ane Plastics, Inc. Los Angeles, CA Gates Engineering Co. New Castle, DE TT-M-261 TT-T-548 TT-X916

In

The coating must be applied only to sanded surfaces completely free from pinholes, voids, or other surface irregularities. Following initial sanding, any pinholes or slight surface defects must be repaired per "Laminated and Moltfet´•l Plastic Parts Finishing" in this chapter.

follows:

as

(Thickness in inches) (density in ozi i n.:l) (10())

K

Solid content

general, the val´•iables

are

as

fairly

percent constant at:

0.009 in.

Thickness

0.69Soz/in.:’

Density= 1.20g/cc Solids= 35%

(0.009)(0.69~)(100)

INSTAI,LATION NI)TES Surface Preparation

per the manufacnlust be used \I’ithill t(

coating being used

turer’s instructions. All materials

Therefore K

35

Then, the amount of material part will be:

0.0178

to spray on an~

(Area of Part in inches")(0.0l78)

pal.ticular

of as received matel´•ial requiretl

ounces

An additional amount will have to be allowed for

over-

spray.

Mixing and HandlinR A l’u II closed contai ner of (;aco N -700-9 Tap Coat material 70 m ay be sto red u nder standard cond itions (temperatu I.e to SOOF) for 8 months from date of manufacture without deterioration. Full closed containers of Gaco N-18 primer must be stored at a temperature between 40-50"F to

Finish The cured

coating

pinholes, lumps,

completely free of blisters, and any other surface irregu-

must be

runs, sags,

larities. Th, total thickness of the coating(primer plus top coat) in all areas must be between 0.0087-0.0111 in.

fully cured coating mag be cleaned with water and mild detergent. Other solvents must not be used. A

a

20-30-65 0


Page 1 Auff:31/84


RAIN EROSION RESISTANT COATINGS APPLICATION Finish

(Cont’d)

(Continued)

COATING APPLICATION

Polishing

Remove surface dust by blowing with clean air or by a clean cloth dampened with toluene dr a similar solvent.

wiping with

The

coating

was

such

as

may be polished with a carnauba base paste Simoniz, Mac’s, or Johnson’s. Liquid type oils,

polishes, cleaners,

etc., must not be used.

Touch Up When coating damage is not localized or if damaged area exceeds 5’ro of coating area, repair by removing the entire coati ng and applyi ng a complete new coating, The coating may be removed by placing cloths saturated with toluene, xylene, or MEK on the surface for 20-30 minutes. Before the coating is reapplied special attention must be given to surfacing the area where the defects were noted. When defects

are

localized and the total of the

Spray

brush the prepared surface with Gaco N-18 a dry film thickness of 0.0002-0.0006 in. ()ne coat will normally suffice. If the primed surfaces are not perfectly smooth, remove nibs by lightly sanding with No. 280 sandpaper after primer has been allowed to air dry a min of 45 minutes. or

primer

areas

to

When the coating is to extend to any edge of a part, the coating must extend around the edge of the part as shown in figure 1.

of the

coating 1´•equiring replacement does not exceed 5% of the coated area, the damage may be touched up as follows: i.

Mask-off

2.

With a sharp knife carefully cut and strip the film \vithin the masked area. Do not cut into the plastic laminate. Next. scuff sand the exposed laminate with sandpaper, taking care not to loosen the edges of the adjacent coating. I~l´•ush the preparetl area with (;aco N-lt~ primer. This p,´•i mer must be brushed extremely carefully so that it barely s the edge of the adjacent coating. The presence of more than a slight amount of primer solvent against the coating will cause blistering and loss of adhesion, and necessitate repeating the entire repair procedure. Air dry the Gaco N-18 primer for at least 1 hour prior to application of the top coat.

4.

Apply sufficient number of coats of catalyzed top coat to make the repaired area slightly higher than the masking tape, allowing an air dry of at least 30 minutes between coats. The top coat may be applied with a brush or spatula, depending upon the size of a

the 5.

COATING

LAMINATE

Coating Ilaminate EdR´•es Pigul´•e

1.

dry the patch for

temperature prior

to

a min of 96 hours at illstallation of the part.

Spray the

rain erosion coating with a speed and pattern that will result in an even, uniform, wet,

smooth coat. 2,

Allow each coat to flash off for approximately 10-15 minutes before the next coat is applied.

NOTE The initial coats should be very light in, order to prevent thP Gaco N-1(3 primer being dissolved into the topcoat material. Allow sufficient dr2ling time between coats

After the last coat of the top coat has dried for 24 hours 1´•emove the masking tape and cautiously feather the edges of the repair using a clean cheese cloth slightly dampened with toluene. Use of an

Ail´•

1

After primer has dried at least 60 minutes spray the surface with the top coat material as follows:

repair.

excessive amountof the solvent in this operation will c;~use bl istering and loss of adhesion, and necesssitate I’cl,~‘;ltillR the ent.ire I,roc’edu,´•e. ti.

I

rectangle which includes the defective area plus a perimeter of at least 1/2 in. of non-defective area. The masking should be at least 2 in, wide. a

to

3~

prevent sagging.

If entrapped bubbles are present in the coati ng, they should be dispersed by spraying the surface with a. mist coat of the N-450-I) thinnel´•.

room

20-30-65 Page 2 Aug 31/84

o

COPYRIGHT,

1984 BY SABRELINER CDRPORATION

SR-76-023 CORROSION CONTROI, MANUAI,

RAIN EROSION RESISTANT COATINGS APPLICATION

(Continued)

COATING APPLICATION (Cont’d) 4.

A min of 9 spray coats normally should be applied to achieve required film thickness (0.0085 +0.002).

T,.

Tht! following spray combination or its recommended for best spray results;

equivalent is

DeVilbiss MUC spray gun TII’-AV15EX Cap 704 Pot Pressure 4-6 psi Atomizing I’ressure

15-25

psi

The finished coating must be air dried for a min of 96 hours at room temperature prior to installation of the coated part. In an emergency the coated article may be put into service after farce curing 3 hours at 150"F.

20-30-65 0



SR-76-023 CORROSION (:ON’rR()L MANl.iAI,

SPRAY PAINTING METHODS AND TECHNIQUES ~INSTRUCTION AND INFOR1MATION GUIDE) (;ENERAL covers general spray painting techniques, eclllil,mcnt use and maintenance for air type spray equipnicnt and painting facilities.

This section

7

3

´•~´•´•-´•r´•´•´• ´•´•´•´•´•-´•-´•i´•´•´•--´•´•-i´•´• i-´• only and does not contain inspection requirements. Specific requirements specified elsewhere must take

+3

precedence.

I..~

EQUIPMENT

2

‘6

IPI

Spray Gun A spray gun is

a

tool

using compressed air

to atomize

spr´•ayable material and apply it to the surface. Air and material enter the gun thru separate ages and are mixed and ejected at the air cap in a controlled pattern. A typical spray gun is shown in figure i. Common

Type Spray (;uns

PressureFeed

i.

AIRCAP

5.

FLUIDADJUSTMENT SCREW

2.

FLUIDTIP

6.

AIRVALVE

3.

FLUIDNEEDLE

7.

SPREADER ADJUSTIENT VALVE

4.

TRIOOER

8.

OUNBODY

A spray gun with an air cap not necessarily designed create a vacuum, (The fluid tip is generally flush with the air cap), Material is forced to the gun by air pressure from of the same a tank, cup or pump. When large amounts color material are being used, when the material is too to

heavy to be siphoned from when fast

application

is

a

cupor container

required,

a

by suction, or

pressure feed gun is

Standard Nozzles The letter(s) identifies diameter is in inches.

used. Suction Feed A type of spray gun in which

a

stream of

compressed air

force a vacuum allowing atmospheric pressure to material from an attached container to the spray head of the gun. This gun is usually limited to quart-size containthe fluid tip ers or smaller and is easily identified by feed guns Suction air the cap. extending slightly beyond and small are used where there are many color changes amounts of material involved.

creates

These two types

Principal Parts of Spray Gun Figure 1

can

be further divided into bleeder and

non-bleeder, external and internal mix and pressure, gravity or suction feed guns. Other types include automatic, extension and special spray guns.

0.086 0.078 0.070 0.070 0.070 0.055 0.047

D DE E EE EX FF FZ

i

the

nozzle, while aperature FX F G H AS AC CS

0.0425 0.041 0.028 0.018 0.140 0.110 0.110

Pressure Tanks Pressure feed tanks (pots) are closed, metal containers, ranging in sizes from 2-120 gallons, that provide a constant flow of material at a uniform pressure to the out of the tank by spray gun.ISee figure 2.) Fluid is forced To material. the change the rate to air applied compressed of flow, air pressure must be increased or reduced. Pressure tanks are constructed for working pressures as

high

as

110

psi.

20-30-70 o


Page 1 Aug 31/84

SR-76-023 CORHOSION CONTROL MANUAL

SPRAY PAINTING METHODS AND TECHNIQUES (INSTRUCTION AND INFORMATION GUIDE) (Continued) Pressure Tanks

Air Pressure

(Cont’d)

Where continuous production is maintained, pressure feed tanks provide a practical, economical method of feed ing material to the spray gun. The flow of material is posjtive and uniform.

When specified, use the air pressure indicated in the applicable section. The indicated pressure is a recommendation only, unless a close pressure control (psi) is indicated by a section.

Usually production material in constant use may be left in pressure pots under constant agitation,

When not

s

6, 12

4\

specified, use the general pressure of 45 psi for lacquers, primers and 50 psi for enamels, urethanes, etc. NOTE

a

Pressures

p9/

measured and maintained

trigger to indieate true air pressure, or adjust main line air pressure to compensatefor hose length air pressure dropfrom

to

tr~L

11

are

at the spray gun. Insert a temporary air gage at gun end of air hose and pull gun

~g 64

table i,

i.

SHELL(POT)

2.

CLAMP-ONLID

7.

OUTLEfVALVES,AIR INLET VALVE

(POT HEAD)

8.

SAFETY RELIEF VALVE

3.

FLUIDTUBE

g~

AGITATORS

4.

FLUIDHEADER

10.

PRESSUREREGULATOR

5.

AIRVALVE

l1.

PRESSURERELEASE

FLUID VALVE

12.

PRESSURE GAUGE

Pressure Tank

Figure Table 1.

Air Pressure

Drop

2

In Hoses

AIR PRESSURE DROP AT SPRAY GUN IN PSI AIR HOSE INSIDE I)IAMETER ANI) INI)ICATED LINE PRESSURE

At 40 Ibs At 50 Ibs At 60 Ibs At 70 ibs At 80 Ibs At 90 Ibs

5-FT LENGTH

2-1/4 3

3-3/4 4-1/2 5-1/2 6-1/2

tO-FT

LENGTH

2-3/4 3-1/2 4-1/2

15-FT LENGTH

20-FT

LENGTH

4-1/2

4 5 6

6-3/4

7-1/4

6-1/4

4 5 6 7

8

7-1/2

8-1/2

9-1/2

5-1/4

25-FT I,ENGTH

8-3/4 re-1/2

S0-E’T LEN(;TN

X-1/2 10

11-1/2 13

14-1/2 16

20130-70 Page 2 Aug 31/84

o

COQYRIGHT, 1984 BY SABRELINER CORPORATION


SPRAY PAINTING METHODS AND TECHNIQUES (INSTRUCTION AND INFORMATION GUIDE) (Continued) Equipment Cleaning

Air Line Filters Irse an air line filter which is adequate to remove water and oils, a DeVilbiss No. P-HLG air transformer, or

Insure that equipment, such

equivalent,

are

Drain fluids from air line filters at least

once a

day.

siphon

or

as

spray guns, material hoses, paint pumps

pressure cups, pressure pots and

clean prior to introducing materials color.

or

changing

a

Time of Cleaning Hoses

Fluid Hose Use

only solvent resistant hose, Thiokol cored, a min I.n. of 3/8 in. Length should

ecluivalent. IJse

or

not

exceed 50 ft.

Materials are easily removed while in the wet state and become harder to remove as they begin to harden. The most practical method is to clean painting equipment immediately after use. Pressure Pot Care

Air Hose

NOTE Where necessary the lengthfrom main line regulator or tank may be increased to a

to

of 150 ft provided only high pressure hose with a min I.n, of rllB in. is used.

mat

Unless otherwise specified by applicable sections production materials in constant use may be left in pressure pots under constant agitation. At least once a week or when paints begin to build up and cake on the upper surfaces of the pot or on the agitator or head, the pot must be cleaned follows:

as

i.

Dump or drain remaining paint into an auxiliary pot Or can.

17se a min I.D. of 5/16 in., except an I.D, of 1/4 in, may be used for small touch-up type spray guns. Length should not exceed 50 ft.

2.

Clean pot using scrapers, brushes, rags and the recommended solvent or stripper for the type of

paint.

CI,EANING

rw!nmnzl

The meticulous cleaning and surface treatment of all metal surfaces prior to all painting operations cannot be of prime importance overem phasized, si nce this factor is i n obtai ni ng a satisfactory pal nt fi n ish. Reclai med thinner must not he used for cleaning purposes, since these matel´•ials may leave a grease film which will cause poor adhesion. (:leaninK shall be accomplished with solvents which have no damaging effect on the surface and which produce surfaces that are satisfactory for receiving subsequent finishes. Cleaning materials which may be effective against one type of contamination may be ineffective another. Only recommended and approved clean-

When cleaning the pot head, protect the safety valve, pressure gauge and pressure reliefualve inletsfrom eontaminants such solvents or strippers which as paints, would damage the ltelms. 3.

relief valve. 4´•

Replace head gasket or filler cap gasket when evidence of flaking or cracking is apparent. Damaged gaskets will cause pressure leaks and/or of rubber. gun, or hose plugging from bits

5.

Remove fluid outlet valves and inspect for plugging condition. Clean as or otherwise contaminated necessary and re-assemble.

6.

Insure that

against ing materials shall be used.

Cleaners and Strippers for Paint Equipment

following equipment cleaners or strippers degree of hardness of the material.

Choice of the

depends

on

Wet State Ilse

Semi-cured

(Cured) State

paint stripper, Turco

7. 5351,

agitator and

motor

condition. Request repairs this condition.

methyl ethyl ketone (MEK).

Hard I~se

or

a qualified maintenance mechanic may repair inoperative safety valve, pressure gauge. or pressure

Only

as

are

in

good operating

necessary to maintain

insure or wipe down with clean solvent to complete removal of any residues or contaminants.

Rinse

20-30-70 0


Page 3 Aug 31/84


SPRAY PAINTING METHQBS AND TECHNI&VES (INSTRUCTION AND INFORMATION GUTDE) (Continued) Pressure Pot Care 8.

Strain

pressure

9.

(Cont’d)

all materials

during filling

refilling

or

pat.

Pressure pots containing materials must be kept under constant slow agitation. Insure that agitator motors are never turned off.

paint pigments from settling in the fluid hose during periods of non-use, flow back the fluid to the use as

follows:

i.

Keleasepressurein paintpressurepot.

2.

Loosen air cap and hold Pull gun

spray guns clean and in

good operating condition.

rags, and the solvent recommended for cleaning the particular paint while it is wet or semi-cured.

Use brushes,

To prevent

pot after

~pray Gun Care

~eep

Fluid Hose Care

pressure

At the end of each work shift, or immediately after use, ~hen paint will not be re-used during the work shift, clean the fluid hoses, using a hose cleaner or pressure pot and the solvent recommended for cleaning the applicable material.

trigger

a

folded rag

full open for

a

over

Clean immediately after use and during use and as follows. (See figures 3, 4, and 5.)

Operation has been successfully plish.ed when fluid hose can be fluctuate from surge of pressure.

Remove and soak air cap until paint is softened. Brush away residues. Never use metallic objects to clean air ages, as these will distort critical soft brass orifices.

2.

Cieanremainderofgun beingcareful nottobumpor

fluid tip.

otherwise damage fluid tip. Never soak entire gun in solvent as this will dry out packings.

ascsmseen

necessary

i.

few seconds,

NOTE

as

to

i

;s

52´•f

WHEN USED WITH A cue, THINNER OR SUITABLE

SOLVENT MUST BE 81PMONED THRU OUN BY INSERT!NG TUBE IN OPEN CONTAINER OF THAT LIQUID. MOVE TRIGGER

CONSTANTLY

TO

THOROUGHLY

FLUSH AGEWAY AND TO CLEAN TIP OF NEEDLE. GU)I( MAY BE BLOWNBACK.

Cleaning Cup Type Gun Figure 3

20-30-70 Page 4 Aug 31/84

O

1984 BY: ~RELINER CORPORATION

SR-76-023 CORROSION CONTROL MANI!AI,

:i

WHEN THE GUN IS USED WITH A PRESSURE TANK OR GRAVITY BUCKET, REMOVE HOSE, TURN THE GUN

UPSIDE DOWN AND POUR THINNER INTO FLUID OPEN)N(3 WHILE MOVING TRIGGER CONSTANTLY. THIS WILL

rr~r

.I:´•:´•::::;:::´•:´•:´•:´•

FLUSH ALL AGEWAYS.

-t-j:-:j:i:::::::: I:´•I´•-

i~ i´•~ir´•;

:’:´•.I´•:´•:´•:’:’:’´•:´•:´•:´•:´•:’:´•: ;’´•’´•:´•:´•:.´•´•>:´•:’;’´•´•´•:´•:´•:´•:’;’´•’´•’I

Cleaning Tank Type Gun

Figure

4

ENTIRE IS EXTREMELY POOR PRACTICE TO PLACE GUN IN THINNER. WHEN THIS IS DONE, SOLVENT DISSOLVES OIL IN LEATHER PACKING AND CAUSES IT

GUN TO SPIT.

FLUID IT IS GOOD PRACTICE TO PLACE NOZZLE AND

q:.r

CONNECTION IN THINNER. VESSEL USED MUST BE SHALLOW ENOUGH TO PREVENT THINNER FRO# .,q

REACHING PACKING.

;i: :i:i

Cleaning Gun ~Ellozzle and Fluid Connections Figure 5

20-30-70 Page 5 COPYRIGHT, 1984 BY SABRELINER CORPORATION

Aug 31/84


SPRAY PAINTING METHOrDS AND TECHNIQUES (INSTRUCTION AND INFORMGTION GUIDE) (Continued) Spray Gun Care (Cont’d) 3.

6.

Lightly oil leather packings and moving parts except those in with paints or air supply.

4.

Re-assembleaircap tospraygun.

5.

See adjusting procedures and fault correcting procedures in figures and in tables. When simple adjustments or cleaning will not correct faulty conditions, spray gun must be overhauled but only by a qualified spray gun mechanic.

Once started, do not stop spraying until job is

complete. 7.

Avoid excessive paint feed which would result in excessive film thickness.

8.

Paintcornersasshown infigure9.

MAINTAIN 8-10 IN. DISTANCE. MAINTAIN OUN PERPENDICULAR.

m~wnazl Plncu spray gun on a hook ol´• other safe place when in non-use. A dropped spray gun usually results in damage and distortion ofa.ir cap and its critical orifices and

possibly SPRAY GUN

a

damugedPuid tip.

TECHNIQUES

AIR TYPE

Spray Gun Use The following

are

general techniques for

spray gun.

1.

Hold spray gun perpendicular to area being coated. (See figure 6.) Do not tilt spray gun. (See figure 7.)

2.

Depending

on

spray

width, maintain a 6-10 in. area being coated.(See narrow pattern requires the

distance between air cap and

figure 6.) Generally

a

Gun To Part Distance

greater distance.

Figure

6

NOTE Less than B in, will cause poor atomixation. More than 10 in. will cause dusting of paint particles with resultant specks and

MORE MATERIAL IS APPLIED HERE

lumps. 3.

Always trigger spray gun to avoid build-up at beginning and end of each stroke. Triggering is technique of starting gun moving toward area to be spl´•ayed, before trigger is pulled and, similarly, moving gun past area which has just been painted aftel´• trigger is released. (See figure 8.)

4.

Avoid too much overlapping of strokes which would result in excessive film thickness. Overlap each successive stroke approximately 50% into previous stroke.

i2djust

stroke

STREAKS OCCUR HERE

spttetl

to

lay down

a

uniform wet coat. LESS MATERIAL IS APPLIED HERE

Some Problems Caused Hy’l’ilted (:un

Figure

7

20-30-70 Page 6 AuR.31/84

o

CQBYRIGHT,

1984 BY S~PiBRELINER CORPORATION


RIGHT

i

I

~i

i

8-101N.

MOVE GUN IN STRAIGHT LINE

RELEASE TRIGGER

BEGIN STROKE THEN PULL TRIGGER

411C~

61P~A I R

KEEP WRIST

BEFORE COMPLETING STROKE

FLEXIBLE

WRONG

ARCING GIVES UNEVEN

COATING

WRIST IS TOO STIFF

r

Spray Gun Motions Figure

8

20-30-70 COPYRIGHT, 1984 BY SABRELINER CORPORATION

Page 7 Aug 31/84


CORRECT

INCORRECT

METHOD

METHOD

OUTSIDE CORNERS

THICK THIN

INCORRECT

CORRECT

METHOD

METHOD

INSIDE CORNERS

Spraying Corners Figure

9

20-30-70 Page 8 Aug 31/84

o



SPRAY PAINTING METHODS AND TECHNIQUES (INSTRUCTION AND INFORMATION GUIDE) (Conlinued) Faulty Spray Patterns

Examples of faulty spray patterns, causes, and corrections are

shown in table 2.

Table 2,

Faulty Patterns and Suggested Corrections

Dried material in or damage to side port "A" restricts age of air through it. Result: Full pressure of air from clean side port forces fan pattern in direction of clogged side.

,i

ru!X

iS~

Dissolve material in port with thinner or air cap. Do not poke of the openings with

A

Dried material around outside of fluid nozzle tip at position "B" restricts age of atomizing air at one point thru center opening Of air nozzle and results in pattern shown. This pattern can also be caused by loose or damaged air cap or fluid nozzle.

split

spray

material. ~r,´•

side

replace in any metal

instruments.

If dried material is causing trouble, remove air nozzle and wipe off fluid tip, using

8

o

I

end of a fan or one that is heavy on each caused by (1) is usually middle in weak pattern and tao high an atomizing air pressure, or (2) by attempting to get too wide a spray with thin A

~c-

CORRECTION

CAUSE

PATTERN

raff wet with thinner. Tighten air cap or fluid

nozzle.

Reducing air correct

cause

pressure will (1). To correct

open material control to full position by turning to left. At same time turn spray width adjustment to right. This will reduce width of spray but will

(2),

correct

split

spray

pattern.

r,i?

20-30-70 Page 9 0


Aug31/H4


SPRAY PAINTING METHODS AND TECHNIQUES (INSTRUCTION AND INFORMATION GUIDE) (Continued) Table 2.

Faulty Patterns and Suggested Corrections (Cont’d) PATTERN

CAUSE 1.

CORRECTI<)N

Dried out packing around material needle valve to get; into fluid ageway. This results in spitting.

permits air 2.

Dirtbetweenfluid nozzleseatandbodyora loosely installed fluid nozzle will make a gun spit.

3.

A loose or defective swivel nut on siphon cup material hose can cause spitting.

or

~I q:::::

::iz

To correct cause (1), back up knurled nut C, place 2 drops of machine oil on packing, replace nut and tighten tyith fingers only. In aggravated cases,

replace packing.

To correct cause (2), remove fluid nozzle D, clean back of nozzle Beat in gun body using rag wet with thinner, replace nozzle and draw up tightly

against body. To correct

cause

replace swivel

A fan spray pattern that is heavy in middle, or a pattern that has an unatomized "salt-and-pepper" -c’"’"

effect, indicates that atomizing air high enough.

(3) tighten

or

nut E.

Increase pressure from your air supply.

pressure is not

20-30-70 Page 10 Aug 31/84

o


SR-76-023 CORROSION CONTROI~ MANI!AL,

SPRAY PAINTING NLETHODS AND TECHNIQUES (INSTRUCTION AND TNFORMATION GUIDE) (Continued) Correct

Spray Patterns

See figure 10 for

example of correct

spray

pattern.

Relation of Air Cap Position to Spray Pattern to The flat spray patterns will always be at right angles 11.) figure (See the air cap wings.

tSiiiiiii~ii

SPRAY PATTERN IS VARIABLE FROM ROUND TO FLAT WITH ALL PATTERNS IN BETWEEN.

~orrect Spray Patterns

Figure

10

HORNS ARE

HORIZONTAL

(i~ ARE IN HORIZONTAL OPERATION, WINGS ON NOZZLE HQRIZONTAL. THIS PROVIDES VERTICAL FAN-SHAPED PATTERN WHICH GIVES MAX COVERAGE AS GUN IS MOVED BACK AND FORTH PARALLEL TO SURFACE

BEING FINISHED.

Relationship of Aireap Position Figure 11

to

Spray Pattern

20-30-70 Page 11 0


AuR 31/84

SR-76-023. CORKOSION CONTROL MANUAL

SPRAY PAINTING METHODS AND TECHNI&UES (INSTRUCTION AND TNFORMATION GUIDE) (Continued) Spray

Gun

Adjustments and Corrections

See figures 12 and 1,3 for examples of spray gun adjustments and corrections. Cheek and maintain the proper pattt´•ln fol´• adjusting or cleanina the gun frequently.

SPRAY WIDTH ADJUSTMENT TURN RIGHT FOR ROUND, LEFT FOR FAN. (SOME TOUCHUP GUNS HAVE THIS ADJUSTMENT ON SIDE)

::1:::

MATERIAL CONTROL SCREW. TURN RIGHT TO DECREASE FLOW, LEFT TO INCREASE.

ii::::i::::::; ,:::;t

As WIDTH OF SPRAY IS INCREASED, MORE MATERIAL

:,i::

MUST BE ALLOWED TO THRU GUN TO GET SAME COVERAGE QN INCREASED AREA.

NOTE NEVER ADJUST WITH PLIERS. IF CONTROL SCREWS BIND,

HAVE

GUN

REPAIRED

BY

A

SPRAY

GUN

MECHANIC

spray Gun’A~ustment Figure -18

20-38´•70 Page 12 Aug 31/84

o

CQPYRIGMT,

1984 BY SA~PELINER CORPORATION

SR-76-023 CORROSI<)N CC)NTHOL MANlrAL

JERKY OR

FLUTTERING SPRAY

OBSTRUCTED FLUID AGE

LOOSE TIP OR DAMAGED LOOSE PACKING NUT OR

SEAT

DRIED OUT PACKING

s, ’15L

LOOSE OR DAMAGED

COUPLING NUT

CLOGGED AIR VENT

LOOSE OR

DAMAGED FLVID

I

I

TUBE

CUP TIPPED TOO FAR

LACK OF SUFFICIENT MATERIAL IN CUP

Causes of Jerky

or

Fluttering Spray

Figure

13

20-30-70 0


Page 13 Aug 31/84


SPRAY PAINTING METHODS AND TECHNIQUES (INSTRUCTTON AND INFORMATION GUIDE) (Continued) SPRAY PAINTING PROBLEMS See table 3 for spray painting troubles, and possible remedies. Table 3.

possible

causes,

Spray Painting Problems, Possible Causes, and Possible Remedies

TROUBLE

Sandpaper

finish

POSSIBLE CAUSES 1.

Unsatisfactory

POSSIBLE REMEDIES

surface finish of

previous

I.

Checkapplication proceduresofsll coatingsinvolved.

2.

Providecleaner

coats

2.

Exclessive dirt contamination from

painting

Slon´• Drying Pret2´•eatment

Coating

paintingarea.

area

3.

Insufficient scuff sanding of previous coats

3.

Scuff sand previouscoats.

4.

Improperly cleaned paintequipment

4.

Flush paint lines and clean equipment.

yj~

Dried overspray

5.

Sand complete finish until smooth fingertips.

6.

Wrongthinner used

6.

Compare

7.

I~sc´•cssive ait´• pressure

7.

(:heck for correct air pressure recom mended at gun.

8.

Dustonparts

8.

Removedust.

1,

Wrongthinner used

1.

Compare

to

on test with material using recommended thinner.

on

test

with material using

recommended thinner. 2.

Excessivefilm thickness

2.

Strip and reapply

3.

High humiditycondition

3.

Checkhumiditycontrol equipmentwhere employed. Suspend painting operation until humidity drops.

Blushing

1,

Excessive humidity

1.

Checkhumidity control equipmentwhere employed. Suspend painting operation until humidity drops. Use slower

Pinhole C:avities or (’1´•aters

i.

Lack

2.

Entrapped oils, water, and/or solvent.

correct amount.

evaporating solvents. of/or improper surface

treatment

1.

Apply

2.

Microscopic examination of surface and paint removed during tape test. Clean

correct surface treatment.

air filter. 3.

Insufficient primerdryingtime

4.

Excessive alcohol additions to pretreatment

5.

3.

1

4.

coating

Check

drying time requirements.

Compare

on

test

with material using

correct amount.

Improper thinner

5.

Compare

on

test

with material using

recommended thillner. 6.

Siliconeson surface

7.

’I’oo heavy acoat

7.

Apply thinner

X.

Forcedryingbefore allowingsolventsto

8.

Allow

6.

Strip, thoroughly reclean surface and reapply finish. coats of material.

enough time for solvent flash-off.

flash-off

20-30-70 Page 14 Aug 31/84

o

COPYRIGHT, 1984



SPRAY PAINTING METHODS AND TECHNI&UES (INSTRUCTION AND INFORMATION GUIDE) (Continued) ’I’ahle 3.

Spray Painting Problems, Possible Causes, and Possible

TROUBLE

Tape Test Paint Transfer

Sags

Streaks

POSSIBLE REMEDIES

I

P<)SSIBLE CAUSES

1

1.

Checkdryingtime requirements.

2.

Thoroughly clean surface, using clean damp with solvent.

3.

Apply

4.

Scuff sand, clean with solvent, and apply light coat of same primer.

i.

nemove air cap and clean tip and air cap carefully. Replace if necessary.

Gun stroked too close to surface

2.

StrokegunG-lO in.fromsurface.

3.

Trigger not released at end of stroke (when stroke does not go beyond object)

3.

Releasetrigger atendof

4.

Gun held at

4.

Hold gun at

5.

Painttoocold

5.

Heat paint in an approved paint heater, keep in warm area.

6,

Paint

6.

Learn to calculate

1.

Insufficient drying time of primer

2.

Improperly cleaned surface, oils and soil in primer

3.

Impropersurface

4.

Excessively aged primer

i.

Dirty

2.

entrapped

treatment

damaged air cap and (distorted spray pattern) or

piled

wrong

too

on

angle

to

fluid

tip

surface

heavy

correct surface treatment.

right angles

every stroke.

to surface.

depth of

wet film

Paint thinned out too much

7.

Add correct amount of solvent by

8.

Excessive potpressure

8.

Reduce potpressure.

9.

Temperature

9.

Increase temperature.

2.

3.

in

paint

area

too low

Dirtyordamaged aircapandfluidtip (distorted

spray

Insufficient strokes.

or

of

paint.

7.

1.

rags

or

incorrect

(;un stroked too the paint)

1´•

over-lapping of

Remove air cap and clean

carefully. Replace if

pattern) 2.

Follow a

rapidly ("dusting"

of

3.

measure.

tip and air

cap

necessary.

previous stroke accurately. Deposit

wet coat.

Avoid"whipping". Takedeliberateeven stroke.

angles

4.

Gun should be stroked at right to surface.

5.

Strokefi-lOin. fromsurface.

Too much air pressure

6.

Useleastair pressurenecessarv.

7.

Splitspray

7.

Clean the fluid tip and air cap.

8.

Painttoocold

8.

Heatpaintto getgoodflowout.

9.

Temperaturein paintarea

9.

Increase temperature.

to surface

4.

Gun stroked at wrong

angle

5.

Strokingtoofarfrom

surface

6.

too low

20-30-70 0


Page 15 Aug 31/84


SPRAY PAINTING METHODS AND TECHNIQUES (INSTRUCTION AND INFORMATION GUIDE) (Continued) Table 3.

Spray Painting Problems, Possible Causes, and Possible Remedies (Cont’d)

TROUBLE

Orange peel

I

POSSIBLE CAUSES

POSSIBLE REMEDIES

Paintnotthinned outsufficiently

1.

Add correct amount of solvent by

2.

faint toocold

2.

Heat

3.

Not depositing

3.

Chteck solvent. Use correct overlap of stroke.

4.

Avoid "whipping". Take deliberate slow strokes.

1.

4.

wet coat

a

Gun stroked too rapidly ("dusting"

paint) 5.

Insufficientair pressure

5.

measure.

painttogetflowout.

Increase air pressure

or

speed and

reduce fluid

pressure.

air cap

fluid nozzle

6.

Using

7.

Gun stroked too far from surface

8.

wrong

Overspray striking

or

a

or

too close to

previously sprayed

6.

Select correct air cap and nozzle for material and feed.

7.

StrokegunG-10in. fromsurface.

8.

surface 9. 10.

Excessive Paint I,oss

Temperature

in

paint

room

too low

9.

Excessive air pressure

"triggering"

10.

1.

Not

2.

Stroking

at wrong

3.

Stroking

gun too

4.

Wrongaircaporfluid tip

5.

Depositing

a

gun at

each stroke

Spray

detail parts first. End with

a

wet

angle

to surface

far from surface

1

paint film of irregular

Increase t;emperature. Reduce

airpressure.

1.

Release trigger after every stroke.

2.

Stroke gun at right angles to surface.

3.

Stroke gun 6-10 in, from surface.

4.

Usecorrectset-up.

5.

Learn to calculate depth of wet film of Finish.

thickness

Excessive

Spray coat

6.

Air pressure too high

6.

Useleastamountof air necessary.

7.

Fluid pressuretoohigh

7.

Reducepressure. Ifpressurekeeps climbing, clean regulator on pressure

8.

Paint too cold

8.

Heat

1.

Air

1.

Use least amount of compressed air

2.

Spraying past surface of product

2.

Release

3.

Wrong air

3.

Use correct set-up.

4.

(;un stroked too far from surface

4.

StrokegunG-10 in.fromsurface.

5.

Material thinnedouttoomuch

5.

Add correct amount of solvent

6.

Stroking

6.

Use correct method.

pressuretoohigh

FoR

paint

tank.

to reduce air pressure.

necessary.

cap

or

fluid

at wrong

tip

angle

to surface

trigger when

gun es

by

target.

measure.

29-30-70 Page 16 Aug 31/84

o

~PYRIGHT, 1984 BY $ABRELINER CORPORATION

SR-7fi-083 CORROSION CONTROL MANUAI,

SPRAY PAINTING METHODS AND TECHNI&UES (INSTRUCTION AND INFORMATION GUIDE) (Continued) Table 3.

Spray Painting Problems, Possible Causes, and Possible Remedies (Cont’d)

~aint will not come from Pr´•essure Sy,ray (;un

Paint will not come from Pr´•essure Tank

POSSIBLE REMEDIES

POSSIBLE CAUSES

TROUBLE

i.

Add paint, correctly thinned out and strained.

tip

2.

Remove obstruction, stil´•

gun

3.

Clean spray gun thoroughly, and strain paint. Always strain paint before using it.

4.

Check viscosity.

5.

Checkgun parts.

Lack of proper air pressure in pressure tank

1.

Check for leaks

Airintakeopening, insideofpressure

2.

Clean

beginstosputter)

i.

Outof paint(gun

2.

Settled, caked pigment blocking

3.

Grit, dirt, paint skins, etc., blocking tip, fluid valve, or strainer

4.

Painttoo thick

5.

Wrong tip,

i.

2.

cap

gun

and/or needle combination

or

paint thoroughly.

lack of air entry.

opening.

tank lid, clogged by dried-up paint

I’aint will not come from Suction C:up

I’aint leaks from Sl,ray (;un

3.

Leakinggasketson tankcover

3.

Replacewith newgasket.

4.

Painttoo thick

4.

Check viscosity.

Dirtyfluidtipand aircap

i.

2.

Clogged air

2.

Remove obstruction.

3.

Usingwrongaircapor needle

3.

Use correct setup.

4.

Leaky connections

4.

Check for leaks under water, and repail´•.

5.

Painttoo thick

5.

Check viscosity.

1.

Fluid needle packing nut too tight

i.

Iloosen nut, lubricate

Packingforflnid needledry

2.

T,ubric´•ate this part daily.

Foreign particle blocks fluid tip

3.

Removetipand

L)amaged fluidtiporneedle

4.

Replace both tip and needle.

i.

2.

4.

vent

on

cup

on

cover

fluid tube

Remove air cap and clean tip and air cap

carefully.

or

nozzle

packing.

clean.

20-30-70 0


Page 17 Aug 31/84

81t-76-02S (’()KR()SI()N C()NTROL M~NCIAL

SPRAY PAINTING METHODS AND TECHNIQUES (INSTRUCTION AND INFORMATION GUIDE) (Continued) Fluid Pressure

Electrical

When specified, use fluid pressure indicated in the applicable ~ection. The indicated pressure is a t´•ecommendation only unless a close pressure control of +O.f, psi or less is indicated.

Prior to spray ing o f paint, the ai rcraft ol´• major assem bl ies the reef m ust be su i tably grou nded to pr´•event ex plos ion o r´• fires caused by static discharges during the spraying

Grounding

operation.

When not specified, use the general range of 8-12 psi. Visc´•ositv of mateial is controlling factor. FIeavier viscosilics rt~ciu i I’(l higher prc´•ssures.

NOTE ~essle res are for normal sprray painting at Sl,r id ta n.k beu!el, using a stand~c´•rd fluid hosr..iX i~n. r.n. by ~Oft length. Inc~´•t´•ase material pressure at the rate of 1 psi for each ft of elevation when spray painting above the normal fluid tank level. A proportionate increase of fluid pressure is requil´•ed for fluid hoses longer than 20 ft.

FACII,ITIES Ventilation Ventilation rate must be commensurate with

protective

measures

necessary to

personnel

protect painters and

helpel´•s from health hazards created by cleaning and painting procedures employed: and must be capable of preventing build-up of explosive vapors or mists. Air must be introduced into spray rooms in such a manner not to cause turbulence or excessive air currents which \I´•ould have effect of causing orange peel in applied paint film.

as

Intluceti ail´• in spray rooms must be filtered to ensure that dirt and tlust are kept to a min.

Lighting Adecluate lighting

must be provided to illuminate all of surfaces to be painted and to ensure uniform appliclxtion of coatings. I,ights must be cleaned as frequently as necessary to maintain this level. area~

Scaffolding Suitable scaffolding or´• staging must be provided to fac i litate painting from different levels and to enable the sl"’a!’ paintel´•s to maintain ;1, wet-edge on the coating

beiny applied.

Housekeeping Clean spray necessary to

from

room

floors and scaffolding

as

often

as

prevent dirt, dusts and dried paint materials

contaminating the surfaces being painted.

I)o Ilot

lint

bearing

1´•ags in the

paint

area.

20-30-70 Page 18 Aug 31/84

o

COPYRIGHT, 1984 BY SRB-RELINER CORPORATION


RADOME COATING MATERIAL APPLICATION INSTAI,LATION NOTES

(;ENERAI, the materials and procedures used to

Safety

abrasion-resistant, chemical-resistant, and impact-resistant coating to the plastic surfaces. The

MEKP

’I’his section

apply

covers

an

surfaces to be coated are usually glass fabric forced rein plastic resin laminates. The coating material is material. a fast curing, air drying polyester

plastic

The coating is available in black, white, and various colors.

MATERIALS Acetone, Technical Grade

Methyl Ethyl Ketone(MEK) Methyl Isobutyl Ketone Prestec Finish No. 2111 I)ark Blue Color Prestec Finish No. 2113 I,ight Blue Color Prestec Finish No. 2125 Med i nm (;reen (:olor PI´•estec Finish No. 2141 I)ark Red Color Prestec Finish No. 2165 Tan Color Prcstec Finish No. 2192 Medium Gray Color Prestec Finish No. 2181 White Color Pres;tec Finish No. 21812 ()ff-White (~olor PI´•estec Finish No. 21(11 lilask Color I’rc!stokleen No. 5411

Methyl Ethyl Ketone Peroxide Catalyst (MF,KP)

Fed. Spec. 0-A-51 Fed. Spec. TT-M-261 Fed. Spec. TT-M-268 Presto Chemicals, Inc. Sun Valley, CA Presto Chemicals, Inc. Sun Valley, C:A Presto Chemicals, Inc. Sun Valley, CA Presto Chemicals, Inc. Sun Valley, CA Presto Chemicals, Inc. Sun Valley, CA Presto Chemicals, Inc. Sun Valley, CA Presto Chemicals, Inc. Sun Valley, CA

(or equivalent) Cat-A-i,ac White Filler

Bostik-Finch Inc.

Putty No. 467-1) (ol´• ccluivalent)

Torrance, CA

(:le;ln ()il-Free (:loth (:hcc!se C:loth

or

Nu-Wipe Absorbent I’al,er Toweling, (or’

equ

Commercial

skin irritation. It is

Scuff sand surfaces to be coated with Na. 240 grit sandpaper and wipe clean. The sanding should not extend

into the outer ply of fabric. All wax, grease, dust and dirt must be cleaned from the sanded surface by wiping with a clean cloth or Nu-Wipe toweling moistened (not saturated) with MEK.

Following initial scuff sanding, fill all pinholes, voids and other slight surface irregularities. Fill with Cat-A-Lac White Filler Putty No. 467-~ (or equivalent). Mis the Cat-A-I,ac Filler Putty resin and catalyst I,er the mallufacturer’s instructions immediately pr´•ior to use, mixing within a 24 hour period. no more putty than will be used Discard catalyzed putty which is unused at the end of any

24 hours. The filler putty may be

squeegeeing,

or

Mliping with

a

dry

applied by knifing.

rag.

NOTE Use only sand

o´•r

gal´•net

onr

pape´•~´• wken the

lygr of rlpet,~ral

applied filler to dry overnight (a min of Ifi bake at 2500F for 15 minutes. Remove excess filler by wet sanding dawn to the laminate with No. 240 grit followed by No. 400 grit sandpaper. The sanding must not extend into the outer ply of fabric. Wipe sanding

Allow the

hours)

or

dust off with

a

clean cloth

or

Nu-Wipe toweling.

Mixing and Handling must be maintained fol´• storage periotls 65"F and 40 between a temperature exceeding 7 days.

Uncatalyzed Prestec Finish material

naniel S. Morris Co. I,os Angeles. CA

ivalent)

Sand or (;arnet Paper No. 240 (;rit, No. 400 Grit and No. 600 (;rit

cause

Surface Preparation

Presto Chemicals, Inc. Sun Valley, (:A Presto Chemicals, Inc.

Sun Valley, (:A Presto Chemicals, Inc. Sun Valley, CA Ram Chemical Co. Gardena, CA

liquid will sometimes

recommended that rubber gloves and eye protection be while handling this material. Do not wash skin with solvent. MEKP must be kept away from heat, sparks, and of MEKP with any open flame. Avoid contamination readily oxidizable materials.

Commer´•cial

at

Stir thoroughly and catalyze Prestec Finish material with MEKP catalyst prior to application. Catalyze the material by adding 2 parts (by weight) of MEKP catalyst and to 100 parts (by weight) of Prestec Finish material blended. Catalyze is thoroughly mixture the until stirring used. only the amount of Prestec Finish material to be

20-30-75 0


Page I Aug 31/84

SR-76-023 COKROSION CONTROI, MANUAL

RADOME COATING MATERIAL APPLICATION Mixing and Handling (Cont’d) Although Prestec is often applied without thinning, it mR)´• be thinned prior to application by adding up to 30 pal.ts (by weight) of acetone to 70 parts (by weight) of catalyzed Prestec. The thinned material must be stirred thoroughly prior to application, If the catalyzed material is maintained at a temperature of 77"F or less, it must be applied within 20 minutes after it has been catalyzed. If maintained at a temperature between 78 and 87"F, it must be applied within 11 minutes after it has been catalyzed. If these time limits exceeded, the material may begin to gel in the spray gun. The catalyzed material must not be heated above 87"F’ between the time it is catalyzed and the time it is are

sprayed, Remove catalyzed Prestec material from the spray equip-

immediately after completion of the spraying operation. Clean spray equipment as soon as possible with either acetone or methyl isobutyl ketone. Prestokleen No. 5411 may be used to r´•ernove any material which may gel in the equipment. ment

(Continued)

For thinned material, a pressure of between 30 and 40 psi i9 USU"lly satisfactory. During spraying, the gun should be held at a distance of 12-18 in. from the surface. If a pressure pot is used, approximately 10 psi air pressure Should be maintained on the material, and the moisture trap and pressure tank must be drained frequently. I" SP’"Ying parts which have unusual or complicated or which have compound curvatures (such as co"ve"tional radomes), it is important that the path followed by the spray gun be carefully selected so that the "Umber of spray es made over each area of the ´•part will be approximately the same. Otherwise, the thickness of the applied coating may not be uniform. Failure to carefully select the spray path followed in coating a radome will generally result in excessive coating thickness over the rounded nose of the radome.

"h"pes

Whe" the coating is to extend to any edge of a part, the coating must be applied around the edge of the part as Shown in figure 1.

COATING

Coating Application

Sl,raZ’ (:oating All surfaces which with a clean cloth

to be coated must be wiped clean Nu-Wipe toweling moistened (not

are or

PLASTIC LAMINATE

saturated) with MEK. The surface must be free of all wate!

moisture. 5116 +1/18 IN.

Mask over any areas not to be coated with any suitable clean masking paper held in position along the edges of the masked area with conventional masking tape. A spray tack coat may be applied, if desired, prior to the required flow or wet coats. In most cases several spray coats will be necessary to produce the required coating thickness.

Edge Treatment Fig´•ure 1

Coating Finish The cured coating must be smooth and free of defects such

NOTE

as

blisters, pin holes, lumps,

runs, sags, orange

peel, anti

other surface irregularities.

Th.e th~ckness of the applied Prestec coating ~rza.y be determ´•inedfrorn thickness mea.surements made on, a test coated at the sa,ne time alzd in the same manner as the

pl´•oduction part. The Prestec coating material is applied by spraying using a suitable spr´•ay gun. An example of acceptable spray equipment is the nink’s Model 18, using a No. 66SD Air Nozzlc, a No. 66 Fluid Tip and a No. 65 Needle. When unthinned matel´•ial, an air pressure of between Il):~lld ~O r,si i~ usually satisfactory.

20-30-75 Page 2 Aug 81/84

o

GOPYRIGHT,



RADONLE COATING MATERIAL APPLICATION (Continued) (;oating Gpplication (Cont’d) Coating Finish (Cont’d) If the final finish coating has an orange peel surface, with No. 240 remove the orange peel pattern by sanding grit sandpaper and recoat the surface. Where additional coats of Prestec Finish are applied to cover surface blemishes or surf ace discontinuities las in the local area of alightning diverter installation), the local surface should be appropyiate)y sanded to preclude excessive local buildup of the

coating thickness. NOTE

Thickness of Prestec coatings builds rapidly during spray application due to high solids content of material. Material a good filler coating for smoothing rough surfaces. When filling is desired, apply R or 3 coats and sand with either No. grit or No. 4´•00 grit sandpaper either by hand or using a power sander. Sand drll possible, and remove dust by wiping with a clean, cloth or Nu- Wipe towelingjust prior to application offinal finish coat.

makes

The coati ng will cure in from 20-60 m i nutes, depending on the roam temperature. Fully cured coatings may be cleaned with water and mild detergent solution, but must not be cleaned with solvents. A fter the Prestec material has cured, sand (with No. 600 area that has been coated. Remove overspray by sanding with No. 600 grit

grit sandpaper) the total any

sand paper. The recoated surface areas should be polished to the desired gloss using any rubbing compound suitable for use on plastic materials.

Touch-Up Damaged touched The

or

worn

areas

up in much the

area or

of the coated surface can be way as painted surfaces.

same

spot to be recoated should be sanded with No.

grit sandpaper. Sand areas from which the coating has been chipped to a feather-edge. If the coating continues to flake during sanding, continue sanding until a well bonded area of coating is reached. Otherwise the repaired

24()

surface will continue to flake due to lack of a bond. The surfaces around the spot to be touched up should be cleaned by sanding with No. 600 grit sandpaper. Clean the surface to be repaired by wiping with clean cloth or N u-Wipe toweling moistened (not saturated) with ME:K. The Prestec Finish material is prepared and applied to a repair area the same as applying a total recoat.

20-30-75 COPYRIGHT, 1984 BY SABRELINER C~ORPORATION


SR-76-023 CORROSION CONTROL MANIIAI,

POLYURETHANE INTEGRAL FUEL TANK COATING APPLICATION GENEHAL

Air

’I’his section covers the materials, equipment, and procedures for application of a fuel resistant, corrosion inhibiting coating to specified detail parts for use in integral fuel

The paint spray room must use filtered air. The amount of air forced into the spray room should exceed the volume withdrawn. Air must be introduced in such a manner as not to cause turbulence or excessive air currents and must be maintained at a min of 125 fpm at the exhaust in the painting area. Room air must be exhausted thru an exhaust system so that overspray does not settle an parts

tanks,

MATERIALS

Polyurethane Coatings for Integral Fuel Tanks No. 827

x

SB0125-006

376

as kits) DeSoto Chemical Co. (Tinted)

(Purchased

Floors

Trichloroethane, 1, 1, i, Technical,

0-T-(i20

Inhibited

Methyl F,thyl

Ketone

(MEK)

Oxolvo. I~tch Solvent, No. 020-~38, DrS(,to Chemical Co.

Naphtha, Type II Lacquer Thinner Paper., Kraft, Untreated Wrapping Non-woven, Non-metallic Abrasive Mats, Type I, Class 1 or 2, Grade A or Finer, Scotchbrite (.7M Co.) Cleaning Compound, Aircraft Surface Alkaline Waterbase (Air Tech No. 19, Turco Products) Neutral Paint Remover, No. 5351, Turco Products Paint Straining Funnels Cheesecloth No. GR-99 Bostik Div., Tack Rags

Corp.. Middleton, MA, or eyuivalent Ru bber Cloves (Rubber Hase or Nylon)

TT-M-261 Commercial TT-N-SS TT-B-266

UU-P-268 MIL-A-9962

The spray room must be kept clean, and free of rags, the beginning paper and other debris. Hose down floors at of each shift to keep the overspray and other dust contained on the floor

Temperature and Humdity

Temperature and humidity indicators must be installed and in proper operation during the time of painting and drying. The temperature of the spray room must be in the of 60 to 900F and the relative humidity the range of 25-75~0. range

MIL-C-25769


UXM

4()() (;rit

being painted.

Spray Guns, Hoses, and Brushes Spray

Guns

The following equipment and adjustments are satisfactory for use in the application of this material. i.

Pressure a.

Commercial

I’al,er

b.

Tape. Masking (3M Co., No. 250 Mystik No. 62~0, or eyuivalent) (:hemical C:artridge Respirator

or


No. R21

2.

Commercial

Regulateair pressureasfollows: 6-I) Dsi (Increase Pressure feed tank air necessary for elevated painting)

Commercial b.

Spray Eyuipment

I,i~hting

36-45

psi

as

at the spray gun

Sil-then CupGun a.

EQUIPMENT I’aint

SprayCun

Use a DeVilbiss MBC spray gun with a No. E needle and nozzle and a No. 30 air cap.

Atomization air

(Wilson Model No. 1200 with

Cartridges) (;lasses, (;oRlr;les or Face Shields, Safety I"ibel´• Brushes or Tampico Brushes

be in

Discontinue application or curing of coating when ambient air temperature is below 60"F.

Commer´•cial

Wet-or-Dry Abrasive

must

Use a DeVilbiss MB(I spray gun ~´•ith a No. E needle and nozzle and a No. ~O ail cap.

Regulate atomization air psi at the spray gun.

pressure to deliver

35-45

following precautions should be observed while spray painting the integral fuel tank coating. Dusting or rippling will be caused by too high an air

The

min of 50 roam should be well illuminated (a ft-candles), using vapor and explosion-proof lights, and floor lighting equipment, when necessary.

The spray

pressure.

Orange peel and sags will result when the air pressure is too low or the fluid pressure is too high.

20-30-80 Page 1 0


AuK:11/~4

SR-7Ci-023 CORROSION CONTROL MANUAL

POLYURETHANE INTEGRAL FUEL TANK COATING APPLICATION (Continued) Sl,ray (;uns, Hoses, and Hrushes (Cont’d)

Painters and others mixing these materials must wear solvent-resistant gauntlet style gloves, and goggles to

Ail´• I,ines

protect

131ow out air lines at least twice each day when painting to purge lines of oil or water. Air lines must contain an air filtel´• and water separator. The filter must be changed at least

once a

month.

Brushes Ensul´•e that brushes have good quality bristles and are of of adequate size for optimum application to the area

requiring touchup. Equipment Cleaning

eyes.

Surface Preparation

integral fuel tank coating is applied to surfaces that have been properly surface treated. All surfaces to be coated must be free of foreign material. If necessary they must be wiped with a clean cloth dampened with ME:K, then wiped dry. The integral fuel tank coating must be applied within 2rl hours after surface treatment subject to the following: Time after Treatment

Clean equipment immediately after this purpose,

use.

Use MEK for

If

coating has cured on equipment, MEK will not remove it. Use Turco stripper No. 5351. When stripper is used it is important to thoroughly rinse away all residue, using water followed by repeated rinses of MEK.

Action Before Coating

1-4 hours

No further preparation when clean and dry.

4-24 hours

Solvent clean.

Mixing and Handling Procedures

NOTE’ Uo not use stripper medium. Use stripper

as

a

The fuel tank coating is a two component catalyzing material that is purchased and stocked as a kit. Do not intermix product components of one manufacturer with

pump purge

for parts cleaning

product components of another manufacturer.

onlll.

When mixing,

INSTALLATION NOTES

supplied

Solvents and coating materials are toxic and flammable, Observe fire, health and safety precautions to preelude injury to personnel and damage to equipment and facilities, Painters and others when

gral fuel tank coatings

mixing and spraying intewear a chemical cartridge

must

respirator. Parts to be coated, and the spray equipment must be grounded prior to air spray application and equipment purging. This requirement is mandatory to prevent flash fires or possible explosion resulting from build-up of staticl electricity.

Apl,ly these coatings

in adequate ventilation. Avoid i th the sk in and eyes. Do not ingest. i)o not inhale vapors. WASH HANDS BEFORE EATING OR SMOKING. In case of of the coating material with skin, wash with soap and water. In case of eye , immediately wash eyes for at least 15 minutes; get medical attention. t.ac´•t

the batch of base material and catalyst kit. Never substitute the catalyst from

use

a

another batch.

Safety

con

as

w

Mix the material by agitating the base while slowly add ing the catalyst. M ix quantities less th an complete k its

by weight only. i.

SprayApplication MixingRatios Product

Component

Base Material No. 827 x 376 Catalyst No. 910-702

Volume

Weight

4 parts

100.0 parts

1 part

22.5 parts

Allow mixed material to chemically react for :~O minutes, then add: Thinner No. 020-707

4 parts

63.7 parts

NOTE

After chemical reaction restir before use.

and

thinning,

20-30-80 Page 2 Aug 31/84

o

COPVRIGHT, 1984 BY SABRELINER CORPORATION


POLYURETHANE INTEGRAL FUEL TANK COATING APPLICATION (Continued)

I)ryin~ ’rime

I’I´•occ!tfurcs (~:ont’d) I~rush

2.

Application MixingRatios

Product

Component

Weight

Volume

Rase Material No. 827 x ~76 Catalyst No. 910-702 Thinner No, 020-707

4

parts

1

part part

1

100.0 parts 22.5 parts 16.0 parts

NOTE

must be cooled to ambient

Slozalll add the catalyst to base material while stirring, ne?ler the rever~e. Material m~zacl and thinnedfor brushing must stand 30 miTLutas

after catalyxing prior

Stir material

to

use,

before using,

Str´•ain material. Coating mixture requires continuous agitation to maintain its stability. This requirement can bt! accomplished in the following ways. I’ressure circulating system with material hose not to exceed 5 ft.

Agitation

pressure

pot with material hose

not to

exceed 5 ft,

or

When painting of coating has ceased for more than 10 minutes it is mandatory to bleed out the material in the line. Pressure cup

or

agitation byhand

suction cup shall be kept under or by mechanical stirring.

Max pot life of spray material is 7 hours at temperatures of 75"F’. After max pot life, discard any unused catalyzed

material.

C:oatinlJ. Application Spray apply I iRhl wet s i ngle coats to ach ieve the requ i red film thickness. When touch-up is applied by brush, apply uniform wet coat.

Coating Repair Sand and clean the affected area with Oxolve etch solvent No, 020-338 using clean wipers, and wipe dry immediately. Repeat this cleaning as often as necessary to ensure cle""liness.

Coating Finish

Appearance The dried coating must be uniform, smooth and free of

applied coating

on

capable of ing the

An adhesion cure test must be made solvent wipe test.

wet

using the follo\\~ing

After the applied catalyzed coating has reached ultimate of cure in accordance with table i, saturate a piece cheesecloth with MEK solvent, then wipe a selected ar´•ea with at least 50 double strokes using moderate hand removed from pressure. If coati ng m aterial is d issolved or and is failed considered is as substrate, coating unacceptable. A slight strain evident on cheesecloth will

total dry film thickness of the applied mils. The absolute min film thickness is is 0.8-1.5 coating 0.5 mils and the absolute max film thickness for flat areas is 2.0 mils. Edge, ends and areas adjacent to recessed the max. areas due to confiffuration of parts may exceed

acceptable

be

Cure Test

optimum

requirements are not applicable to grit or roughness. Runs, sags, and grit are not

must

adhesion tape test after ultimate cure or at the timetemperature conditions specified for exposure to fuel or traffic as specified in table 1.

not be

runs, sags,

grit.

Adhesion Test The

Film Thickness The

temperature before handling

traffic.

runs, sags or

NOTE

one

Table I gives min drying times of the coating at va,’ious temperatures and humidities, prior to subsequent exposure l,o fuel, production, traffic or handling of detail pal.ts. Where force drying is specified, a period of 15 minutes at ambient temperature is required to permit solvents to flash. Time at force cure temperatures means time after the structure has attained the specified temperature. All Detail cure times must be conducted with air circulation. parts and subassemblies which have been force cured

cause

for rejection.

NOTE This test may be performed on p,´•ocess control s cleaned and coated in conjunction with detail parts.

The film thickness

detail parts.

20-30-80 o

COPYRIGHT, 198´•4 BY SABRELINER CORPORATION

Page Aug 31/X4

SR-76-023 C()KROSION CONTROI, MANUAL

POLYURETHANE INTEGRAL FUEL TANK COATING APPLICATION (Continued) Table i.

CoatinffCureSchedule

EXPOSURE Fuel

ol´•

Traffic

HandlinR of Detail P~trts

Immetliate Assembly

Irltimate Cure

TEMPERATURE ("F)

RELATIVE HUMIDITY (96)

TIME MINIMUM

Ambient Cure Force Cure Force Cure

90-115

20 Hours 6 Hours

120-14Fj

i-Hour

Ambient Cure Force Cure F’orce (:ure

120-14Fj 170-200

Force Cure

170-190

Air Dry Force Cure plus Air Dry Force Cure plus Ail´• Dry Force Cure

60

(Min.)

GO(Min.)

40-80

40-80

llj Minutes I Hour 50-80

120-145 50-80 170-200 50-80

2fj0

2 Hours RO Minutes

14 Days 2 Hours 7 I)ays 1 Hour 7 Days ~O Minutes

20-30-80 Page 4 Aug 31/84

o



ORGANIC INTEGRAL FUEL TANK COATINGS APPLICATION NOTE

(;ENERAL This section covers the application of a two-part polyul´•ethane coating to be applied to all surfaces within the inln~Kral fuel tank.

The polyurethanefuel tank coating m´•u.st be appl´•ied to titanium surfare,s within L4

ol’ an ot,solcte ’I’his soct(.io~l also covc!l´•s the I(u II a- N ~,ased coati nff to litan i um with i n the i ntegral fuel

One c.oal of spl´•ay al,l,lic!tf Co;ltinK rnusl h;lvr:~ dry Fillll thickness of 0.8-1.2 mils.’l’wo coats must have a dry fil ill

tank.

thickness of 1.6-2.4 mile.

MA1’ERIALS

Measure coating thickness by micrometer method after cure is completed.

I’oiyurethane Coating

integral

ST0125LB0006

for

Fuel Tanks

after chPmiccrlf´•ilm

INSTALLATION NOTES

equivalent

highly flammable ketones

as

cure

Polyurethane Coating:

Cure per

solvents,

Preparation

A min of 14

one

of the follou´•ing

days (450F min; Relative humidity, 200~,,

min). OR 2~

A min of 30 minutes after part has reached 260"F

(26FjOF max), Buna-N-Coating: Cure a min of 30 minutes aftel´• part reached 250"F (2fi6"F max).

A I I ~u rfaces must be free of d i 1,t, oi I. Kr.case and other shop soils I,l.ior to applying fuel tank coatinR.

NO TE

I~rocedures employed for the removal of shop soils must be they do not remove or damage surface treatments. Any bare metal or damaged surface treatment

coating application.

has

The Buna-N coating will change colo~rfr´•orn cerise to rPdish brown 07´• da.rk tan on

such that

before

coatings in accordance with

Prior to exposure to fuel, the following:

1.

Polyurethane coatings contain solvents and other comtoxic ponents such as toluene diisocyanate (TDI) that are the skin in an sensitizing if inhaled or absorbed through excessive quantities. Buna-N based coatings contain

repaired

ol´•

schedules:

Safety

must l,e

trPatment.

Coating Cure ST012FiLB007

Coating for Integral Fuel Tank Titanium Components

Surface

ho~l´•s

curing,

Appearance and Adhesion pin holes, blisters, and

Mixing and Handling

The coating must be free of other defects.

I’olyur´•t´•lhane (:oating

Test coating adhesion by applying a 1 in, wide by about 4 in. long strip of masking tape to the coating. Press at least Z i,~ of the tape tightly to the surface using either a rubber roller or the palm of the hand. Remove the tape with one quick motion. Visually examine the coating for evidence df damage. Evidence of coating removal is cause for rejection- Discoloration of the tape does not constitute

Combine catalyst and thinner supplied into the base material in the ratios recommended by the manufacturer, The material must stand for 1 hour after mixing, No material may be used longer than 4 hours after the

standing period. Run;l-N Coating

runs,

failure.

Hetluce cctatina to viscosity suitable for atl(lition of methyl-isobutyl-ketone.

spraying by

the

NOTE l’hhs ´•u.ur of the Bunu-N coating ´•ix o~solete and its uxc! is rastrietud to maintenance of H´•M.´•w,tr-N c´•ouf.c´•d

Up Touch-up is permissable provided it does not damage any metal pretreatment. Coati ng th ick ness ii m i tations tlo not

Touch

apply when repaired

or

touched up

area

is 4 squwre in.

oi

less.

After´• touch-up, where curing at ~T,OOF is im~,r´•actical, the material for a min of 48 hours :~1 room leln-

cul´•e

Coating Application

perature.

Al,plication Method Coati nlSs

are

normally applied by spraying. If spraying is

impractical, brushing

may be

used.

20-30-85 0




PROTECTION OF AIRCRAFT IN OUT-OF-DOORS TEMPORARY STORAGE Rubber Gloves

GENERAL covers the preparation and application of a temporary coating system which will provide protection of aircraft exterior aluminum surfaces when stored in an

This section

out-of-doors condition for

a

period of up

to 1 year.

MATERIALS

Corrosion Preventative Soft Film Type III, Class I or II

Non-Flame Sustaining Aluminum Surface Cleaning Compound

TT-M-261 TT-N-95 (Type II) TT-T-266 UU-P-268 MIL-C-81309 MIL-C-5410

(Type II)

Paper

Tape, Masking (3M Co., No. 250) Decal Material (Fascal 500G or

PPP-T60


Striping Brushes Fiber Brushes or Tampico Brushes Polyethylene Film (0.005 in.) No. 471 Vinyl Tape (3M Co.)


Fabric or Aluminum Foil Tape Cheesecloth Visqueen Polyethylene Film Tack Rags No. GR-99 Bostik Div.,

or

Commercial

equivalent)

Blackout Tire

Commercial

Coating

room should be well illuminated (a min of 50 ft-candles) using vapor and explosion-proof lights, and floor lighting equipment, when necessary.

The spray

SB0125-024 MIL-C-25769

Stripper) Dyed Deep Blue for Markings (Turco Products) or equivalent Waterbase, Alkaline Removable Coating paint Straining Funnels Aluminum Foi1(0.00Tj in. min)

equivalent

Corrosion Preventative Soft Film

Paint Spray Room

Commercial

Turco No. 4983

or

EQUIPMENT

Surface Alkaline, Waterbase Turco AirTech No. 19 or

equivalent) Epoxy System Paint Remover, Turco No. 5351 (Neutral


MIL-A-9962

equivalent)

Epoxy Polyamide Primer, Filiform Corrosion Inhibiting Cleaning Compound, Aircraft


Boots, Treat Cloth or Rubber Coveralls, Lint-Free Caps, Painter Type Glasses, Goggles or Face Shields, Safety

(WD-40 TT-P-1757 MIL-C-5541

Commercial

equivalent Decal)

or

Cloth Rack Adhesive Tape (Waterproof) Class I Zinc Chromate, Primer Chemical Conversion Coatings on Aluminum and AluminumAlloys Non-Woven, Nonmetallic Abrasive Mats (Require Type I, Class I or II, C;rade A or Finer, Scotchbrite

Commercial

Use filtered air in the paint spray room. The amount of air forced into the spray room should exceed the volume withdrawn. Introduced air in such manner as not to cause turbulence and excessive air currents and maintain a min of 125 FPM at the exhaust in the painting area. Withdraw room air thru an exhaust system immediately at one end of the aircraft or part being painted so overspray does not drift into other

areas

of the

room.

spray room floors clean, and free of rags, paper, and other debris. Hose down the floors at the beginning of each shift, and in the area of the aircraft, approximately 1 hour prior to the beginning of the painting of the aircraft. Additional floor wetting may be required to keep the overspray and other debris on the

Keep the and

Commercial Commercial Commercial Commercial Commercial Commercial

or

eqyivalent Scotch-Brite (3M Co.) Thymol Blue Indicator Paper (Van Waters and Rogers)

Base

Glove Powder (Talc) No. 400 Grit Wet-or-Dry Abrasive

0-T-620

Inhibited

Methyl Ethyl Ketone (MEK) Naphtha Lacquer Thinner Paper, Kraft, Untreated, Wrapping

USM Corp., Middleton, MA,

(Rubber

Nylon)

3M Co., No. 4600 Series

Trichlorethane 1, 1, 1, Technical,

or

or


floor. Do not open hangar doors (large) for an hour before, during, and for at least 1 hour after the painting of an aircraft with the coating system. Personnel doors (small) must be restricted, so that only one door to the outside is available to foot traffic during this time period.

20-30-90 Page 1 a


Aug 31/84

SR-76-023 COKROSION C~NTROL MANUAL

PROTECTION OF AIRCRAFT IN OUT-OF-DOORS

TEMPORARY STORAGE (Continued) Paint

The

Spray Room (Cont’d)

Temperature and humidity indicators must be installed and in proper operation during the time of painting and drying. Keep temperature of the spray room in the range of 60 to 900F 1 hour before, during, and for 1 hour after spl.ay painting this paint system. The relative humidity must be in the range of 25-75% during this same time period.

Spray Guns and Hoses Spray gu ns and accessories used must conform with table I requirements or be equivalent. Table I. Paint

Epoxy Primer

Type Gun

DeVilbiss JGA OR TEA Model 502

Tank Gun Fluid Tip Needle Air Cap Cup Gun Fluid Tip Needle Air Cap

FF FF 765

or

EX EX 30

or

or

or

must be observed while spray

Dusting

or

rippling will be caused by

too

high

an

air

pressure. sags will result when air pressure is too low and fluid pressure too high.

Orange Peel and

The epoxy primer builds up in equi pment very rapidly. Clean spray guns, lines, and pressure pots thoroughly before and immediately after use with MEK. When MEK is not available, use thinner commercially available from primer supplier and compatible with

the epoxy primer. Blow air lines out at least twice each day, or oftener if necessary, when painting an aircraft to purge lines of oil and water.

INSTALLATION NOTES

Surface Preparation

FX FX

Mask off all plastics, glass, rubber, fabric or other surfaces that would be damaged by solvents, chemicals or water using aluminum foil or fabric tape and Visqueen paiyethylene film.

FX FX

Fluid lines must have a min I.D. of exceed 75 ft in length.

following precautions

painting.

wax deposits, soils, oils or other surface contamination by washing aircraft metal surfaces with clean, lint-free cloths saturated with MEK or equivalent.

Remove

3/8 in. from tank

to

gun, and not

Areas suspected of corrosion must be repaired.

High pressure air hoses leading to regulator or tank must have a min I.D. of 7/16 in., and a max length of 150 ft. Air hoses from tank to gun must have a min I.D. of 5/16 in., and a max length of 75 ft.

All abraded areas where surface treatment has been removed must receive a chemical film touchup prior to

Recommended pressure settings for fluid tank, regulator, and spray gun are listed below: Fluid tank setting Air regulator setting Air pressure at spray gun

8-12 psi 60 psi 40-45 psi

Add 1 Ib of fluid pressure for each ft of height of the gun abo~e thefluid tank level, for nomzal operation. a

Mixing and Handling The unmixed epoxy primer components have limit of 1 year.

a

shelf life

Stir Component I until pigments are thoroughly mixed. (Mix on Red Devil shaker or equivalent method.) Reduce Component I(pigmented solution) with Component II (clear solution) in a 1 volume to 1 volume ratio. Temperature of components must be above 600F(160C)before mixing.

NOTES

Frequent cheeks should be made with

applying primer.

Pour Component I into a proper size empty container, allowing adequate time for complete drainage. Component Il is then slowly poured into Component I with constant stirring. Allow proper drainage time for Component II. Each container of Components I and II may be rinsed with the non-photochemically reactive solvent type thinner. Component II must always be added to Component I; this procedure must not be reversed.

test

gauge to detemnine air pressure at the gun.

20-39-90 Page 2 Aua:11/84

o

COPYRI~HI, 1984

BY SABRELINER @ORPORATION

SR-76-023 CORROSION CONTROL MANIIAL

PROTECTION OF AIRCRAFT IN OUT-OF-DOORS TENIPORARY STORAGE (Continued) Windshields and Windows

Mixing and Handling (Cont’d)

or glass surfaces with soft clean all dirt particles are removed. PI´•otect with polyethylene film or aluminum fail (min thickness 0.005 in.). The film or foil is cut to the desired shape and overlaps the structure 1/2 +1/4 in. Tape and seal all edges to ai rcraft structure using No. 471 vinyl tape or cloth back adhesive tape (PPP-TBO).

Clean and

NOTE Never mit epoall prilnerfrom one supplier .UYith primerfrom anotlker ctupplier. ~omponents are also not interchangeable. l’hin 2 volumes of the Class 2 ired primer for spraying by adding approximately I volume of nonphotochemically reactive thinner compatible with Class 2 primer as specified in manufacturer’s directions. The spraying viscosity must have a range of 16-20 seconds when checked with

a

dry plastic

cloth, making

No. 2 Zahn cup,

Stir the thinned primer thoroughly, strain thru 2 paint strai ning funnels or 2-3 layers of lint-free cheesecloth, and allow tocatalyze at room temperature for 1 hour before

sure

Exterior Plated and Hydraulic Surfaces Coat all plated metal surfaces and hydraulic struts and piston rods (such as slat-tracks and landing gear shock struts) with corrosion preventive solvent soft film c0mp0u"d MIL-C-81309, WD-40, or equivalent. Exterior Rubber Parts Coat all exterior rubber parts (except deicer boots) exposed to weather with a coating of blackout tire coating. Do not allow oil or grease on tires.

using.

NOTE

Epoxy primer should be ized onB in tile amount that can be used in I sh~ft. The pot life of the ized primer is 8 hours.

Application of Protective Coating Inspect prior to primer application to ensure surfaces are free from corrosion

or

other surface contamination.

Surface finish

After completion of the catalyzing period, the ired

The pr i med su rfaces must be free of su rface i rregularities such as excessive or insufficient paint coverage.

and thinned

Film l,hickness can be checked using Thickness gauge or equivalent,

a

Boonton Film

Touch Up

Scratched or abraded paint areas must have primer touched up prior to extended outside storage. Areas may be touched up with zinc chromate primer TT-P-1757. Additional Aircraft Preservation

epoxy-polyamide primer is sprayed with 1 to coat a cross dry film thickness of 0.0005-0.0008 in. The films of spray gun must be kept moving to avoid thick epoxy run as

coating. (Thick coats of epoxy coating do not sag or readily as do other types of paint.) Allow to ail´• dl´•y

for a min of 4 hours prior to subjecting to inclement weather. Relative humidity seems to have no significant effect on the epaxy primer. However, the temperature of the surface to be painted and the paint should be between 60 and 90"F.

Slight color differences between adjacent Exterior

Openings

practical, any openings (unsealed access and inspection doors, vent holes, seams, personnel door, etc.)

Wherever

i nto which moisture can enter the interior of the aircraft is closed by suitable means. (Aircraft in flight status are exempt from this requirement providing that the windows, doors, covers and other closures normally a part of the aircraft are maintained in a closed position

when there is danger of water entering.)

cause

for

areas

is not

a

rejection of the primer.

Masking for temporary insignia and markings for flight tack free; a min may be begun after the coating has dried of 2 hours. The temporary insignia and markings are stenciled or sprayed over the primer. Use either Turco No. 4983 coating dyed deep blue in color or decal material. Stripping Protective Coating Prior to

processing aircraft

remasking all surfaces that strippers, solvents, water.

by damage by

for final finish, pl.otect are

subject

to

20-30-90 0


Page 3 Aug 31/84

9~3-76-023 C()HROSION CONTROL MANUAL

PROTECTION OF AIRCRAFT IN OUT-OF-DOORS TEMPORARY STORAGE (Continued) Stripping Protective Coating (Cont’d) IIWrlOl[ll~l Protective clothing, rubber gloves, andface mask must be worn during stripping

operations. Remove the temporary protective coating by applying a paint stripper, Turco No. 5351, full coating to be stripped. The remover may be applied by brush, roller or spray. Aircraft surfaces and stripper must be above 70"F. unifo,´•m coat of strength over the

Allow sufficient dwell time for stripper to thoroughly loosen the coating. Agitation with a stiff fiber brush will aid in the removal. Rinse surface with high pressure, high volume water or by steam cleaning. Slight brushing during rinsing operation will assist in complete removal of all residue.

20-30-90 Page 4 Aug 31/84

O

CBPYRIGHT,

1984 By SABRELINER CORPORATION


ANODIZING AND COLORING OF ALUMINUM ALLOYS to suspend parts being processed must be made of suitable aluminum alloys and capable of withstanding high anodizing currents.

Wires, clamps and racks used

GENERAL This section includes procedures for forming an anodic film by either the sulfuric acid process or the chromic acid process; and the procedures for coloring the anodic film, either by means of dyes or by precipitation of an organic

pigment.

Aluminum alloys t100, 3003, 5052. 5056, and 606 1 may be anodized by either the chromic acid process or the sulfuric acid process before coloring. Anodize aluminum alloys 2011, 13, A13, 2014, 2024, 7075, 220, 356, 360, and 384 by the sulfuric acid process before

MATERIALS Nitric Acid, Technical Grade

0-A-88

Acid, Sulphuric, (For) Storage Batteries Chromic Acid, Technical

0-S-801

coloring. Handle and store processed parts in a manner that will or contamination of the anodic coating.

prevent damage

0-C-303

APPLICATION NOTES

Grade

Phosphoric Acid, Technical Grade Sodium Dichromate, Technical Grade Caustic Soda (Lye)

Acid, Hydrofluoric, Technical Cleaner: Alkaline, lilild Metal Black MP Aluminum Black 3B

Preliminary cleaning may be accomplished quired. (Refer to Section 20-10-15.)

0-P-313 0-S-595

Anodizing and coloring

operation of the Corp.

Sandoz Chemical

Neolan Green WA Nickel Acetate, Technical

Los Angeles, CA Sandoz Chemical Works, Inc. Ciba Company, Inc. San Francisco, CA Ciba Company, Inc. Commercial

Grade emmonium Hydrosulfide,

Commercial

Neolan Black ALU

Technical Grade Cobalt Acetate, Technical Grade

accomplished

in

Tanks, electrical generators and other equipment must be of such construction and capacity as to provide satisfactory

Works, Inc. Aluminum Black BK

be

re-

accordance with tables 1 thru 4.

P-S-631 0-H-795 RB0210-005 American Aniline Chicago, IL

must

when

Commercial

entire process.

Thermostatically controlled heating must be provided in the cleaning, anodizing, coloring, setting and sealing tanks. Air agitation must be

provided

in the

anodizing tanks.

Removal of anodic coatings from parts must be accomplished in accordance with the procedure outlined in table 5. Wires, clamps and other connectors or part holders must be stripped of any anodic coating on electrical areas before reuse, since the coating prevents proper electrical with the work. FINISH Parts or assemblies found to have unsatisfactory film characteristics must be completely stripped and

reprocessed. PREPARATION Hazardous chemicals used in these procedures must be handled with caution. Weld parts

or

assemblies before anodizing.

A nodize welded parts and assemblies by the chromic acid process per table 1.

Do not anodize by the sulfuric acid process parts and assemblies which contain ts and recesses capable of retaining the anodizing solution. Parts and assemblies containing exposed material other than an aluminum alloy surface may be anodized only if the non-aluminum surfaces are completely masked, including a safe margin of overlap.

20-40-05 0

COPVRIGHI, 1984 BY SABRELINER CORPORATION

Page 1 Aug 31/84


ANODIZING AND COLORING OF ALUMINUM ALLOYS Table 1.

Chromic Acid Anodize and Dye Process

Degrease

TEMP "F

SOLUTION COMPOSITION

OPERATION i.

(Continued)

I

I

TIME

pH

I

I

REMARKS

I

I (Refer

to

Section 20-10-55.) 2.

(a)

Clean

6 oz mild alkaline cleaner per gal of water,

(b)

160-180

I I

or

5% caustic soda solution

10 minutes

I I

I I

Use either the non-etch

I cleaner(a) or the etch I cleaner(b) as required. 60 seconds

120-150

3.

Rinse

Tap Water (flowing)

Room

20-30 seconds

With agitation

4.

Pickle

10% nitric, 1% hydrofluoric acid by volume

80-100

5.

Rinse

Tap Water (flowing)

Room

20-30 seconds

With

6.

Rinse

Tap Water (flowing)

140-160

20-30 seconds

With agitation

7.

Anodize

5% chromic acid solution

120-125

60 minutes

Voltage and current density requirements vary with each alloy. (6-

5 minutes

agitation

12 amperes per square ft

typical) 8.

Rinse

Tap Water (flowing)

I).

Dye

(a)

2.2~1, Metal Black

Room

MP,

20-30 seconds

150-170

6.4-6.6

10-15 minutes

I 1 140-160

5.5-5.8

10 minutes

With agitation

or

(b)

1.2%Aluminum Black

BK,

(c)

or

1.2%Neolan Black ALU 0.20m Neolan Green WA

10.

Rinse

11.

Seal

1% nickel acetate solution in distilled water.

12.

Rinse

Tap Water (flowing)

13.

Dry

14.

Wipe

Room

I Tap Water (flowing)

I

I

200-210

Room

I

1 20-30 seconds 5.5-5.8

In distilled water

With agitation

1 5 minutes

I

1 20-30 seconds

I

I

With agitation

I Dry

cotton cloth

20-40-05 Page 2 Aug 31/84

o

COPYRIGHT,

1984 BY ~BRELINER CORPOS1´•A~ION

SR-76-023 CORROSION CONTROI, MANI~AI,

ANODIZING AND COLORING OF ALUMINUM ALLOYS (Continued) Table 2.

Sulfuric Acid Anodize and

OPERATION

I

Degrease

I

i.

Dye Process TEMP "F


I

I

REMARKS

TIME

pH

I

I (Refer

to

Section 20-10-55.) 2. Clean

I

(a)

oz mild aikaline cleaner per gal of water, or

(b)

59bcaustic sodasolution

3. Rinse

Tap

water

4. Pickle

(a)

(flowing)

l0%hydrofluoric acid, acid, by

90% nitric volume

I

I

I

I

I

I

I cleaner(b)

Room

I

1

I I

I I

With

20-30 seconds

(a)

10 seconds

Room

I I

as

required.

50 seconds

120-150

I

Use either the non-etch cleaner(a) or the etch

10 minutes

160-180

6

1 I

agitation

Shall beusedon 13, 360, 384. Operation 4(a) preferred for 43, 85 and 356

alloys, but they be pickled as per 4(b). (b) 5. Rinse

35-400/onitric volume

acidby

I Tap water (flowing)

Fia. Rinse

all other alloys

Room

30 seconds

(b)

Room

20-30 seconds

With agitation As

Room

Water Jet

may

required

in holes and

recesses

6. Rinse

Tap water (flowinff) (With agitation)

Required following

20-30 seconds

90-110

I

I

I pickling solution (a)

I

operation

I

Per Table 4

7. Anodize

15%by weightsulfuric acid

8. Rinse

Tap

water

(flowing)

Room

(a)

1.2%Aluminum Black

140-160

9.

Dye

3B

5.8-6.2

of

in

4

50 minutes

Per Table 4

20-30 seconds

With agitation

10 minutes

(a)

Mandatory foralloys with 9%

(distilled water)

use

or more

Si

(13,360, 380,384); not to be used

other

(b)

2.2% Metal Black MP

(distilled water) (c)

(d)

150-170

1.8’lhAluminum Black I 1 140-160 BK 1.2%Nealan Black I I ALU 0.2% Neolan

I

I (c)

10 minutes

5.5-5.8

Green WA

(b)

10-15 minutes

6.4-6.6

I

I

I

I

I I

on

alloys

Preferred for all other alloys

or

(d)

are

possible

substitutes which may be used for other type aluminum

alloys.

20-40-05 0

C;QPYRIGHT,


Page 3 Aug 31/84

SR-76-023 CORKOSION CONTROL MANUAL

ANODIZING AND COLORING OF ALUMINUM ALLOYS (Continued) Table 2.

Sulfuric Acid Anodize and Dye Process SOLUTION COMPOSITION

OPERATION 10.

Rinse

Tap Water (flowing)

11.

Set

1% nickel acetate solution

12.

Rinse

Tap

13.

Seal

water

(flowing)

5’%, sodium dichromate

(Cont’d)

TEMP OF Room 200-210

20-30 seconds 5,5-5.8

Room 200-210

TIME

pH

With

agitation

5 minutes

20-30 seconds 5.0-0.0

REMARKS

With agitation

15 minutes

solution 14.

Rinse

15.

Dry

16.

Wipe

Tap

water

(flowing)

Room

20-30 seconds

Dry

With agitation

cotton cloth

20-40-05 Page 4 Aug 31/84

o

COP~RIGHT,

1984 BY´•SA.BRELINER CORPORATION

8B-76-023 CORROSION CONTROL MANUAL

ANODIZING AND COLORING OF ALUNLINUM ALLOYS ~Continued) Table 3.

Sulfuric Acid Anodize and Pigment

i.

Degrease

2.

Clean

TEMP "F


OPEE1ATION

Precipitation

Process

pi-I

(Refer

(a)

6 oz mild alkaline cleaner per gal of

(b)

4. Pickle

160-180

10 minutes

5% caustic soda solution

120-150

60 seconds

I Tap Water (flowing) l0%hydrofluoric acid, 90% nitric acid by

(a)

Room

20-30 seconds

Room

10 seconds

(b)

5a. Rinse

35-40% nitric acid by volume

I Tap water (flowing) Water

Agitate parts Pickle (a) must be used 13, 360 and 384 alloys, 4(a) preferred for 43, 85 and 356 alloys but they

Room

30 seconds

,~y b, pickled as per 4(b). Pickle (b) must be used on all other alloys.

Room

20-30 seconds

Agitate parts As

Room

jet

Use either the non-etch cleaner (a) or the etch cleaner (b) as required.

on

volume

5. Rinse

to

Section 20-10-55.)

water

3. Rinse

REMARKS

TTME

required

in holes and

recesses.

6.

Tap water (flowing) (With agitation)

7. Anodize

15%

by weight sulfuric

8. Rinse

Tap

water.

9. First Color

Cobalt acetate 204b

acid

(flowinff)

90-110

20-30 seconds

Required following use of pickle operation 4(a).

84-86

50-60 minutes

Current density 16 amps/sq. ft.

Room

20-30 seconds

Agitate parts.

110-120

5.9-6.2

15 minutes

Dip

(flowing)

10. Rinse

Tap

11. Second

Ammonium

water

hydrosulfide

3%

Room

20-30 seconds

Room

5-15 minutes

20-30 seconds

Color Dip 12. Rinse

Tap

water

(flowing)

Room

13. Wash

Tap

water

(flowing)

Room

Wash, using soft cloths

as

remove

wet

necessary to

any loose

pigment. 14.

Dry

20-40-05 0


Page 5 Aug 31/84

SR-76-023 (:()IIK()SION CONTROL MANUAL

ANODIZING AND COLORING OF ALUMINUM ALLOYS ´•(Continued) Tabltt´•l.

SulfuricAcid ProcessVariables

ALUMINUM ALLOY NO. 18 85

360 384 ~S I1S 2ilS 52S 61,’,

MAXIMUM VOLTAGE

MAXIMUM CURRENT DENSITY

(AMPERES

(AMPERE:S

PER SQ. FT.)

PER S6t. E’T.)

18 15 15 16 18 17

10 10 10 10 10

84-86 70-72 70-72 84-86 84-86

12 12 12 12

12 12

15 Ifi 17 14 14.5

16 12; 12 18 16

Stripping Procedure

OPERATION

2.

MAXIMUM STARTING VOLTAGE 10

70-72 84-86 84-86 70-72

356

i.

"F

84-86 84-86

4~

Table 5.

ANODIZING TEMPERATURE

MAXIMUM STARTING CURRENT DENSITY

I

SOLUTION

TEMPERATURE "F

Strip

2% chromic acid and 7% phosphoric acid by weight in tap water

170-190

Rinse

Tap

Room

water

I

TIME 5-10 minutes

NOTE

Stripping procedurefor 1 3, 3~0, and S8~ aluminumallo?ls must befollowed by a physical of cleaning such asfine sandblasting, rubbing with aluminum wool, or eguivalent.

means

20-40-05 Page 6

Aun a´•I!H4

o

CQPYRIGHT, 1984 BY SA&RELINER CORPORATION


CHROMIC ACID AND SULFURIC ACID ANODIZING

l‘his section

covers

the requirements for anodic coatings alloys by the chronic acid and

to aluminum and aluminum

sulphuric acid The

Types

II: Anodic

coatings applied by the sulphuric acid

process.

LIMITATIONS must not be applied to aluminum alloys with nominal copper content in excess of 5% or when the total alloying elements exceed 7.5%.

Type I coatings

Type II coatings must not be applied to parts containing ts or recesses which may entrap the anodizing solution. APPLICATION NOTES

(12efer

to sec’tion

Surfaces to be anodized must be free from oil, scale, or

Appearance The anodic coating must be adherent, continuous, smooth. uniform in appearance and free from powdery areas, discontinuities such as breaks, scratches and burned must be held to a areas. Size and number of marks min consistant with good practice and must be limited to noncriticai areas.

Coating Continuity The continuity and presence of an anodic coating ton other than as cast, or as forged surfaces)must be determined by using a battery operated ohmmeter or equivalent. A resistance of less than 200,000 ohms on any anodized

surface is

Preparation

welding flux

film.

20-40-35.) FINISH

following type designations applies.

process.

Surface

application of colored chemical

processes.

Type I: Anodic coatings applied by the chromic acid

Type

up of marks, blemishes. superficial scratches, and minor rework may be accomplished \,y

Touch

(;ENERAL

other foreign matter.

Maukina Prior to anodizing, mask exposed surfaces of nonaluminum materials and any exposed surfaces where an anodic film is not required.

cause

for rejection.

Process Controls Process control s should be processed at least monthly for coating weight and corrosion resistance. The s must be 2024-T3 bare (&&-A-250/4) 0.032 x 3 x 3 in. for coatinff weight determination and 0.032 x 3 x 10 in. for

salt spray testing.

Coating Weight must meet the following requirements when tested per ASTM-B-137:

Coating weight

Application Anodic coatings must be

deposited only after all heat and perforating

treatment. machining, forming, operations have been completed.

Type I

200

Milligrams

per so. ft.

Type II

600

Milligrams

per so. ft.

Sealing

Corrosion Resistance

Type I and Type II coatings meet the corrosion resistance

suitably sealed to requirements of Corrosion

must be

Resistance below.

Coating Weight Coating weight

must meet the

requirements of

Process

Controls below.

After sealing, Type I and Type II coatings must be exposed for 336 hours to the salt spray in accordance with ASTM-B-117, except the significant surface must be inclined 6" from the vertical. The specimens must show no than 1/32 more than 5 isolated spots or pits, none larger inches in diameter, except within

1/16 in. from edaes,

marks. corners, identification markings and racking Corrosion in excess of the foregoing is cause for rejection.

Rework

Stripping Anodic coatings may be stripped only if dimensional tolerances can be maintained. The solution must not cause pitting or other damage to the basic metal,

20-40-10 0



SR-76-023 CORROSION CONTROI, MANUAL

DOW NO. 17 ANODIZE PROCESS FOR MAGNESIUM ALLOYS Electrical Installation

(;ENERAL

procedure for. direct current (dc) anodizing malSnesium alloys by a process called Dow No. ’I’his section

covers

the

17 Anodize.

This

specification

meets the

requirements of MIL-M-

45202, Type I Class C, and Type II Class D. The designations indicate the following characteristics.

The equipment nlust be installed in such a manner as to meet the electrical safety requirements under SAFE’I’Y below. Timers

Suitable timing equipment, either manual

Class C:

Lightcoating Light yellow-green coating (Dow 17)

TypeII:

Heavycoatinff

Class D:

Dark green coating (I)ow 17)

TypeI:

automatic,

provided.

Electrodes

1Jnless otherwise indicated, the Type I Class C coating must be

or

It is suggested that the timing equipment be installed in such a manner that the de electrical power source is shut off upon completion of anodizing.

must be

applied.

When a lined tank is used, the cathode electrode must be made of steel. When an unlined tank is used, the tank itself must be the cathode electrode.

MATERIALS Ammonium Bifluoride (Talc-free

Commercial

preferred) Sodium Dichromate

(Na2Crz07,2Hz0)

Phosphoric Acid, 850~wt (sp, 1.09-1.70 C.P.

or

0-S-595A Commercial

gr.

N.F.

0-C-303 Commercial

Chromic Acid Sodium Rifluoride (Talc-free

LIMITATIONS Whenever possible, magnesium parts must be anodized before any inserts are placed. If the foregoing is not possible the inserts must be carefully insulated from the anodizi ng bath by either a baked phenolic coating or vinyl coating (5 or more mils thick). PVC type rack plastic coatings are not resistant to chemical attack during

anodizing.

preferred) NA3´•5167 3M Company

Alkaline Cleaner No. 410 Electroplaters Tape (or

equivalent)

Unless otherwise indicated, the Type II Class D coating must be applied to all magnesium alloys processed accord ing to this section.

EQUIPMENT

SAFETY

Anodizing Tank

Electrical

The anodizing tank must be made of unlined steel or steel tank lined with synthetic rubber or vinyl base materials. Stainless steel or aluminum tanks are unsuitable and must not be used. The tank must be of such size that the parts to be anodized are a minimum of 2 in, from the tank

Unlined steel tanks, used as cathodes during the anod i zing operation, must be electrically grounded. In addition, suitable safety devices, such as any physical barrier, to prevent short-circuits during anodizing must be instal led. Physical barriers must be installed in such manner as to

and/or heating coil.

shut off the de electrical

Heating and/or Cooling Coils The heating coil must be made of carbon steel. Stainless, lead, copper, aluminum or titanium must not be used.

Racks and Clamps All racks and clamps for holding magnesium articles immersed in the solution during anodizing must be made of any suitable aluminum or magnesium alloy. They must be protected at the electrolyte-air interface with No, 470 F,lectroplaters vinyl tape (or equivalent) to resist the action of the electrolyte. Steel, CRES, copper or titanium

components must

not be used for racks

source

if they

are

not in proper

place during anodizing.

or

clamps.

Chem ical The concentration of air-borne fluoride and hexavalent chromium substances during anodizing operations must be removed by operation of the exhaust system.

APPLICATION NOTES

Application of Coating The coating produced by anodizing of the magnesium surface must be uniformly applied over the enti re su rf ace, and must be free from scratches or other damage or irregularities, and from breaks other than at the point of

20-40-15 0


Page 1 Aug 31/114

SI1-7fi-023 COHH()SION CONTROL MANUAL

Dow NO. 17 ANODIZE PROCESS FOR

I~MAGNESIUM

ALLOYS

(Continued)

Application of Coating (Cont’d) electrical . The color of the anodize coating must be chal´•acteristic of good quality of the Type and Class specified. marks must be touched-up as necessary

using the Dow

19 soution.

Coating Thickness The coating thickness resulting from anodizing must comply with the following values.

Type I Class C: 0.0001-0.0004 in./side Type II Class D: 0.001-0.002 in./side The coating thickness coating below.

must be measured

as

stated in

ANODIZING PROCEDURE All magnesium with table 1.

alloys

must be anodized in accordance

STRIPPING OF DOW NO. 17 COATINGS When it is necessary to strip Dow No. 17 anodic coatings from all areas of a part and/or magnesium assembly or to rejuvenate magnesium s upon racks and/or clamps a 200/n/wt solution of chromic acid at a temperature of 160 to 2100F must be used.

REWORK AND/OR REPAIR OF now No. 17 COATINGS

Refinishing of Dow No. 17 anodized magnesium alloy surfaces which are corroded, abraded or scratched must be done in accordance with section 20-40-85. Re-anodizing of maffnesium surfaces due to rework of maanesium alloy basis metal can be done without removal of the previous anodize coating. Anodizing takes place only on the bare areas until the new coating builds up to the same thickness as the original. Proceed according to table 1 but omit operation 5.

20140-15 Page 2 Aug ~1/84

o

1984 BV

~ABRELINER CORP6RATION

tj

O

O

Table 1.

o

DC Dow No. 17 Anodize Process Sequence for Magnesiun Alloys

II

SOLUTION

C,

CONSTITUENTS

I -f

OPERATION 1.

1

1

AND

TEMPERATURE

CONCENTRATIONtjl

"F

i

I

r

Mask

Maskand/or

areas as necessary

before

1

racking. 10

m

2.

(n a a

Refer to section 20-10-55. Note: Masking materials must be resistant to degreasing fluid or vapors.

Vapor Degrease

~optional)

F

3.

Z

Alkaline Soak Clean

Z O

PROCESS DETAILS

TIME

Rack

p

O

Z O

tj n

N NA3-5167 cleaner, 6-8 oz/gal

195-205

Until clean

free-rinsing

steel tank. The pH of this solution must always be greater than 11. Use

a

0 O

’d

~a

surface is obtained

m a

m

O C3

a

4.

Rinse

5.

ChromicAcid

Water

I~

Ambient

30-60

Water should be flowing

freely.

m

seconds

O a

Pickle

o

Chromic Acid, 24 ~fi2

130-140

1-15 minutes

Ambient

30-60 seconds

160-180

See table 2.

oz/gal

Z

6.

Rinse

Water

O

Tank must be either PVC, lead-iined, stainless steel or 2002 aluminum. Provide adequate ventilation. Dump when colored films form on magnesium Surfaces.

O

Water must be flowing freely.

M 7.

Magnesium Anodize

Ammonium Bifluoride, 36-40 oz/gal Sodium Dichromate, 13.3 f2 oz/gal Phosiilric Acid 11.5 f2 fl. oz per gal

Type I, Class C 5-50 ASF

1

5-50 ASF c~

to 100 de

to 72 de

50-60

r

cl

d

Current Density

Amp minutes

I\S

Type II, Class D

per sq. ft.

300 min

Dissolve chemicals in order listed using 160"F water. Stir vigomuslyandheatto 1800F. For replenishment see Agitation must be per O Ventilation and

r O cC M

B o o Z C Z

o

Q

b g

safety

must be

o 13

adequate and positive.

O ´•a

a

c~3 p~

B eu

C~

z~ e b ~to r

cs

c~ Os

os,

a o

-o Z O

cn

O

r

DC Dow No. 17 Anodize Process

Table 1.

SOLUTION CONSTITUENTS AND CONCENTRATION O

OPERATION 8.

9.

Sequence

Rinse

Water

HotRinse

Water

for

4~

Magnesium Alloys (Cont’d)

r

~Z: TEMPERATURE "F

a TIME

PROCESS DETAILS

ct

N

O

Ambient

O

160-120

30-60 seconds

Water should be

30-45 seconds

Use lined steel

flowing freely,

m Cd

or

stainless steel tank.

O m

10.

Dry

I

Air blast

toil

and

water-free)

or

suitable

drying

M M

oven

r

NOTES C>

Concentrations are by weight of softened distilled or deionized water, or by volume as noted. Maintenance-of-volume water and water used to dissolve chemicals must be of same quality.

Q a

t)

Iii

p

(n

m r

Z n

o

O

O O

Ij Replenishment of bath

should be made when about 20 sq. ft. of surface area per gallon of bath have been treated, or when final volta-ge exceeds v~ues established by 10 volts. Amounts of various ingredients to be added are determined by chemical analysis. If operating voltage attained after addition of make-up chemicals is lower than that specified, add sodium (not ammonium) acid fluoride until correct voltage is attained,

It is mandatory that firm be made at all times between the rack s and part to be anodized. If not done, severe pitting and/or etching will occur at areas of loose . It is preferable to rack parts on non-critical areas, if possible. Water must be

softened, distilled,

or

deionized.

Due to increasing resistance of anodic coating being deposited, voltage required to produce a given current density increases during anodizing process. Voltage must be regulated manually or automatically to maintain desired current density.

El

O ~d

Z M

d

When

complex partsare tobe anodized,they mustbe agitated while totally immersed in order to minimite entrapment of air in pockets or blind holes. Parts should be repositioned periodically to bring anodizing solution in with uncoated areas and to prevent attack at solution-air interface at such pockets.

F O cC C~ o

=f 0 a -I

O

9

c’

3 e

a v

r

SR-76-02:3 COHROSIO~i CONTR()L MANUAI,

DOW NO. 17 ANODIZE PROCESS FOR MAGNESIUM ALLOYS

(Continued)

COATING Thic´•knctns The coating thickness must be in compliance with API’IJICATION N()TES above. Coating thickness must be measured by nermitron or equivalent.

Appearance Refer to APPLICATION NOTES above.

Table 2.

Anodizing Time in Minutes CURRENT DENSITY

AMPERE~1MINUTES/S&.

FT.

5 ASF

10; ASF

20 ASF

30 ASF

50 ASF

TYPE ICLASSC 1

50

10

5

2.5

1.66

BO

12

6

3

2

112

30

6

TYPE II CLASS D 300

60

30

15

400

80

40

20

8

25

L()

500

100

50

16.6

20-40-15 o




APPLICATION OF TFE INFUSED COATING ON ALUMINUM GENERAL

Abrasion Resistance

gives the requirements for the application of synergistic coating consisting of anodize per MIL-A8625 (aluminum) infused with tetrafluorethylene (TFE).

The weight loss of the coated part must not be greater than 40 milligrams when tester under Abrasion Resistance.

This section a

TFF, infused anodize is intended for metal surfaces that will be subjected to service conditions that require a combination of such properties as corrosion resistance and abrasion resistance.

The coating is TFE infused hard anodize

on

aluminum

Coating Thickness The coating thickness must be 0.002 ~0.0002 in. unless otherwise specified on the engineering drawing.

TESTS

parts.

Appearance

EQUIPMENT Alpha LFW-1 Tester or equivalent

Faville-Levally Corp. Bellwood, IL

COATING QUALITY

QUALITY. Corrosion Protection

Appearance The coating must have a smooth, uniform appearance and must be free of burned spots, chips, scratches or other discontinuities when examined.

Subject the test specimens to salt spray per ASTM B 117 for 1500 hours. After the s are removed from the salt spray chamber, they must show no evidence of corrosion. Wear Life

Corrosion Resistance Coated parts must show no evidence of corrosion after salt spray

Visual examination shall be used to determine conformof the coating to the requirements of COATING

ance

testing. (Refer to Corrosion Protection below.)

Wear life performance must be tested on an Alpha LFW-1 tester, or equivalent. All test specimens must be the standard size for the Alpha LFW-1 tester and must consist of the materials given in table i.

Wear Life wear life of specimen costing must be at least 200 cycles when tested with the Alpha LEW-I, or equivalent,

The

tester.

Table 1.

Wear Life Test

MATERIALS 2024 Aluminum

4130 Steel Block

Ring

Specimens TFE COATING

DIMENSIONS AND SURFACE FINISH BEFORE COATING APPLICATION a surface finish of 16-32 microin. and O.D. concentricity must be within 0.0004 in. Coating must be applied to the O.D. surface.

Coated

Outside diameter must have

No Coating

Steel must have a hardness of R,57-60. Surface finish must be 6-12 microin. on area. No coating must be applied to block.

20-40-20 COPYRleHT, 1984 BY SABRELINER CORPORATION

Page 1 Aug 31/84


APPLICATION OF TFE INFUSED COATING ON ALUMINUM (Continued) Test Procedure For this test, the ring is in sliding with a 4130 steel block. The ring is mounted on the test mandrel and rotated at a speed of 72 rpm (26 ft/minute). Within 1 minute of test initiation, a 30 Ib normal force must be gently applied to the ~tationary block mounted in the block holder. The test is run at room temperature using unidirectional motion only. A coefficient of friction of 0.175 must be used as the failure point.

stationary

Abrasion Resistance Test two test

specimens

as

indicated in table 2.

Test Procedure

Test the specimens in accordance with FED-STD-141, Method No. 6192, using CS-17 wheels with a 1900 gram load. The wheels must revolve on the coating at a speed of 70 rpm for 10,000 cycles. Prior to and after abrading, the specimens must be weighed and the weight loss obtained to determine compliance with COATING QUALITY

requirements. Thickness Make thickness measurements

using any suitable instru-

ment, such as a micrometer or eddy current devices, where such instrument is capable of determining the coating thickness to plus or minus 10% of its true thickness.

Table 2.

Abrasion Test Specimens

MATERIAL 2024-’13 Aluminum

TFE COATING

DIMENSIONS

Coated

Specimen dimensions x

0.040 in. All

must be

corners

approximately4.0 x 4.0 must be rounded and a0.25 hole

cut in center.

20-40-20 Page

2

Aug 31/84

O

~YRIGHT,

1984 BY

~BRELINER CORPORATION


APPLICATION OF SCALE INHIBITING COMPOUND (;ENERAL ’I’h is section covers methods and materials for application of a ctoati ng for i n hibiting scale du ri nrs heat treating. Th is section should be used in conjunction with other sections where pretreatment is called out.

I)rying Applied films of the com pound must be allowed to ail’ d ry at i east 15 m inutes at room temperatu re or fo rce dry fo r 5 minutes at 1500F before heat treatment. Touch-up

MATERIALS

Compound. Scale Inhibiting

ST0225GB0001

APPLICATION NOTES Surface Preparation The surfaces to which the scale inhibiting compound is to be applied must be clean. There must be no foreign material such as pencil marks, ink stamps, etc., on the cleaned parts prior to application of the compound. The compound must be applied as soon as possible after cleaning, but in no case later than 24 hours after cleaning, Cleaned surfaces must be handled only with clean fabric

Protection of coated paris during heat treatment is dependent upon an unbroken film of the required thickfor ness on all surfaces. Coated parts must be inspected film defects before heat treatment. Film defects may be touched up by brushing or spraying, whichever is convenient.

Handling Normal precautions must be taken to prevent accumulation of surface contaminants, dirt or physical damage to the applied film of the coating.

Racking

gloves.

drying, coated parts must be placed in suitable racks for heat treating. The racks should be made of such construction that a min area of coated surfaces are in with them, and at least one half in, space is maintained between coated parts and surrounding furnace structure. After

Cuatinff Preparation (;cnerally the compound in the "as received" condition is If thinning is necessary, it app I led by spraying or dipping. is accomplished by the addition to the material of not more than by volume of toluene.

Heat Treatment

NOTE Material

as

reeeived must be

thoroughly before

agitated

use,

Heat; treat according being processed.

to methods

applicable

to materials

NOTE

Film Thickness

During heat treatment, visible fumes will evolve. These fumes are non-tozic, so no special precautions are necessar2/.

The applied material must form a continuous coating with a max dry film thickness of 0.0005 in.

Spray Application compound may be applied by the use of conventional will generally depositthe sl,ray ttpplication. One thin coat material. of requirement optimum

The

Oil, Application Generally only one dip is required to deposit the optimum requirement of material. After dipping, all parts must be allowed to drain at least 5 minutes,

Coating Removal Before

Heat Treatment

When it is necessary to remove the applied coating prior to heat treatment, solvent wipe with toluene or methyl ethyl ketone

(MEK).

Coating Removal After Heat Treatment Removal of the spent coating after heat treatment must be

accomplished according rials being processed.

to

cleaning applicable

to mate-

NOTE’ To p~re´•oent ious of Yolvent, the dip tank shozLld be adeguately covered when not in uue.

20-40-25 0

COPYRIGHT, 1984 BY SABR~LINER CORPORATION



PHOSPHATE TREAT~MENT

Classification:

Rodine No. 50 Acid Inhibitor Rust Inhibitor, Amine Type for Water Rinse R-2 Oxalic Acid, Technical Grade Turcoat Activator Parcolene "Z"

Heavy Manganese TypeI TypeTI --HeavyZine Light Zinc Type Iii

Iron Powder, 200 Mesh, Technical Grade 75%, Phosphoric Acid

(table 1) compares these types with the Government specifications and lists the usage for each type of phosphate coating.

TechnicalGrade Corrosion Preventative, Soft Film, Cold Application Coating, Organic, Corrosion

(;ENEeAI, This section covers the materials and processes to be used in the phosphate treatment of bare, cium plated, or xine coated iron and steel.

A cross-reference chart

Amchem, Inc. Wyandote Chemicals Commercial Turco Products, Inc. Parker Rust Proof Co. Commercial

Commercial MIL-C-14201 RB0130-006

Protective, for Liquid Oxygen

MATERIALS

and other Service

Phosphating Compounds: Type I(MIT~-P-16232, Type M) Parco Lubrite 2

Type II(MIL-0-16232, Type Z) Farce 1A

Cryscoat HC Tn

4432

SAFETY Parker Rust Proof Co.

Some of the chemicals used in this process and must be handled with that in mind.

Parker Rust Proof Co. Oakite Products, Inc. Turco Products, Inc.

SURFACE PREPARATION

Tyr,e iii (’l"r-C-490, Type 1) Bunderite 32 Accelerator 130

Neutralizer 200 Indicator I’aper No. 17 Test Paper) Parco 1A

(Iron

Cr.vscoat HC Tul´•coat 4432

Parker Rust Proof Co. Parker Rust Proof Co. Parker Rust Proof Co. Parker Rust Proof Co. Parker Rust Proof Co. Oakite Products, Inc. Turco Products, Inc.

are

hazardous

Complete all forming, machining, welding and heat treatment prior to cleaning operation. Pictkling must not be used where prohibited by embrittlement relief method used. to relieve hydrogen embrittlement must be suitable in duration, temperature, and timeliness for the metal and process in use.

Baking

Phosphating Requirements Th, processes used

are

listed in tables 2, :3,

or

4,

as

applicable. All parts to be phosphated must be processed using one of the compounds listed in MATERIALS.

FINISH Alkaline Cleaner for Steel: Oakite 77 Parco 341

Oakite Products, Inc. Parker Rust Proof Co.

I,BOB1C)-10~

Cleaner; Electrolytic, Alkaline

Chromic Acid, Technical Grades

Federal Specifica-

Ilubricating Oil, Preservative

tion 0-C-303 MIL-L-3150

The rust

coatings must be evenly deposited. There or finger prints.

must be

no

Stains from chromic acid rinse are not cause for rejection.

Nonuniformity of appearance due to heat treatment, degree of cold work, or composition of base metal are

icceptable.

Medium

Compound, Corrosion Preventative Finger Printing Remover

MIL-C-15074

Stoddard Solvent Hydrochloric Acid, Technical

P-S-661 Federal Specification 0-A-86

Grade

Appearance

Salt Spray Resistance The phosphated article must show no signs of corrosion when tested by standard salt spray (5 or 20% sodium chloride) method (Federal Test Method Standard No. 151, Method 181) for periods shown following.

20-40-30 0

COPYRIQHT, 1984 BY SABRELINER CORPORATION

Page 1 Aug 31/84

8~3-76-023 CORROSION CONTROL MANUAL

PHOSPHATE TREATMENT Salt

(Continued)

Partially Phosphated Items

Spray Resistance (Cont’d)

In phosphating steel parts which have cium plated masking of the;cium plated area is not

Phosphated Steels

areas,

HOURS RESISTANCE

necessary.

TYPE OF COATING

NO SUPPLEMENTARYOILING

WITH SUPPLEMENTARYOILING

1.Tj

24 48

Type I Type II

2

Phosphated Cium

There must be no observable attack of either nickel or chromium plated portions of phoshated treated parts.

Rinsing The water used for make-up of chromic acid rinses must contain no more than 70 ppm of combined sulphate and chloride ions.

Plate

THICKNESS OF OF CIUM (IN.)

HOURS TO CORROSION OF BASIC METAL

0.0005 0.0003 0.0002

240

Stripping Unless prohibited by embrittiement relief method used,

192 96

phosphate coatings may be stripped by immersion in 1:1 hydrochloric acid containing 1/8-1/40/0 Rodine No. 50 Inhibitor. Use room temperature until stripped; then rinse with water. If acid pickling is prohibited, strip by use of abrasive cleaning melhod compatible with object being stripped.

Minimum Weight

weight for each type of coating formed on bare (dry ground, not sand blasted) steel must be as given below. Test s must be the same alloy, heat treatment, The min

surface finish, etc.,

as

is the largest part treated.

TYPE OF COATING

MIN. WEIGHT MG SQ FT

I II III

1500 1000 300

Tests Tests to determine conformance with Salt ance and Min Weight must be made.

Spray Resist-

For salt spray resistance, 3 specimen items, or standard s to simulate these items, must be tested for each of Type I and Type II coatings, with and without supple-

mentary oiling. For coating weight determination 3 specimen items, or standard s to simulate these items, must be tested for each of Types I, II and III coatings.

20-40-30 Page 2 Aug 31/(34

a

~PVRIGHT, 1984 BY $B~RELINER CORPORATION

I

Table 1,

CrossReferenceChart

MIL

1

TYPE I

DESCRIPTION

Chemical Description

Zinc

TYPE III

TT-C-490, Grade 1

MIGPP16232, Type Z

MIIrP-162s2,’i~pe M

Spec

1

TYPEII

Light Zinc Phosphate

Phosphate

Heavy Manganese Phosphate

Heavy

i. Used on bare steel base for solid film

1. When applied as a heavy coat, it is used to increase corrosion resistance,

Cd

td

a

Purpose(s)

r

of

use

as a

I]

lubricants. (CAUTION: do not apply oil to phosphated

O

surface.)

O 2. Used to increase

a 73

2. When applied coat, it is used

wear

resistance of Sliding surfaces.

O II

O Z

1. Do not oil. See

in temperature, duration, and timeliness for the metal

2. Oil with MIGL-3150

and process involved,

1.

Dip in MIGG3150

or

MI1-C-15074 and drain.

call-out.

2. Do not oil. Paint

or

as

drawing call-out,

MJL-C-15074 oil and drain or as

as

base.

drawing

Post-Treatment. Embrittlement relief must be suitable

light a paint

as a

drawing designates.

bare steel or cium plated steel to increase paint adhesion.

O

on cium plated steel as a base for solid film lubricants.

m

i. Used

on

2. Used

1. Do not oil. Paint

2. Do not oil.

phosphating materials

Apply

later.

table 3 may be used to form Type III Times are as follows: Parco 1A

3-4 minutes

used to

Cryscote HC

I

’g

solid film

Z M

2: c3 C3 O

1

~f.

a

listed in produce! Type III coating. Phosphating solutions in table 3. those from given times coatings by reducing phosphating

may be

per

lubricant as per drawing call-out. Chromic aCid rinses cannot be used as a final rinse of cium plating cycle when solidfilm lubricants are to be

NOTE II

as

drawing call-out.

applied

O l’ype

31

a O ~fl

Z

3-5 minutes

Turcoat 4432

8-14 minutes

IP OSc~ w

2~ c b rCs

s ´•a

o

1\3

Bm

-a 4

Table 2.

a

Type I Phouphating Procedure

I

I OPERATION

I MATERIAL

CleaningO

Degrease by

grit,

Rinse

Spray

Phosphate

Type I I’hosphating Solution (Parco Lubrite 2)

Rinse

1

vapor

blast with 220

I

I

I TEMP"F

CONCENTRATION

IMMERSION TIME MINUTES

I

I REMARKS

r

degreaser, clean solvent dip, or clead solvent wipe. Remove scale or adherent soils by grit or equivalent. Vapor blasting does not leave a satisfactory surface. O

Cd

with cold water; then immerse for 2 minutes in clean hot water.

Make up to 10

Maintain at 11.5-12.5

Points are mi N/10 sodium hydroxide needed to neutralize 2 mi sample; use phenol

points III

phthalein indicator.

100

gals tap

gals

202-208

per

Total Acid, 0.2 max in 25 mi sample. Keep free of visible contamination.

Tap-water, overflowing

12-15

water.

Roomto 180

I

Chromic Acid Rinse

Chromic Acid

rjIake upto 6

a

I

oz/100 gals

140-180

I

I

0.8 free acid points. Refer to Rinsing. O

I

Clean, oil-free

Dry

1/2-1 (no more)

water.

air

225

I

Until

max

I

I

m c~

~d M C~

Discard when total acid is 6 times-free-acid, or sooner if otherwise contaminated. Use 25 mi sample.

mt c3

dry

I

I

I

(r,

o

I

NOTES

m

j

Cleaning is very important to promote uniform penetration of the metal and to avoid excessive coating build-up. Do not use strong acid or alkaline cleaners.

r

Z a

a

9 r

td

Direction of flow must keep main body of rinse from being contaminated.

1

~d O Cd

O

m

r~

Where internal areas of complex configuration, such as interiors of small fuel tanks, are too small to permit grit- blasting and are subsequently to be

131

coated, inhibited acid descaling may be used. In this case, the part should be rinsed and vapor degreased

prior

a

to

phosphating.

Maintain iron content at 0.2-0.30~

powdered iron

O

as

by

additions of

necessary.

One-half the weightof chromic acid may be replaced an equal weight of phosphoric acid.

by ;´•:z

O

Table 3A.

~o

1

C,

I OPERATION

1 -e

Procedure for Phosphatlug With Parco 1A

Type II Phosphatiag Procedures 1 MATERIAL

i.

Degrease

2.

Descale

2a.

Rinse(if aciddescale isused).

3.

Clean

i

CONCENTRATION

I TEMP "F

TIME

Cd

v,

m~

Alkaline Cleaner

REMARKS

MINUTES

5-8

185-210

oz/gal

15

or

~d

until free

running

m

4.

r

Rinse

Z

Max 0.2

Tap water overflowing

carry

Room

points alkalinity

over

1/2-1-1/2

from cleaner

m

5.

Pretreat

73

i. ParcoleneZor 2. Oxalic acid

8.0-9.01bs/100gal 2.0-3.0 oz/gal

O n

6.

Rinse


7.

Phosphate

Parco 1A

Room

10-60 seconds

Room

1/2-1-1/2

Room

1-3

O

O Points are mi N/10 sulfuric acid needed to neutralize a 10 mi sample using phenolphthalein indicator. Bath should be

Cd

td c~ M

agitated.

cj

5a

In all water rinses, direction of flow must keep main body of rinse from being contaminated.

M

Z

2-1/2-3-1/2 100

gal

gatl_I~’

190-200

water

25-30. See Remarks for cium

plated parts 8.

Rinse


9.

Seal

Chromic Acid

I Partly or completely

Make up to 8 100 gal

oz

140-180

per

1: c~ C: o

1/2-1

Control to free acid 0.8-1.2 on 25 mi sample. Discard when total acid reaches 5 points (25 mi

Dry

Clean, oil-free

225

max

Until dry

a a

~a m

Z

a

air

(U

1

points

sample). 10.

m

be phosphated for 12-15 minutes

Room

O

I

cium plated parts shall

NOTES

ri

b e~o

0)

Control total acid 28-30 points on 10 mi sample. Titrate with N/10 sodium hydroxide. Control iron (ferrous) to 0.1-0.45’~/0

O

One-half by weight of chromic acitl may be replaced by phosphoric acid.

p

Cr3 (P

i~iU1’

rm

W

~I z

ts 01

a

X ~t

h)

c~ c

i

"b

o"

mb

t-

Table 3B.

Type

II

Phosphating Procedures

Procedure for

Phosphating

with

c~

Cryscote HC

r

OPERATION

MATERIAL

i.

Degrease

2.

Descale if necessary.

2a.

Rinse(if acid descaled).

CONCENTRATION

TEMP "F

TIME MINUTES

REMARKS

Clean

Oakite No. 77

4.

Rinse


1

12-16 oz/gal Max 0.2 carry

I :Oxalic acid

6.

Rinse

r

Phosphate

CryscoteHC

-1

8.

Rinse


p

9.

Seal

Chromic Acid

10.

Dry

z

O

r

180-212

points alkalinity

over

Room

Up

to 5

1-2

Until clean

Points are mi N/10 sulfuric acid needed to neutralize a 10 mi sample using phenol-

from cleaner

oz/gal

Room

Free of visible contamination

Room

Cd

td t~ c3 M c3

56 M

1/2-1-1/4

~P´• Tap wat~r

overflowing

a

m

2-3

(Conditioning)

o

Cd

1%2

phthalein indicator.

r)

o

I

3.

Pretreat

Q

1

3-4

ga1/100 gal

water

M

P 1

Z


a

Clean, oil-free air

63

2-3

63

2-3

Make up to 8 oz/100 gal

140-180 225

O

1/2-1

Control

as

in table 3A.

~f

d max

Until dry

tl

NOTES r

Z~I ~a

O)

m

~d

Control by titration of 10 mi. samae with N/10 sadium hydroxide. N/10 sodium hydroxide 0.5 gal Cryscote BC per 100 gal water.

Calculate 4.a mi

O Adjust

immersion time for partly or completely cium plated parts to prevent removal of cium plate, generally 3-5 minutes is sufficient.

One-half by weight of chromic acid may be replaced by phosphoric acid.

O

O

O

Ta~le

3C.

Type

II

Phosphating Procedures

Procedure

for:Phosphating with

C)

Turco 4432 TIME

I -I

OPERATION

1

p

1.

Degrease

I~

2.

Descale if necessary

3.

Rinse if acid

4.

m r

Clean

TEMP"F i

CONCENTRATION

MATERIAL

REMARKS

MINUTES

descalingused.

~1 5-8

Alkaline Cleaner

15

185-210

ozlgal

or

until free

I

I

z

5.

m

Rinse

II

Room

Max 0.2 points carry over from cleaner


)1/2-1-1/2

Cd

1

O

O 6.

Pretreat

Turcoat Activator

1/2-1 oz/gal

7.

Rinse



Turcoat 4432

Make up to 3 ga1/100 gal water. Maintain at 17-23 points. Maintain ferrous iron at 0.05-0.40 points. 10 mi sample; N/10 NaOH. Ratio 7:12

a

O 8.

9.

10.

Phosphate

Rinse

Seal


ChromicAcideSI

Dry

5-7

Room

3-5

I

~d

f~

1

I

I Partly or completely plated parts shall be phosphated

10-30 See Remarks

M c3 O

orange

I

I

I

I

I

I

I

Room

1

2-3

I a

MakeuptoSoz/per

100

170 min

1/2-1

225

Until

~FI

water

Clean, oil-free air

max

dry

NOTE L1

c~ m

10-12 minutes

I

I

Points are mi N/10 sulfuric acid needed to neutralize a 10 mi sample using phenolphthalein indicator.

M

170-185

Phenolphthalein: methyl

gal 11.

Room to 125

O M

rinsing

One-half by weight of chromic acid may be

replaced by phosphoric acid to lessen staining.

a

z a

~L II

~9 ;U

9

4

~J

~j db

-1

PCW

a

:10

r~

P"

w

o

~-b

m

P~ a

Tablel.

TypeIII PhosphatingProcedures

OPERATION I.

Clean

MATERIAL Mild alkaline cleaner (Parco

CONCENTRATION 2-4

TEMP OF

oz/gal

TIME MINUTES

180-200

1-1/2

341) 2.

Rinse

Must be free of "water break." Repeat cleaning, if necessary.


Max 0.2 points aikaline over from cleaner

160-180

1

Points are mi N/10 sulfuric acid needed to neutralize a 10 mi sample using phenol-

carry

r

REMARKS

Cd

3:

4

O

r

~3

Cd

3e

phthalein indicator. 3.

Phosphate

Type

III

Ig

6.4-7.0

Phosphating

O

water

gals/100 gals tap

165-175

O

c3 m

1-1/4-1-1/2

solution

c3

(Bonderite 32)

56 M

o

4.

Rinse


Q

Keep free of visible contamination

Room

Direction of flow must keep main body of rinse from

I

c3

being eontarninatedl 1]

5.

Chromic

Chromic acid

~1

acid rinse --I

6.

Dry

Clean,

6

oz/100 gals (Refer to Rinsing.) 0.6-0.8 parts free acid (25 mi sample)

oil-free air

140-180

225

max

1/2-1

Discard when total acid is 6 times free acid or sooner if otherwise contaminated.

M

Z cj

Until dry O

p

~t

NOTES

m

Phosphating solutions listed in table 3 may be used to form Type phosphating times from those given in table 3. Times are as follows: Parco 1A

O

r

Z ~o

1

Parker 1-2

(O

3-4 minutes

Cryscote HC

Company’s Accelerator

3-5 minutes

III

coatings by reducing

Turcoat 4432

8-14 minutes

130 must be added to this bath to coat bare steel. Maintain from

oz/100 gallons.

One-half the weight of chromic acid may be replaced by phosphoric acid.

t~


APPLICATION OF CHEMICAL FILMS TO ALUMINUM ALLOYS Corrosion Resistance

GENERAL Th is section covers the material and process reyuirements for application of Class 1A (MII-C-5Tj41), chemical, chromate conversion coatings (chemical films) to the surfaces of aluminum and aluminum alloys. All coatings must be visible, naturally colored (iridescent yellow or 1 ght brown)or dyed a specific color. All coatings must be

dniform in appearance; continuous; free from powdery

or

loose film areas; free from breaks, scratches, flaws or other defects and damages that will reduce the serviceability or be detrimental to appearance.

MATERIALS

Acid, Nitric (61% or 39.30 Bk., Min.), Tech. Acid, Sulfuric (93% or 600 Bk.,

Min.), Tech.

0-S-809 Amchem Products, Inc. or Van Dusen Aircraft Supplies Amchem Products, Inc. or Van Dusen Aircraft Supplies Turco Products

Alodine 1200 Powder

Alodine 1201

0-N-350

Liquid

Accelagold Series Bifluoyide, Ammonium Brushes, Soft Bristles Chromium Trioxide, Tech. Cleaner, Acid

Commercial Commercial 0-C-303 MIL-C-5410,

Type II Cleaner, Mild Alkaline, NonSilicated, Low Foaming Cleaner, Mild Alkaline

Cleaner, Mild Alkaline, Turcd 4215 with Turco 4215

MB0210-004

RB0210-005 Turco Products, Inc.

Additive

ST0210GB0001 Allie~dResearch

Deoxidizer, Aluminum iridite 14 Powder

Products

PROPERTIES OF CLASS 1A COATING

as

less than 40 milligrams per square ft. of area determined by MIL-C-5541, Amendment 2, no

Section 4.5.2.

Appearance

square

within 1/4 in. from the edges, identification markings and holding points during processing or salt spray shall be inclined exposure. The significant coated surface 6" from the vertical. A min of 3 coated s must be tested. The coated test surfaces/s must be aged a min of 24 hours before testing. Corrosion resistance requirements are specified in MIL-C-5541, except as deviation(s) are given herein.

areas

Paint Adhesion Properties The paint adhesion properties of conversion coated subject surfaces must be satisfactory with the specified paint the paint must neither chip nor peel from the system conversion coated surface(s) after application and curing. If the conversion coated part(s) is not designed to be this paint adhesion requirement can be

painted, disregarded. Limits

must not be heated above 1400F, to protect them from diminution of corrosion

Unpainted subject coatings resistance

properties.

Chemical film coatings are not a satisfactory general substitute for anodized aluminum coatings and must not be substituted automatically for anodized aluminum

coatings. These coatings must not be applied prior to any aluminum forming, welding, surface mechanical processing, thermal

processing

etc.

Material and Components All materials used must comply with MATF,RIALS above. Water

Weight of Coatings Must be

1A chemical coatings must ~’ithstand 330 hours of direct exposure to 5"/0 salt spray with the of a max of 15 occurrence on the conversion coated surface isolated spots or pits, none larger than 1/32 in. diameter´• in in. of exposed test area, except those a total of 30

Unpainted Class

All make-up water must have a chloride level between 20-50 parts per million parts of water.

Material Processing Requirements of

Coatings naturally colored (iridescent dyed a specific color; uniform in

All coatings must be visible;

yellow or light brown) or

or loose film appearance; continuous; free from powdery flaws or other defects areas; free from breaks, scratches, and damages that will reduce the serviceability of parts or be detrimental to appearance, protective value and paint bonding characteristics. Variation in color between parts or between areas on same part is satisfactory.

Only Class

1A

(MIL-C-5541) coatings

must be

applied.

APPLICATION NOTES Conversion coatings must be applied according to the instructions of the specific table. The tables listed below shows the key to the correct procedures for application of Class 1A Chromate, Chemical Conversion Coatings

(Chem Film).

20-40-35 0


Page 1 Aug 31/84


APPLICATION OF CHEMICAL FILMS TO ALUMINUM ALLOYS APPLICATION NOTES (Cont’d) Table No.

NOTE Procedures

1

Immersion

2

Spray

3

Brush-On

IOrA Etch per table i, used as an alternate.

Dip

Small

Iridated Parts a

of sulfuric acid, 66"Bk. chromic acid Water to make 1 gallon ounces

temperature of 170 flO"F, rinse in

perature tap

room

tem-

water.

NOTE 10rA Etch per table i, Operation 3, may be used as an alternate. Alodized Parts

Immerse until stripped in

a

solution consisting of:

1 volume water 1 volume nitric acid

Use at

room

temperature, rinse in

resistance limits

by applicable specifications, small areas may be abrasively stripped. set

Re-Processing in the

applicable chart for

necessary

DO "Ot allow rags, sponges, swabs, etc., used for applying the Class 1A solutions to dry out. If allowed to dry, they

constitute a fire hazard. Immediately after use, all such materials must be thoroughly rinsed in clear tap water; after such rinsing they may be re-used or discarded.

Spray application of the solutions called out in table 3 may be used for chem film treatment of a limited number of parts too large to be processed either by the brush-on procedures of table 3 or in existing conveyorized equipment. If this spray application cannot be carried out in a paint spray type booth with water scrubbed vents, extreme caution must be exercised to prevent droplets contaminatinp; adjacent work areas or drifting over parking lots or buildings where they will cause staining. Protective clothing to protect eyes, lungs and skin should be worn by operators spraying the chem film solutions. The spray solutions called out in table 2 may be used only in the temperature controlled conveyorized equipment for which they

room

of

Under no conditions must the solutions be heated above the temperatures specified. Strictly avoid breathing dust from the makeup powders, and avoid inhaling vapors or spray from the solutions as much as possible.

solution consisting of:

av ounces

a

use

Normally, chemical films do not prevent adequatd electrical bonding. V electrical measurements indicate that chemicalfilm

Use the procedures re-processing.

When it is necessary to strip the chemical film from the entire surface of a part, the following procedures must be used,

Use at

may be stripped of chemical film by No. 320 grit or finer abrasive paper.

must be removed to meet

Stripping of Chemical Films

13 fluid

or

NOTE

surfaces where resistance to

Chemical film brush-on solutions for touch-up must be stored in proper containers. They must be applied in accordance with table 3. No solution is to be returned to the storage container after use.

4.4

areas

Bon Ami

This brush-on procedure may be used to touch-up small rework or abraded surfaces on assembled parts which have been anodized (MIL-A-8625) in accordance with

Immerse for 1-5 minutes in

may 6(?

l[n!nll(l]~l

If the Class 1A films are removed by rework or abrasion in local areas they may be touched up by applying the appropriate solution by the brush-on method described in table 3.

on

Operation 3,

Do not usefollowing process on assemblies with xine or cium plated parts.

Touch-Up Requirements

section 20-40-10, except abrasion is required.

(continLk~)

temperature tap

water.

are

qualified.

Make-up chemicls m~st not be stared near easily oxidizable material such as paints, solvents, lubricants, etc.

20-40-35 Page 2 Aug 31/84

o

C~PYRIGHT, 1984

BY

SABPELINER CORPORATION

D

g

O

Cd ’d

O

P

r

a

C:

-I

c~

p

O r(

ct

a

Table i.

Chemical Film Immersion Procedure

OPERATION i. Clean

m r

z

r TEMP"F

MATERIAL Mildslkaline cleaner Mild alkaline cleaner, non-

TIME MINUTES

CONCENTRATION

CONSTITUENTS a P

O

O

RB0210U05

7.0 f1.0

~MB0210-004

5.0 +1.0

av

oJgal

REMARKS

m

Ail parts must be rinsed to a.’wa~er break free.,

5-10

180 r10

m

surface. av.

145 f10

oz/gal

C~

silicated

8

2. Rinse

Spray and air agitation are desirable. An overflow is mandatory. Direction of flow must aid in keeping main body of rinse from being contaminated. Drain parts well before next step.

2-5

145 f10

Tap water over-flowing

Wa~er

a ’73

O a

3. Deoxidize

O

NA107A Etch

O z or

Deoxidizer

Nitrie Acid (703h)

16 i2 fl.

av.

oz/gal

Chromic Acid

2.1 t0.6

av.

oz/gal

Ammonium Bifluoride

2 +1

oz/gal

ST0210GB0001

Per

av.

Mfg’rs

80 ~15

2-5

80 f15

3-5

Room 180

2-5

O

r c~l cl

r

PJ

O

Data Sheets 4. Rinse

5. Chem-film

Wa~er

Tap water. over-flowing

See

:1.0 +0.5

Iridite 14

av.

Avoid drag into

Maintain

2-5

85 ~15

oz/gal

or

Alodine 121)0

2.0 f0..50

or

Alodine 1201

100’X~

or

Acrela~olti

av.

Maintain

8.5 i15

oz/gal

~.i and

O

I

r

operation.Iil.

d

pH

Insure free circulation to all parts of work, but do not agitate. Area sur rounding tank must be lueli v.niila~eii.

between

1.5 and 1.7

Appl ication, Immersion

next

to

between

i.?m

0.5-1.0

85 +15

I

pH

I

I

I

I CI

2:

d

Z

C?

O

Ir r

O CC

z c;

o

2:

CU O

1

O

rm

cc

c=J

~e

w

cb r

ew

~a1\3

c~

’50 s;

Cb Cd r

’b

4

;F

R

cl

C3

2:

c3

z

ct

~3

o

1: o

Table i.

Chemical Film Immersion

CONSTITUENTS

<:ONCENTRATION

CI1

O

MATERIAI,

OPE:KA’I‘ION

ProcedureO(Cont’d) TEMP"F

TIME MINUTES

I

Roomto

2-5

120

7.

Optional

8. I)rv

rinse

I

Water

I

I

max

I Imax

Until

dry

Used to aid in the

Circulating

air

drying of parts

oven or room

O;i 131 O

c:onstituents and their

p

use

operation

specifications

are

61 5. 6. 7. 8 sequence. Omit

listed in MATERIALS.

(:oneentrations are of materials in water. Oz per amounts to be added to water to make 1 gallon.

r

e: O:

may

cl

r rB

(Mandatory)- Om it deoxidizing step on parts with cium-plated, zinlate, or-anodized. surfaces.

C3

O

For other materials which meet requirements, use make-up and mainteinstructions as recommended by manufacturer.

nance

gal (fl and av) indicate

D(mineralized water is preferred to tap or softened water for all operations, especially operations 6 and 7. Overflow water from one rinse tank to an~,ther should not be used except where counterflow rinse tanks are used.

r r

temperature air

NOTES

I

~1 REMARKS Maintain pH at 5.0-7.0. Carry-over from chemical film application is usually sufficient: add chemical film make-up, if necessary.

be used.

For spot welded assemblies oparatians-l; 2,:3, and: 4.

a.

I -f

120-160 160

O

D

1

a~r

O

-
1

Clean. Oilfree

z

cc

I

Water

6. Rinsr

r

M

IEl

When using Etch as a deoxidizer for Chemical Film i,, Bifluoride concentrations of from 1-2 av oz/gal

Application, Ammonare

preferred.

r

d

Controlled b?´• discrete additions of nitrir acid. n

p

d

L~ 1: ma

z m

r t-’

O cC

a

~3

O

h

O a -1

o´•

=1

O a

O z

a

ra

co

O

’d Cd r

O

O -O

CI

~D

O I -i

C~ ~I

O m

Table 2,

Chemical Film

O

Spray Procedure

v,

r

n m

1. Clean

Mild alkaline cleaner

Turco 4215 with Turco 4215 additive

m n

2. Rinse

Water

see

O

3. Deoxidize

Deoxidizer

ST0210GB0001

r

TEMP"F 150 +10

1.0-1.5

All parts must rinse to "water break free" surface.

1

145t55

0.5-1

Constant overflow mandatory.

C~i

1

80 +15

0.5-1

This

operation must be omitted when processing assemblies containing zinc-plated, cium plated, or anodized surfaces.

r

O

MATERIAL

OPERATION

m

TIME MINUTES

CONCENTRATIONI

CONSTITUENTS

Z

0.5-2.0

av.

oz/gal

I

C11

REMARKS

ed M W

I

Notel~

12-14

av.

o

o ~a

Room 180

O

Water

4. Rinse

O n

Alodine 1201

5. Chem Film

--I

Application,

o

I

I

1

100%

or

I

Accelagold

r

Constant overflow mandatory.

0.5-2

to

r 0.5-1.0

85 f15

I

I

I

I

spray

Z

6. Rinse

7.

Dry

85 +15

Water

160

Clean, Oil-

max

pH

0.5 to 1

Do not allow overflow.

Until dry

Circulating air be used,

free air

to

exceed 6.5. Maintain constant

oven or room

~1

C~

O

temperature air may

r

d NOTES

O O

Constituents and

their

specifications

are

listd

in

MATERIALS.

Concentrations are of the MATERIALS in water. Oz per indieillt. amountr, to be added to water ,,,k, 1 gal,

gal (fi

or

O

av)

Demineralized water is preferred to tap of softened water for all operations, especially operation 6. Overflow from one rinse tank to another should not be used except where counterflow rinse tanks are uad.

O

Operations 3 (Deoxidize) and processed parts the MIL-C omitted surfaces. must be

on

n

d ci

4 (Rinse): May be omitted as lonK as 5541 salt spray requirement(lfi8 hours);

parts with cium plated, zinc-plated,

or

anoclizt-d

P

r O

cC

1\3

O ~d ~d O m

Z

cl o

s:

g

~D

,a%

~to

rl

w

cn

t3

ru

w

R~O CD

s; s ~e

ChemicalFilm Brush-OnProcedure

TableS.

Cd r

Q,

C1

O~ Z

c3

az

I

CONCENTRATION

B

n

I

I

TIME

MII,-C-.5410 II

Deoxidize

Asapplicable

TEMP~P

MINUTES

Room

As needed

REMARKS

Scotchbrite

or

etchings

pad Type Tap

1. Rinse

Tap

water

1 part

by volume

1 part

by volume

5-100

80 +1T,

Keep surfaces wet. Use soft bristle brush rags. Wear rubber Rloves. aa

I

I

Room

I

I

Room

I

j

A

water

I

a

Wet abrade until been obtained

a

or

r?

3:

Type I

Alodine

o

brush

8

or

1

100%

or

85+15

0.5-1.0

or

until

Accetagold

application.

coating is

spral´•

~ormed 6.

RinseO

As needed

Room

Water

m

clean

"water-break-free" surface has

r

Hand wipe with clean wet rags frequently rinsed in clean water. (A spray rinse is preferred, if

practical.) Fj~ (.hem Film

~d o

r

Solvent clean per section 20-10-15. Heavily soiled surfaces may be steam cleaned prior to solvent

Type

Water :i. (’lean

c3

O

r CI

I

r

General; Coat only small

areas at a time. Use nylon clean rags. If no color develops, repeat Operations 2 or 3. Do not allow solution to dry on surface.

bristle brush

or

Rinse by flushing with water. Avoid hand the wet film is easily removed.

rubbing

r~

c3 O

as

t) 160

Clean, Oilfree air

I --I

’i. Dry

p

a O

Constituents and

133

Deonjdizer t0peration 2)w nor requirrd when surface is abraded u´•ith Scotchhrite pads (Operation 3,.

a

Avoid

max

Until dry

Circulating

oven or room

temperature air.

NOTES m

m

n m r

specifications

are

listd in

Concentrations are of the MATERIALS in water. Oz per indicate amounts to be added to water to make 1 gal.

prolonged

with

zinc

or

cium

gal (fl

or

on rinsing, (Operation 3).

appear

avf

plated components.

r

d cc

"water-break-free" surface. If water breaks re-apply the de-oxidizing solution or re-abrade

Surface must rinse to

MATERIALS.

a

s

Scotchbrite pad cleaning or abrading deoxidizer (Operation 2) is used.

a

Demineralized water is preferred to tap operations, especially Operation 6.

(Operation 3) or

not

Z C

required if

softened water for all

r r O

CC IO

O

~3

O

C~

n -D

=f

O

O n

J E (3

O Z

r

o

cleaning.

a

ct

=z:

CONSTITUENTS .MATEHLAL

OPEHATION i. Solventclean

B i ~P

pj

cc

cn

o

CC~

a

z C r


CHEMI~AL FILM TREATMENT FOR TITANIUM AND TITANIUM ALLOYS Low Temperature Flexibility

GENERAL chromate conversion coatings applied to titanium for the purpose of promoting adhesion of

l’his section

covers

organic coatings. MATERIALS Iridite 14-2

Potyurethane Coating for Integral Fuel Tanks J P-4 Turbine Fuel 6A1-4V Titanium Sheet Masking Tape, 3M No. 250 Scotch Brite Type S, Medium Alodine 1200 Touch-Up Solution Nitric Acid, 420B$

Allied Research Products, Inc. ST0125LB0006

MIL-T-5624 MIL-T-9046 3M Co. 3M Co. hmchem Products, Inc.

Commercial

APPLICATION NOTES

Appearance The chemical film coating formed must be discernible to the unaided eye. It must be a tightly adherent, nonpowdery coating. It may be non-uniform in appearance

but must be continuous. Adhesion The chemical film formed must be such that the coating system produced by 2 coats of ST0125LB0006 polyurethane fuel tank coating applied over the chem filled surface must meet the following requirements. (Refer to

section

20-30-85.)

JP-4 Fuel

FINISH Process Evaluation

When procedures or materials other than those detailed in table 1 or 2 are used, the following tests must be made.

High Temperature Fuel Immersion Test Two test s prepared as described below must be placed in a test chamber vented thru a water cooled condenser so arranged that test fluid vapors are condensed and returned to the test chamber. The s must be so placed that their painted surfaces do not the test chamber wall or adjacent s. Sufficient JP-4 from which the light ends boiling below 2750F have been removed by distillation must be added to immerse the bottom half of the test s. The test chamber must be held at 270 ~5"F for 390 hours. At the conclusion of the immersion period, the specimens must be removed and patted dry with soft cloth or paper tissue. The paint film is then inspected for blisters and other film defects. Immediately after visual inspection, the paint films must be subjected to the adhesion tape test described in Federal Test Method Standard No. 141, Method 6301 except that th, 24 hour distilled water immersion is to be omitted. The scribe lines required for this adhesion test must be so placed that they extend into portions of the paint film that have been exposed both to liquid immersion and vapors

above the liquid level.

(270"F)

The coating system must remain firmly adhered to its substrate and exhibit no blisters, checking, cracks, or crazing after 390 hours exposure at 2700F to JP-4 Fuel from which the light ends have been removed as described in High Temperature Fuel Immersion Test below.

Fuel and Brine (2009F) The coating system must remain firmly adhered to its blisters 1/16 in. or pu hstrate and exhibit no more than 10 less in diameter in the coating when subjected to 390 hours at 200"F in a two layer solution of JP-4 fuel and 3% brine in accordance with the Fuel and Brine Immersion

Test below.

The coating system must remain firmly adhered to its substrate and exhibit no cracking, checking nor’ crazing when bent over a mandrel at -650F after 390 hours exposure to 2650F in accordance with the Low Temperature Flexibility test below.

Fuel and Brine Immersion Test This test must be conducted in the same manner as the test described above with the exception that the test liquid must consist of 2 layers. The lower strata consists of 30/0 brine and upper liquid JP-4 jet fuel conforming to MIL-T-5624. Each liquid should cover approximately 1/3 of the test s and 1/3 of the exposed to vapors above the liquids. The adhesion test must cover all 3 test areas.

Low

Temperature Flexibility

This test must be conducted as described in MIL-C-27725 with the exception that test strips must be subjected to 390 hours at 2650F +5"F prior to testing.

20-40-40 o

CQPYRIGMT,


Page 1 Aug 31/84

SR-76-023 C(IRROSION CONTROL MANUAL

CHEMICAL FILM TREATMENT FOR TITANIUM AND TITANIUM ALLOY’S (Continued) Low

Temperature Flexibility (Cont’d)

except that the 24 hour distilled water immersion must be conducted

Organic coatings applied to chem filmed titanium surfaces must meet the following adhesion test. Two in. or more of a 4 in. long strip of 3M No. 250 masking tape must be pressed tightly to the surface using either a rubber roller ol´• the palm of the hand. The tape must be removed with one quick motion. The coating must be examined visually for evidence of damage. No separation of the pal n t syste m from the metal m ust be perm itted. Discoloration of the tape adhesive does not constitute a failure.

Prepare s of 6A 1-4V titanium alloy. size m ust x 6 x 0.025 in. for low temperature flexability and 3 x 6 by 0.025 in. (nominal) for all adhesion tests. be 1

Test s must be cleaned. (Refer to section 20-10-30.)

Cleaned s must be chem filmed by process being evaluated.

(Refer

to Process

Evaluation.)

Two coats of ST0125LB0006 polyurethane fuel tank coating must be applied and cured. (Refer to section 20-30-85.) Farced cured coatings must be aged a min of 24 hours

parts must meet the wet adhesion tape test described in Federai Test Method Standard No. 1111. Method 6301

prior

to

testing.

Immersion Chem Film Process For Titanium

OPERATION

MATERIAL

1.

Clean and pickle. (Refer to section 20-10-30.)

2.

ChemFilmp

Alodine 1200

or

CONCENTRATION

Iridite 14-2

3 f0.5

oz/gal

Temperature Rinse

REMARKS

Must be chem filmed within 1 hour

Adjust pH

pH 1.4-1.6

3.

at 200

Sample Preparation

Two coats of ST0125LB0006 polyurethane fuel tank coating applied (refer to section 20-30-85) to three chem film test s processed concurrently with production

Table 1.

test

f50F. There must be no separation of the paint-chem film system from the base’ metal. Discoloration of the tape adhesive does not consti tute a failure.

Adhesion

with nitric acid.

I Immerse 3-5 minutes 60 to 900F

Deionized Water

Constant overflow spray. CAUTION

or

gentle Wet

film can be damaged easily by abrasion or water jets. 4.

Dry

I

I

I

140"F

max

NOTE Brush chemical film per

operation

4 of table 2 may be substituted.

20-40-40 Page 2 Aug 31/84

o

COPYRIGMT,

1984 BY SAB:RELINER CORPORATION


CHE1MICAL FILM TREATMENT FOR TITANIUM AND TITANIUM ALLOYS (Continued) BrushChemFilm ProcessforTitanium

Table~.

REMARKS

CONCENTRATION

MATERIAL

OPERATION

Solvent wipe, alkaljne

11 FrecleanOl~

clean,

etc.

remove

as

oil,

required

grease and

to

shop

soils,

Abrade

2.

areas to

Abrade until

Scotch Brite Type S, Medium

be

chem filmed

area

uniformly bright. Operation 1 and 2

appears may be

combined. Rinse

4.

BrushChem

Fj.

Rinse

6,

Dry

Part must be water break free.

Tap or´• Deionized Water (Spray and/or wipe)

3.

FilmD

Alodine 1200

or

Iridite 14-2

1

3

Keep area to be chem filmed wet 1-3 minutes using clean gauze or soft bristle brush or spray.

ozlgal

42"F Baume Nitric Acid

0..5 vol

DeionizedWater

Balance Wet film

CAUTION

Tap or deionized water (Spray and/or wipe)

be damaged abrasion.

140"F

can

easily by

max

NOTES Part, shall be free of all scale

O

Do not

use

prior

to start of chem film

operation.

chlorinated solvents.

of formulation Alodine 1200 touch-up solution may be used without dilution in lieu

specified.

20-40-40 0

COPYRI~HT, 1984 BY SABRELINER CORPORATION

Page V4 Blank Aug 31/84


ELECTRODEPOSITED HARD NICKEL PLATING Scale and Oxide Removal

GENERAL This section covers the hartl nickel plating.

requirements for electrodeposited

APPLICATION NOTES

Scale and oxide removal, prior to plating, must be restricted to abrasive blasting (Refer to section 20-IO-(i0.) etching). (Refer to section or anodic pickling (reverse 20- 10-10.)During anodic pickling, the current must be on prior to immersion and remain on until after removal from the electrolyte.

Appearance The nickel plating must be uniform in appearance, smooth, and free from pits, blisters and other visible defects. When plating is performed only on a portion of the surface, the plated areas must be finished in such a manner that they blend smoothly with the adjacent unplated areas. Grinding on the basis metal of parts heat

treated to 180,000 psi

or over

is

prohibited.

to relieve embrittlement from

Stripping Solutions used for stripping of nickel plating must be subject the part to hydrogen embrittlement nor cause pitting of the basis metal.

proven not to

FINISH The following inspection and testing must be conducted to conformance to the requirements of this section.

Hydrogen Embrittlement Relief Baking

(Over 180,000 psi)

hydrogen

must be

suitable in duration, temperature, and timeliness for the

Appearance

metal and process in

The appearance of the nickel plating in APPLICATION NOTES above.

use.

must

be

as

required

Hardness

The hardness of nickel plating must be in the range of RC 40-52 (Vickers hardness No. 390-550).

Tests Hardness

Adhesiaq The adht?sion of nickel plating must be such that it shows 710 separation from the basis metal when tested as described under FINISH.

The hardness requirements specified must be verified by direct measurement, using Diamond Pyramid Hardness numbers or Knoop Hardness numbers equivalent to RC 40 as a min value.

Thickness

Adhesion

The thickness of nickel plating on finished parts must be 0.0015 in. min and 0.004 in, max unless otherwise specified on the applicable drawing or controlled by the following

Adhesion tests must be performed using test coupons of 4130 condition A plated concurrently with production items. The test coupon must be bent thru an angle of 180"F on a diameter equal to the thickness, then examined at 4 diameters magnification for non-adhesion. Cracks that occur during bending which do not cause

exception. Holes,

recesses

and other

areas

sphere 3/4 in, diameter requirement.

a

are

that cannot be touched by a thickness

exempted from

flaking

or

peeling

are

not

cause

for rejection.

Thickness

Preparation for Plating Stress Relief

The thickness requirement of APPLICATTON NOTES must be determined by one of the following methods.

Ail

i.

Dermitronelectronic measurement

or a

2.

Micrometer measurement

3.

Magnegage

feroes base alloys, having a hardness of RC 40 or above heat treat range over 180,000 psi must be stress relieved by a suitable process, after completion of all gri nd ing operations and prior to shot peening and plating.

measurement

Shot Peening


All ferous base alloys having a hardness of RC 40 or above heat treat range over 180,000 psi, must be shot peened by a suitable process.

Corrosion resistance must be determined by salt spray test in accordance with ASTM-B-117 as follows:

or a

x 3 x 0.040 in., of 4130 heat treated to 125-140 KSI and plated to a thickness of 0.0015 in. concurrently with production items must be exposed for 48 hours and exhibit no corrosion of the basis metal.

Test s, 6

20-40-45 0

COPYRIGHV, 1984 BY SABRELINER CORPORATION



GENERAL PROCEDURE FOR BRUSH TYPE ELECTROPLATING

GENERAL This section covers a procedure to be used for the electrodeposit by "brush plating" of nickel, copper, chromium, tin,silver, gold, rhodium, cium and lead upon copper, brass, bronze, iron, steel, nickel, beryllium, silver and

aluminum alloys.

damaged plating in non-functional

areas.

plating" may be used only when specified on the applicable drawing, or when allowed by a plating specification applicable to the part being processed. Touch-up not to may be applied Only to non-functional surfaces, interiors of fluid systems, or to bearings, splines, gears, or

’’Brush

other functional surfaces.

MATERIALS

Paper;

Ltd.

Solution, chromium stripping; I’iddington and Associales.

This process is intended for the plating of small areas of parts that are either too large for immersion in a plating tank, that contain components that would be injured by immersion in plating solutions, or for the "touch-up" of

Abrasive

Solution, cium plating (acid); Piddington and Associates, Ltd. Solution, cium plating (alkaline); Piddington and Associates, Ltd. Solution, chromium plating; Piddington and Associates.

500

or

600

grit; commercial

Alumina; levigated, powdered, 600 grit Baatinnf, Cotton; IJSP

Butyl cellosolve acetate; Union Carbide Cium oxide, technical grade Cellulose wiping tissue; AB0215-001 Cheese cloth, cotton

Cleaner, electrolytic alkaline; LB0210-109 Chromic Acid; O-C-303, Type II

Copper cyanide (cuprous); technical grade, 70-72% copper netergent; Joy, Proctor and Gamble, Cincinnati, OH; or equivalent Epoxy primer; MB0125-006 Gold, Bright gold concentrate No. 1; Wildberg Bros., Los Angeles, CA or equivalent Hydrochloric acid; ACS reagent Iridite No. 8; Allied Research Products, Inc., Baltimore, MD.; or equivalent Methyl chloroform; MIL-T-81533 Nickel chloride; 0-N-335, Type III Nitric acid; 0-N-350 P~per, filter; UU-P-236, Type I, Class 4 Potassium carbonate, anhydrous; technical grade Potassium cyanide, technical grade, 94-96% granular Potassium fluoride; reagent grade

Potassium hydroxide, 0-P-566 Pumice; technical grade Silver conductive compound; AB0120-014, Type IV Silver cyanide, technical grade Sleeving, dacron; Piddington and Associates, Ltd.,

Pasadena, CA Sodium cyanide; teChnical grade, 94-96% granular Sodium gluconate; technical grade Sodium hydroxide; O-S-598, Type I

Ltd.

Solution, tin fluoborate, 47% concentrate, Harshaw Chemical Co.

Solution, lead fluoborate, 50% concentrate, Harshaw Chemical Co. Fluoboric Acid,

purified,

48-50%

Peptone, Industrial, Cudahy Laboratory, Omaha, NE Solution, cleaningand deoxidizing; Piddington and Asso,iate,, Ltd. Solution, copper plating, (acid); Piddington and Associates, Ltd. Solution, copper plating (special); Piddington and Associates, Ltd. Solution, etching No. 1; Piddington and Associates, Ltd. Solution, etching No. 2; Piddington and Associates, Ltd. Solution, gold plating; Piddington and Associates. l,td. Solution, Iridite No. 8; Allied Research Products. Inc.,

Baltimore, MD Solution, lead plating; Piddington and Associates. Ltd. Solution, nickel plating (epais); Piddington and Associates, Ltd. Solution, nickel plating (alkaline); Piddington and Associates, Ltd. Solution, nickel plating (black); Piddington and Associates, Ltd. Solution, Selectron Electrolytic Cleaner, Seiectrons. Ltd. Solution, Selectron, Alkaline Copper, Selectrons, I,td. Solution, Selectron, Acid Copper, Selectrons, Ltd. Solution, Selectron Tin, Selectrons. Ltd. Solution, rhodium plating; Piddington and Associates. Ltd.

Solution, Selectr´•on Activator No. 1: Selectrons, Ltd.. 153 E. 26th St., New York, NY Solution, Selectron Nickel, Acid; Selectrons. ltd. Solution, Selectron Nickel, Neutral; Selectr´•ons, Iltd. Solution, Seleclron Nickel, Special; Selectrons. lid. Solution, silver plating; Piddington and Associates. Ltd. Solution, tin plating (alkaline); Piddington and Associates, Ltd.

Solvent; 50 +5% TT-I-7.75, Grade A, Isopropyl alcohol, 50 f5%, AB0210-008, Type I, Naphtha Sulfuric acid; ACS reagent Assoc. Solution, Selectron, Activator No. 2, Piddington Ltd.

Toluene; TT-T-548 1,1,1 Trichloroethane (methyl chloroform); O-T-620 Water, purified; deionized or distilled with no less than 50,000 ohm resistance and no more than 10 ppm total solids

Water, tap; clear with

no

turbidity

20-40-50 0

CaPYRIGHT, 1984 BY SABRELINER CORPORATION

Page 1 Aug 31/84

9B-76-023 C()RKOSION CONTROL MANUAL

GENERAL PROCEDURE FOR BRUSH TYiPE ELECTROPLATING

(Continued)

EQUIPMENT Cellulose sponge covered carbon anode; NR Industrial Engineering Drawing 1501-76C, or Carbon Anode; Dalic, Piddington and Associates, Ltd., or equivalent Di rect current power source capable of providing a direct cul´•rent meeting the requirement of the specific application.

Safety

An anode of suitable size and shape for the work to be done nnsst be firmly secured in its proper stylus.

Su’fficient cotton batting must be torn

All chemicals must be handled so as to avoid with eyes, skin or mouth. Vapors or mists are dangerous to

respiratory minute quantities

eyes,

ages and skin. must be avoided.

Swallowing

even

Skin. face and respiratory protection may be required during some phases of the use of the chemicals I´•equired by this process. Protective clothing and other devices be used.

Cold Worked Basis Metal All cold worked basis metal must be stress relieved in accordance with applicable processes. Surface

Carbon Anodes:

Carbon anodes, whenever possible, must be enveloped with UU-P-238 Type I, Class 4 filter paper to minimize carbon particle contamination of the plating solution.

APPLICATION NOTES

must

Anode Preparation

Preparation

Cleaning and activation must be accomplished by methods which result in no selective etching or measurable loss of basis metal. Solution Cleanliness The activation and plating solutions must be kept clean and free of grease and insolubles.

to cover anodes with

a

or

cut from the roll

layer approximately 1/4 in. thick.

Enough cotton must be used to prevent the exposure of the ~bzrre anode. The cotton may be wrapped in cheese clot’h. GFeater thickness is advantageous where flexibility is "qui’ed for rough or irregular surfaces. Carbon anodes must be wetted with purified water and then wrapped with the cotton by rolling them over the cotton in the direction of the fibers. A!dacron or cheese cloth tubular sleeve must be used over t:he cotton batting when rough surfaces are to be plated.

~er the anode has been wrapped with the cotton batting, and covered with dacron or cheese cloth sleeving, if used, the covering must be secured to the anode witha rubber band or other suitable means. Cellulose Sponge Anodes The anode must be disassembled and the soution well, the anode, the s, and the brush must be thoroughly cleaned using alumina and electroytic clenaer (LB0210-

109) prior

to

use.

Processing Hydrogen Embrittlement Relief Hydrogen embrittlement relief plating. Handling

and

must be

Purified water may be used wherever tap water is called

performed after

Packaging

Before plating the parts must be examined for nicks, dents, scratches or other damage. Parts that have been damaged to an extent that will prevent them from meeting drawing requirements after plating must be rejected. Parts must be so handled as to be kept clean and free of damage. After plating, parts must be packaged to protect them from contamination and physical damage.

Deposit Thickness ’rlle

deposit thickness

must

conform to the

enai~lrcl´•i,lg´• dr´•awing.

out.

Cium must be electrodeposited upon steel, copper, and copper alloys in accordance with either Processing with Non-Proprietary Solutions, or Processing with Proprietary Solutions.

Si’lver must be electrodeposited upon copper and copper 81:loys in accordance with the respective paragraphs on Non-Proprietary or Proprietary Solutions. Gold must be electrodeposited upon circuit boards in accordance with either the respective paragraphs on NonProprietary or Proprietary Solutions.

Ti´•n must be electrodeposited upon glass-fiber reinforced plastic surfaces in accordance with Application of Tin to Class Fiber Reinforced I’lastic Surface.

20-40-50 Page 2 Aug 31/84

o

C~R´•IGMT, 1984 BY ~tilRELINER CORPORATION

SR-76-O23 CORROSION CONTROL MANUAI,

GENERAL PROCEDURE FOR BRUSH TYPE ELECTROPLATING (Continued) Processing (Cont’d) All other electrodeposits must be made in accordance with Processing with Proprietary Solutions. Remove solder

vestiges from circuit board

abrasion with

motor driven

a

s

eraser no coarser

by

than 320

Parts to be cium plated must be processed in accordance with table 1 using step 8 instead of steps 9, 10, and 11.

Circuit boards

to be

gold plated

must be

processed

in

accordance with table 1, using step 9 instead of steps 8, 10. and 11. Parts to be silver plated must be pr´•ocessed in accordance with table 1 using steps 10 and 11 instead of steps 8 and 9.

grit. Processing with Non-Proprietary Solutions NOTE

A~plolicable to Surfaces Other than 1Modules With Assembled Comloonents Table 1.

Processing With Non-Proprietary Solutions REMARKS

TIME

MATERIAL

STEP i.

Degrease

Isopropyl alcohol and naphtha (Ratio 1:1)

O

2.

Scrub

Pumice and tap water

O

3.

Rinse

Flowing tap

Until free of visible soil and

water

pumice 4.

Cathodic Clean

7-9 oz/gal LB0210-109 cleaner

5.

Rinse

Purified water

6.

Activate

25 f20/o sulfuric acid

Rinse

7.

30 seconds min 30-60 seconds

(by volume)

30-60 seconds

Purified water

Iq Keep

water

flowing

over

all

surfaces

Cium Plate

8.

(;oldPlate

9.

33 6 14 6

+1 +1 -tl fl

oz/gal oz/gal oz/gal oz/gal

sodium cyanide sodium hydroxide cium oxide sodium gluconate

Until required thickness

Undiluted bright gold

is

deposited

Silver Strike

0.25 1.4 10.0 6.0

f0.02 +0.1 f1.0 +1.0

Process with Solutions.

Non-Proprietary

2-3 minutes

Plate in accordance with Plating Process with Non-Proprietary Solutions

O

Plate in accordance with Plating Process with Non-Proprietary Solutions.

concentrate Na. 1

10.

Plate in accordance with Plating

oz/gal silver cyanide

oz/galcoppercyanide oz/galsodiumcyanide oz/galsodium gluconate

11.

SilverPlate

32 fl +1 32 3.0 +0.5 6.5 f1.5

oz/galsilvercyanide oz/gal potassiumcyanide oz/gal potassium

Until required thickness

is

deposited

Plate in accordance with Plating Process with Non-Proprietary Solutions

hydroxide oz/gal potassium carbonate

20-40-50 Page 0


3

Aug 31/84

SR-76-023 COHROSION CONTROL MANUAL

GENERAL PROCEDURE FOR BRUSH TYPE ELECTROPLATING Table I.

(Continued)

Processing with Non-Proprietary Solutions ~Cont’d) STEP

MATERIAL

12.

Rinse

1~.

Embrittlement Relief

14.

Post-treatment

Flowing tap

TIME

water

:30-60 seconds

REMARKS

Dry

upon

When

All cium plate unless otherwise specified

completion.

required

In accordance with Post-Plating Treatment

NO~ES

O 111

Wipe free of visible oil and Sc rub as thorough ly free surface.

O Clean

until

a

as

grease,

configuration

water break free

cleaning, scrub

with

a

or

degrease using clean lint-free cloth. perm its

until part rinses free of visible soi 1 with

a

water break

surface is obtained. Where area to be plated does not permit cathodic (by volume) of detergent.

1-2% solution

O Swab to maintain acid on all surfaces to be plated ~br required time interval. O Apply silver stl´•ike no longer than necessary to obtain min complete coverage.

20-40-50 Page 4 Aug Y1/84

o

Q~PYRIGHT,

1984 BY

ABRELIHER GORPORATION



Processing

with

Non-Proprietary Solutions (Cont’d)

I’lstinR Process with Non-Proprietary Solutions I’ill the anode well with the proper

plating solution.

Adjust the output voltage of the ret,tifier

to

compensate

for the anode size and the solution in use. The pl´•oper voltage and the plating rate may be checked by a preliminary trial upon a steel plate. meter to read

Adjust the ampere-hour

zero.

ampere-hours using the area to be plated,the specified thickness, and the factor determined in accordance with Plating Process with Proprietary

Calculate the necessary

Solutions

Turn the rectifier on. Move the saturated anode over the surface to be plated in a circular motion either by hand or by use of a turning head. Move the anode in respect to the surface being plated at the rate specified in table 3.

The anode must be kept moist while either etching, cleaning, or plating. The runoff may be collected in a porcelain dish and the solution absorbed by the cotton may be recovered by squeezing it into the porcelain dish.

(Continued)

Move the saturated anode over the surface to be plated in a circular motion either by hand or by use of a turning head. Move the anode in respect to the surface being plated at the rate specified in table X.

Calcu late the necessary am pere- hou rs us i n rr the area to I,e plated, the specified thickness, and the factor listed in table 3. Turn the rectifier

on,

and

plate the surface for the time

calculated, moving the anode relative to the surface being plated at the rate specified in table 3.

kept moist while either etching, plating. The runoff may be collected in a dish and the solution absorbed by the cotton may be recovered by squeezing it into the porcelain dish.

The anode must be

cleaning, porcelain

or

The used solution may be stored for re-use in a clean, labeled bottle. It must never be returned to the bottle containing new solution.

After the specified plate thickness has been deposited, rinse with flowing tap water. Rinse a second time with flowing purified water. Dry the part thoroughly.

The used solution may be stored for re-use in a clean, labeled bottle. It must never be returned to the bottle

containing

new

solution.

After the specified plate thickness has been deposited, rinse with flowing tap water. Rinse a second time with

flowing purified

water.

Dry the part thoroughly.

Processing with Proprietary Solutions Parts shall be processed in accordance with table 2 using the procedure given in Plating Process with Proprietary Solutions. Plating Process with Proprietary Solutions Saturate the anode with the proper solution. With cellulose sponge covered anodes: Fill the solution well with the plating solution. With carbon anodes: Pour sufficient plating solution into a. porcelain container. b.

glass

or

Saturate the cotton wrapped anode by immersion in the plating solution.

Adjust the output voltage of the rectifier in Table 2

a

or

to that

specified

table 3.

Adjust the ampere-hour

meter to read

zero.

Calculate the necessary ampere-hours using the area to be plated, the specified thickness, and the factor listed in table 3.

20-40-50 o


Page 5 Aug 31/84

n 093q

m

"rl

2:

,Q;

Processing

Table

Oo

with

Proprietary Solutions

~d

SURFACE

1

r

CJI

HI(:H (:ARHON

ra

1,ESS THAN IS,

Cd

STE~I,(WITH

BRASS:

IH()N: I,OW (:AHHON

HR()N%~

STI~EI.

C.()I’PISK:

I

i.

IVATEL)

THAN 1W Mo. OK

AI,I;MINUM: AI.I:MINIIM

QS (:r)

.41.1,OYS

I

NI(:KEI,

NICKE:I~ PLATE

Omit

O

Omit

scale is present

I(q

B

LI1

Il+lvolts

15f5vol

15 +5 volts

15 f5 volts

15+5volts

6.0f0.5 volts

O

I~

O

O

omit

omit

I

Lfl

O

s. Elrctroelean

4. Rinse a

1

5.

Etch

O

15 -e5 Volts

O

r

voltsl O ed

13

131

B

I

B

L3

cJ

d

Omit

Omit

IPI

Omit

Omit

7. Electroclean

Omit

Omit

13

(3

Omit

Omit

13

Li31

’d M

i

8. Rinse

Omit

Omit

O

O

O

Omit

O

n

Omit

Omit

O

O

r

Omit

C~ c3

O

9.

Bondinglayer

1 10. Rinse

11. c~

m rr!

p

~a n

stripping

-C n

ex, P

3

t~ C

Omit

73

I -I

El

10 lt5

m

Omit

6. Chromium

O

SII.VEH

BERYl,l,lliM

I~

O

10

(O

2. Descale when

I

3 I

O

P

L)e~rease

O

AI,I,OYS:

35 (:r);

Electroplate

O

O

O

Omit

O

O

O

O

O

61

O

O

IQ

M

56

metal

O

required

Cd r

NOTES

i

r

Oil and grease must be removed by vapor degreasing according to section 20-10-55. Where vapor degreasing is impractical, wipe with clean cellulose wiping tissue soaked in toluene or methyl chloroform. Always pour solvent onto either tissue or metal surface rather than dip tissue into container to prevent possible contamination of solvent in container. Use successive squares of clean tissue until tissue surface shows no trace of soil.

z

O

O so

Scour with

73

O

pumice (320 grit

E lectroclean

or

finer)

or

levigated alumina

until surface

can

be rinsed free of water break.

cathodically using cleaning and deoxidizing solution at specified voltage. Surface must be cleaned to a water

c3

jZ: C3 h

O

3

S;

break free surface. O

I

z

~d

STAINI.ESS

STEEL: HI(;H (:ARBON STF:EL (WITH MORE

Mo

HI(;H NICKEI.

ii

Q,

b

M

lo

r

;O

o

Table 2.

o

O =r!

Processing with Proprietary Solutions (Cont’d)

~Z:

O

M

SURFACE

-0

~d

n

n

HIGH CARBON

I -I

LESSTHANI%

r

STEEL(WITH Mo

(D 03

P

OPERATION

m

STAINLESS

COPPER:

IRON;

BRASS;

LOW CARBON

HIGH NICKEL ALLOYS: IVATED

BRONZE

STEEL

NICKEL

’d

STEEL: HIGH

340 Cr);

CARBON STEEL (WITH MORE THANI%Mo.OR 3g Cr)

~d

ELECTROLESS

ALUMINUM: ALUMINUM ALLOYS

NICKEL PLATE

O BERYLLIUM

I

SILVER

m

v,

a

NOTES (Cont’d)

m n

10

F z

O O

m

n

n n

and 6.0 f0.2 oz/gal sodium F,lectroclean cathodically for 2 minutes min using a solution of 6.0 -t0.2 oz/gal sodium cyanide hydroxide in tape water. Rinse with

tap

a

13

water.

Repeat

anodically with No. 2 Etching Solution at 8 +2 vde until

Etch anodically

a.

grey matte surface is obtained. Rinse

in

thoroughly in flowing

for 2 minutes min at either: using a solution of 0.75 +O.lO’ii~ (by

b.

v

a

crrey to black

m

surface is obtained.

weight) potassium fluoride

in 25 +5%

ed

(by weight) hydrochloric

I Anodienliy ctrip

v

using Selectron Activator No.

steels containing

more

i.

than 9% chmmium with chmmium

strippin~

solution at 14 -i-6

15 +5 Electroclean cathodically for.5 ~2 seconds with cleaning and deoxidizing solution at

b.

O

b 1

as w

ca

31

A solution of ~2 i-2

Selectron Nickel

oz/gal nickel chloride and

tr!

v.

4 +1

c3

O ’d Process with

Proprietary Solutions.

oz/gal hydrochloric acid in purified water,

or

rm ~2! o

Special Solution

Use Seleetron Nickel Neutral Solution for del,osits 0.0005 in. thick and over.

~C

v.

9 without rinsing.

O Activate cathodically using No. 1 etching solution at 8 ~2 v. Proceed to Step O Rinse in flowing purified water. O F,lectroplate in accordance with Plating Process with Proprietary Solutons. O E:lectroglate a 0.0001-0.0002 in. thick nickel (Epais) coating ac~cording to Plating either: O Nickel strike at 12.0 +0.05 v for 2-3 minutes over all surface areas using a.

c3 ’d m

or

12.0 +0.5

O ~d W 33

C

with No. 2 Etching Solution at 1216 vde unt,l

6.0 f0.5

acid,

13

a

thoroughly

water.

3 Cathodieally activate Z

purified

m r

water.

surface is obtained. Rinse Etch anodically with No. 1 Etching Solution at Is f3 vdc until a grey matte with levigated alumina. flowing tap water. Remove smut from high carbon steels abrasively Etch

o

flowing tap

rinse with flowing

C ~a

depo8its less

than 0.0005 in

thil:k and Selectran Nickel Acid Solilti~ln ior

o Z

C,

O=I

Fmo

~f. ts C

z~

(1

cb

arul

SR-’iCi-023 (’()KIZOSI()N CONTROL MANUAI,

GENERAL PROCEDURE FOR BRUSH TYPE ELECTROPLATINCI

Table

(Continued)

Plating Process with Proprietary Solutions PRETREATMENT NE(:ESSARY

V()I,TACI~

AMPERE-HOURS F()RO.QUOI IN.

SZ~RFACES DIRECT DEP()SITION IS POSSIBI,E: ON(3

REI,ATIVE CATHODEANOI)E SPEED

I-h

~0-120

O

LII

(’Rdniium (Acid)

8-17

Yes

0.008

(´•Hd ni i u m

8-IT

Yes

0.008

No

0.1:(7 tl()’X,

I-ci

5-:~0

5-1$

Yes

0.012

1-7

:10-100

(:ol,l,t’l’ (Sl,ecial)

Yes

0.012

.5.~i

40-(i0

(;ol(l

Yes

t).()08

I-(i

:~O-(iO

S()I,~ITI()IV

(’lll.l)llliu~n

Nic´•kcl (I~I,Ris)

ow 1

I

1

sc). IN.

20-80

4-12

No

0.000

6.A

:1()-60

8-80

No

0.021

1-7

20-80

1-7

20-80

Fj

20-80

Nickel (Alkaline)

I2-1X

No

Nirkcl (Ilwck)

12-1X

No

I

I

O, O

10-11

No

I

I

r\jic´•kt´•l

Rh(ltl ium

4-1()

Sil\´•c´•,´•

4-2()

’I’in tAlkaline)

8-2()

0.026

No

1

0. 1.57 ?r 10’X,

r,

.5-10

0.004

8

20-60

0.007

1-0

20-80

1-7

20-.50

1 Yes

(’lcwlling and I)eositlizin~

I I

No. 1 I´•:trhinR No,

~l´•:tc´•hing

(FT/MINUTES)

I I

I I

1 1

1

20-r,0

0.()()7

4.7

20-60

I-~i

20-50

NOTES

O ()l,erate I’l;lting

small electrodes in lower end of sl,ecified range. lime may be tlecreased by ol,cl´•ating large elec-

trotles at

enouah

I~

O

a

higher voltage. Voltage used

t" to ’´•’LU"" cause

must not be

8. 9. 10.

high

"l’’’i"B thl’u ""1Utio" ""’I ~’U’"i"R "f

(:old plate, Nickel Silver

Nickel strike areas

I’I´•iol´• to

plating ~´•ith those solutions ~l,ecificd in table to be plated must be swabbed with a 10 l’kl solulion of’ sulfuric acid. Then rinse with flowinR tap water, rinse a second time using flowing purified water´•. Howe\´•er, metals subject to hydrogen umbrittlement must be cleaned anodically with cleaning and deer idizina solution, I. 2. :1. 1.

:i. (i.

i.

Iron and miltl steel ~Iardened and teml,e,ed steel (’ase hardened steel Stainlesssteel (aftel´•clchinR) (’ol,perand b1´•ass I(,´•onze Aluminum alloys (;lftc~l. ctclhina)

at

approximately 0.00001 in, thick

12.()+0..5

v

for 2-:~ minutes

over

all srlrface

using~eilhcr:

8.

A SO1UtiO" Of 82

b´•

Selectron Nickel Special Solution

oz/gal nickel chloride and hytlrochloric acid in purified water, or

4 fl

oz/Rat

O

lise Selectron Nickel Neutral Solution for deposits less than 0.0006 in, thick and Selectron Nickel Acid Solution for deposits 0.0006 in. thick and over.

O

I~ead-tin platingsolution is prepared by by volu me alkaline tin solution with 27 by volumeoflead solution. An al tes nate non props i etasy sol u tion is made by mixing 60-66’Xl by volume tin fluoborate solution, 2()-25’k1 lead fluoborate solution. I:i-15’X, fluot,oric acid and .5.r, t0.6 am/i r,er,tone. l’his solutiorl is to ~,e m;ltic Frt!sh c;tclh

day of

Ilso.

20-40-50 P;lac H AuR:ll/t~4

o

1984 RY SABRELINER ~QPPORATION

8R-76-023 CORROSION CONTROL MANUAL


(Continued)

POST-PLATING TREATMENT

APPLICATION OF TIN TO GLASS-FIBER REINFORCED PLASTIC SURFACE Sand the surface to be plated with No. 500 or No. 600 grit abrasive paper. Swab the surface with 50/50 isopropyl alcohol/naphtha solvent and wipe dry with clean tissues. Apply MB0125-006 epoxy primer, insuring that any gaps are filled and bridged.

Prepare AB0120-014, Type III, silver conductive compound by mixing 40.0 +0.5 parts by weight of Part A with 1.0 +0.1 parts by weight of Part B (catalyst). Mix thoroughly in a smooth walled container or on a flat plate. Mix 1.0 f0.1 parts of the mixed silver compound with 1.0 ~t0.1 parts of butyl cellosolve acetate. Apply a thin brush coat over all prepared areas, extending 1/8-1/4 in, beyond

Embrittlement Relief: When be embrittlement relieved.

required, steel parts

must

All cium plate, unless otherwise specified, must be treated in accordance with table 5 after any necessary embrittlement relief. PLATE

REQUIREMENTS

plating must meet the quality requirements of the appropriate specifiecation listed in table 6.

The

the sanded surface onto any adjacent plated surfaces. Cure for 2.0 +0.2 hours at 120 f5"F. Electroclean cathodically for 5 f2 seconds with Selectron electrolytic cleaner solution at 15 +5 v. Rinse. 0.0005 in. of Selectron alkaline copper using 8.0 for 5 minutes per sq. in. Rinse.

Deposit f0.2

v

Deposit 0.0005 in, of Selectron acid v

copper

using 8.0

+0.2

for 1.5 minutes per sq. in. Rinse.

Deposit 0.0005 in. of Selectron Tin copper using 8.0 +0.2 v for 6 minutes per so. in. Rinse. Gold

Plating s

Gold

plate

ponents

as

s of modules with assembled outlined in table 4.

(;old

Table 4.

STEP i.

2.

com-

Plating of s of Modules with Assembled Components

Degrease

Isopropyl alcohol naphtha (1-1)

Scrub

Pumice and lint free cloth

REMARKS

TIME

MATERIAL

Wipe

free of visible oil

or

grease

using clean, lint-free cloth. 15

seconds, min

Scrub until surface rinses free of water break.

3.

Itinse

Deionized water

4.

GoldPlate

Per step 9 of table 1

15 seconds, min

Use flowing water source (e.g. laboratory wash bottle). If water break occurs, repeat step 2.

20-40-50 0


Page 9 Aug 31/84


GENERAL PROCEDURE FOR BRUSH TYPE ELECTROPLATING (Continued) Table 5.

Post-Plating Treatment

STEP


TIME

REMARKS

I.

Activate

0.7-1.7’ro Nitric Acid (by volume)

5-10 seconds

2.

Rinse

Flowing tap

0.5-2.0 minutes

3.

Chromate Treat

Bath A 1 1.8-2.20/0 Iridite No. 8 (by volume)

20-30 seconds

Bath B 3.5 ~0.536 Chromic Acid

1-2 minutes

10

90-120 seconds

Agitate parts if

water

O

(by weight) 4.

Rinse

Flowing tap

water

an

immersion

tank is used. 5.

SprayRinse

I Purified

6.

Dry

I

15-30 seconds

water

I

I

Use

a

Air

or

spray rinse.

air blast. Chromate

treated surfaces must receive a min of handling until 12 hours

after drying.

NOTES

O May

be omitted when parts have not been embrittlement relieved.

May be omitted when parts have

O

not been embrittlement relieved.

Use Bath A for all parts that will not be as

subjected

to

Agitate parts if

an

immersion tank is used.

temperature above 140"F. Drain and rinse

as

rapidly

possible.

Use Bath B for all parts that will be

Table 6.

subjected

to temperature above 140"F.

PlatingQuality Requirements PLATE

REQUIREMENTS

Cium

QQ-P-416, Type II

Chromium

QQ-C-:I20, Class

(’ol,per

AMS 241tl

I,eatf

AMS 2414

2

Nickel

G2Q-N-2t)O, Class~

Rhodium

AMS 2413

Silvel´•

QQ-s-~sr>

Tin

MIIrT-10727, Type

I

20-40-50 Page 10 Aug 31/84

o

CO:~RI@HT, 1984 BY SA-BRELINER CORPORATION


TIN PLATING BY ELECTRODEPOSITION OR HOT DIPPING

(;ENERAL This section covers the recluirements fol´• the application of lin plating on ferrous and nonferrous metals by electro-

del,osition

or

hot-dipping.

The tin plating applied in conformance with the ments is classified as follows:

Type I Type II

Tin Tin

reyuire-

Plating by Electl´•odeposition Plating by Hot-Dipping

Water, deionized: containing no more than 25 ppm total dissolved and undissolved solids and having a ~pecific resistance at 250C: (770F) of 50,000 ohm-cm, min Zinc Chloride, Tec´•hnical (;radt´•; C:ommercial Zinc Chromate Primer; MI1,-I’-2:~:177 Tinglo-Culmo Starter; Lea-Konal, Inc., Freeport, N\i Tinglo-Culmo Rrightner; Lea-Ronal, Inc., Freeport, NY Neutra-Rinse 40: Lea-Ronal, Inc., Freeport, NY Air or Nitrogen Gas, Dry, Filtered: AA0115-172. Purity Level VIII Sodium Carbonate, 0-S-571

NOTE

Electrodeposition followed by reflowing (Tl/pe I) m&T/ be used os an alternative to hot

dipping (Type II).

Where drawings call out "plate tin in accordance with AMS 2408", this refers to Type I plating applied over low alloy and carbon steels. The result is to delete the copper strike as called for in Type I and apply the tin plate directly to the basis metal.

IMATERIALS

(Infrared-Heat-Iteflective,

Compound; A30125-017,

Organic Coating

Grade A

Ammonium Chloride; 0-A-491, Type II Anodes, Tin; Commercial beta-Naphthol, Technical grade; Commercial Fluoboric Acid, 48-~0% (wt.), Technical (;rade; MS 36040

(;elatin, Technical (;rade; Commercial Hydrofol Tinfat No. 50; Metal and Thermit Corp., Rahway, NJ Hydrogen Peroxide, 3036, sulfuric acid stabilized, Technical Grade; Commercial Kenvert Tintillate Starter; Conversion Chemical Corp., 210 E. Main St., Rockville, CT Kenvert Tintillate

Brightener (Conversion Chemical

Corp.) Tintillaffe Connector (Conversion (:orp.) Methyl Ethyl Ketone (MEK); TT-M-261

Kenvert

Chemical

Potassium Hydroxide; 0-P-566 Potassium Stannate, Technical Grade; Commercial Novaculite 625; Chicago Wheel and Mfg. Co., Chicago, IL Sulfuric Acid, Sp. Gr. 1.84, Technical Grade; 0-S-809, Type I, Class 1 ’I’in, l’iK(for hot dipping); QQ-T-:371 ?’in (Stannous) Fluoborate, 47% (wt.), Technical Grade; Har´•shaw <:hemical Co., Cleveland, OH l’in

In the event of any conflict between the requirements of this section and drawings, the requirements of the draM’ing takes precedence.

Safety All materials and chemicals required by this section must be handled, used, and stored with due regard to their hazardous nature. Immersion Rinses

Acetic acid; 0-A-76

Aluminized

APPLICATION NOTES

(Stannous) Sulfate, Technical (;rade; Commercial

The immersion rinses should be either the single immer sion or double immersion counterflow type. A double immersion counterflow rinse can be substituted for a single immersion rinse.

Rinsing consists of complete immersion flowing deionized water.

in

a

tank of

The flow of deionized water into the tank must be at a sufficient rate to provide adequate rinsing of the part and skimming of the tank. Each immersion rinse step listed in the tables must be discrete except that one rinse tank may serve two solution tanks which contain the same chemicals. Each immersion rinse tank must be equipped with a suitable overflow. The overflow must extend along the longest dimension (width or length) of the tank. Water must be flowing in rinse tanks approximately 1(1 minutes prior to rinsing the first part in any continuous group. Unless otherwise specified, incoming rinsing and making up processing solutions must be as given in MATERIALS. Deionized water may

processing water for

be substituted where tap water is

specified.

Filtration of Tin Plating baths: The tin electroplating bath must be filtered as necessary to prevent co-deposition of solid particles on surfaces being electroplated.

20-40-55 0


Page 1 Aug 31/84


TIN PLATING BY ELECTRODEPOSIT~N OR HOT DIPPING

(Continued)

Handling and Storage

Hot Oil Fusion

for those parts on which tin plating is intended to be used as a solderable coating, both partially and completely plated parts must be protected against corrosion and damage during handling and storage.

The hot oil fusion or flowing operation, as detailed in either table 1 (Operation 6), table 2 (Operation 6), or table 5 (Operation 4), is applicable only to tin plating thickness

Except

I

Type Type I

between 0.0025 and 0.0075

(0.0001 and

0.0003

in).

Stripping

Plating

tin

mm

No selective etching or less of parent metal may result from stripping the plated parts. After stripping, the finish and dimensions of the parts must meet the recluirc!ments of the applicable drawing.

plating must be applied by stannate process, the

the sulfate process below. Tin requirements of AMS 2408 ton low alloy and carbon steels) must be similarly processed except that the copper or nickel strike is not allowed. Alkaline tin plating (stannate) must not, be used on aluminum parts. Acid tin plating(sulfate and fluoborate) must not be used on magnesium. Bright acid tin (table 3 or 4) may be considered to fulfill the requirement for fusion or fio~linff in hot oil. fluoborate process, plating meeting the

or

Tin Plating Rework Small

areas

of uncoated base metal may be coated to

design thickness with electrolytic tin by the brush tech nique. (Refer to section 20-40-50.) This may be applied ody when bare spots have resulted from rework, minor physical damage, or uncoated areas masked by holding

St;lnnate Process After the final activation or "strike" and rinsing operation, the I,arts must be tl´•ansferred immediately, without drying. to the tin electroplating bath (Operation 1 of table 1) and processed in accordance with the requirements of ta~,le i.

fi~ctu res. Bare spots resulting from non-ad hesion of the ti n must not be touched-up by this method but must be stripped of tin land copper strike if present, and replated

according to original drawing requirements. Touch-up by b´•rush techniques is applicable only to external nonfunctional surfaces. The duality of the tin coating must conform to the requirements in COATING.

Fluoborate Process Paint

A fte r the fi nal activation or "strike" and r i nsing operation, the part shall be transferred immediately, without drying

Touch-Up

Pits, voids, minor physical damage and uncoated metal in including surfaces not touchable by a 19.1 mm (3/4 in.) sphere may be paint-coated as follows:

as-cast and other non-functional surfaces

the activation bath (Operation 1 of table 2) and processed in accordance with the requirements of table 2.

to

Sulfate Process Aftel´• the final activation or "strike" and ri nsing operation, the parts must be transferred immediately, without drying, to the activation bath (Operation 1 of table 3 or 4) and pr´•ocessed in accordance with the requirements of table 8 or 4. Since a bright-as-plated tin plate is produced

by this method,

a

final hot oil treatment is not

Cleaning Scrub

area to be coated with clean, unused MEK wiping dry with clean tissues. Repeat this cleaning prior to priming.

area

Priming

required.

Zinc chromate epoxy primer (MTL-P-23377) must be applied by brush over an area extending a min of 3.2 mm (1/8 in.) beyond the defect. The edges of the primer must be th i nned or "feathered Th e primer mu st be cu red for a min of 1 hour at room temperature (160C L60"F] min) prior to application of the topcoat. A forced cure at 49 to 66"C (120 to 1500F) for 20-30 minutes may be substituted for the room temperature cure.

NOTE

T~pe I pluting applied in accordance with tahle 4 reguires the use ofNeutra-Rinse ~O to improve solderahility and minimixe sta~in´•ing ofparts. Type II Plating ~Ctel´• the final activation and rinsing operation, the parts nlust be transferred immediately, without drying, to the fluxinR bath (Operation 1 of table 5) and processed in aclc’or´•tfanc´•e with the I´•equiremenls of table 5.

20-40-55 Page 2 Aug 31/84

O

COP~RIGHT, 1984 BY S~BRELINER CORPORATION


TIN PLATING BY ELECTRODEPOSITION OR HOT DIPPING

(Continued)

Plating Rework (~ont’d)

Tin

Tol, (:oating AI,I,ly aluminized top coat, AB0185-017, Grade A, by br´•llshing so as to c´•over all of prime-coated area. T)ry at room

temperature for

of the

one

a

min of 30 minutes, then

cure

at

following schedules:

177 +6"C (350 121 f60C (2.50

rtlO"F) for .100F) for

90 f15 minutes, 180 ~t15 minutes.

or

C()ATING Adhesion

The adhesion of coating must be such as to show no separation from the basis metal at the common interface when examined at a magnification of 4 diameters when suloiected to a bend test. The test specimens must be bent rel,eated ly thru an angle of 180" on a diameter equal to the th ickness of the specimen until fracture of the basis metal occurs.

Solderability

plated parts must not show evidence of outgassing, blistering or poor adhesion when heated from 180.4"C to 4000C (7520F) on a hot plate or in a hot oil

The

bath, either fluxed

or

unfluxed.

C:ontinuity T i n coati ng over copper substrates must exhibit continu ity when subjected to the continuity test made in accordance with ASTM B33.

(:orrosion Resistance Parts

having a plating thickness of 0.001 in. or greater capable of ing a 24-hour salt spray test in

must be

accordance with Method 6061 of Fed. Test Method Std. No. 141.

plating applied to low alloy and carbon steels in accordance with the modified method (see ~.4 for AMS 2408 requirement) for Type I plating must meet the requirements of AMS 2408. Tin

Apparent pitting of tin plating on cast metals is not cause for rejection since the surfaces of the basis metals themselves are inherently pitted. Where tin plating is adjacent to a surface that is masked has an anodized finish, a line of copper may be visible. A line is defined to have a max width of 0.8 mm (1/32 in).i This condition is not cause for rejection. or

Unless otherwise specified, the plating thickness must be a min. of 0.0025 mm (0.0001 in.).

20-40-55 Page 3 a


Aug 31/84

’rahle 1. P ’F , ~j

Type I Tin Plating By Stannate I’r´•oeess SOI~IITION

CONCENTRATI()N

C()NSI’ITUENTS

P

1~

pt

r:

TEMP, "e

cj

1

i.

142.5 f~7.5 g/l (19 +5 oz/gal) 18.7 i.7.8 g/l (2.5 +0.5 oz/gal)

I’otassium Stannate rotassium

I’late

oo

1

Hydroxide

77 ill

As

Current

(170 +20)

to

amp

recluired specified

2.

3.

50X,

Acetic Acid

Rinse

´•a r

Ambient

by volume

~Z: r: W cC

60 -tYO

M r m

seconds 4.

I

5.

Dry

6.

E’low(Ifrequired)

I Hydrofol

I

CAUTION

Until dry

I Airblast,

See details

(490 f10)

No. 50

I

1 254 i6)

Tinfat

Water should be flowing. Rinse until free of acetic acid.

See details

I Ambient

I

I

I

I

c3

33 O

hotairorother

Treat until tin flows; evident by the brightening of the tin surface.

M Cd O

O

a

n ´•O 6

I

Water

Rinse

7.

M

(Magnesium Castings only)

D

cc

Optional Process. Bake out, if used, must precede any

BakeOut

c3 ct

to

times and temperatures in Tin Plating Rework.

I -I

O ~d

NOTES ex,

P

m

O O

Concentrations Sodium

are

constituents in water.

O

compounds in equivalent quantities

may

V,

be substituted for the

potassium compounds.

c3

t~

m!mnlr~l

9

H,drog,n pem~ide of bath.

´•n

must be added

ct

with vigorozla solution

agitation,

tozc~ard bottom ct

r

Z

O

0

O lo n

O

O n

O

O h

C3 O

J

When work has been put in bath, a high current density strike should be Pure tin anodes, if used, must be polarized used at 50-100~ above normal plating current density. When voltage suddenly increases a couple of volts and current decreases accordingly, anodes have been polarized and current can then be adjusted to normal plating range. if used, do not have to be polarized with thel´•efore easier to discern than in case of pure tin anodes.

O z

A greenish-yellow film must be maintained at all times on anodes during operation of tin plating bath. This film dissolves into bath when no current is flowing. It also tends to dissolve when current density is either too high or too low. In later case, adjustment of current density may restore film and improve tin deposit. If deposit remains dark or rough, additions of hydrogen peroxide (30%) in 0.5 g/l (1/16 oz/gal) increments may be made.

High speed anodes,

-f

Parts must be completely dry before they

are

a

high

current

immersed into hot oil bath.

~b cl

ci

O

for anodes.

Water must be flowing. Rinse until part is free of plating solution and entrapped salts.

See details

Ambient

Water

Rinse

~Z:

hydrogen peroxide 10. Refer to

Cn Cn

CI

density: 2r,-10() per sq ft. Adjust bath

with acetic acid and

thickness

m

c5a

DE:TAII,S

TIME

("E’)

~f. C (P

density strike. Polarized film is darker and

a

I

56 O

5 z C

03to

Oo

Table 2.

Type

I Tin

1

I ~a

OPERATION

SOLUTION CONSTITUENTS

CONCENTRATION

TEMP,

I~

"C ("F)

C) 1,

I -1

15 f5%

Fluoboric acid

Activate

t!

Plating By Fluoborate Process

by

Cd r

90 i-60 seconds

Ambient,

volume

(not to

(48% by wt.)

DETAILS

TIME

c3

exceed 29 P

ct

1

1

G1

[851)

(I,

Rinse

Water

3.

PlateO

Stannous Fluoborate

1

30

I

F

265.2 f15,6 mi/i (34 -t2 fl oz/gal)

to

per so ft

beta-Naphthol

0.8 +0.2 g/l (0.10 +0.02 oz/gal)

I

I

oz/gal)

I

See det~ils

Ambien~

Water

5,

Z

6.

I

I

I

I

I

I

I

I

-n

0

M r m C11

I

Gelatin

O

Kinse

(80 +20)

cC

thickness

6 +0.2 g/l (0.80 ~0.02

(48% by wt.)

4.

Current density: 25-100 amp

(20

Fluoboric Acid m ra

As

required specified

W

flowing.

27 fll

156 +23.4 mi/i +3 fl oz/gal)

(47% by wt.)

Water must be

15 +5 seconds

Ambient

2,

2:

Water must be flo~rjng. Rinse until part is free of fluoborate residues.

other

Dry

Until dry

Air blast, hot air

Flow(Ifrequired)

See details

Treat until tin flows; usually evident by the brightening of the tin

or

~d O tl O r/3 c~

c3 c~

Hydrofol

254 +6

Tinfat

(490 10l

No. 50

CAUTION

O

surfa~es. 7.

process. Bake out, if used, must precede any further processing, see times and temperatures in Tin Plating Kework.

Optional

Bakeout

(Magnesium Casti ngs

only) NOTES

O

Concentrations

O

The

b 0~ wl

;n r~I

following alternate bath composition

beta-Naphthol

O Wp,

constituents in water

Stannous Fluoborate Fluoboric Acid Gelatin

O

09Ce~

are

Parts must be

completely dry

may

be used:

mi/i 46.917.8 mi/i 61+0.2 g/l 0.8 +0.2 ~1

265.2 ~15.fi

before they

are

oz/Rall (54 ozi~al) (6.4 tl (0.80 +0.02 oz/gal) (0.10 +0.02 oz/gal)

tC O c3

Ef

;e

n

z c:

+2 fl

immersed into hot oil.

clz

Cd Cd

a

1~

3

1 E:

~fl

;~e

cD

Pi

z C

b w

Table 3. 3.

C

(:()N(:ENTRATION

3:

b

i.

(SP´• 2.

25 f.5%

Sulful-ic Acid

Activate

gr.

1.84)

Water

Kinse

Cn :i.

(Sp.

gr.

1

105.6 +4

(1X..5

1.84)

5.

Dry

6.

BakeOut

O

(MaRnesium

0

Castings only)

a

15 ~Fj seconds

As

m

O a a

0 a

I

Water must be flowing. Rinse until part is free of plating bath residues.

See details

I

I

Until

dfy

I

Air blast hot air

or

other.

process. Bake out, if used, must precede any further processing, see times and temperatures in Tin

Optional

Plating Rework NOTES

(70 ~10"F) (21"C (700F) preferred) 21 ~6"C

Cathode Current Density:

0.50-29.00 amps/sq ft (still) 15.0-25.0 amps/sq ft (barrel)

Anode Current

15

Density:

amps/sq ft,

152.5 f30.5

Agitation:

or

O

t~ M Cd

O

~f c3 w

O

Cd Cd n

cm/mm (5 sl ft/min),

equivalent

G)

solution movement

Use for sludge removal

Anode Area

Equal

to or

ct

max

Filtration:

O

greater than cathode

area

3

OMaintenance: Hull Cell Tests.

~a

O c~

Temperature:

O

3

~d

Plating Bath:

Add ’74 mi (2.5 fl oz) of Kenvert

~-3

O 33

constituents in water.

-I

Z

M r M

a

O

Cd r

C1 ~d cC

thickness,

I Ambient

are 01 Conditions O Operating

~ia

C~ c3

1

Concentrations

Z

O, O

required

mi/i

I

~Z:

w

specified

mi/i oz/gal)

O

m r

flowing.

to reach

(70 +10)

a

a

Water must be

oz/gal)

Water

I

Ambient

seconds

(100.0 f0.25 fl

Starter Rinse

t)O t60

+0.5 fl

78 +2

Kenvert Tintillate

Ambit´•nt to 1Fi50E’

brightener

per 378.5 ]tr

(100 gal) based

Q,

ct

DETAII,S

TIME:

("F)

21 ~6

30 t3.8 gl/l (4.0 ~0..5 oz/gal)

Stannous Sulfate

Plate

Sulfuric Acid

4.

"C

m

cj

T~MP.

O

C:()NSTITUENTS

OPEKA1’ION

r

O

c:

Type I ’l’in I’latinR By Sulfate (Kenvert) Process

a on

P1

E

to co

c3

0

O

Table 4.

a a

Type I Bright Tin Plating By Sulfate

D i.

I --I

P

2.

Rinse

3.

Plate

25 i5om

Sulfuric Acid (Sp. (;r. 1.84)

Activate

TEMP,

CONCENTRATION


OPERATION

cl

"C ("F)

TIME

Ambient

90 ~60 seconds

by volume

a

1: eo

B~

mi/i

Sulfuric acid

10.5.5 i5

(400 +2 mi/gal)

a a

Tringlo-Culmo

m

Starter

99´•7 f0.5 ml/t (378 ~2 mi/gal)

M r

r

z

4.

I

Rinse

Water

Rinse

Neutra-Rinse 40

5.

Sodium Carbonate

or

a 73

o

6.

a

tj Water must be fiowing. Rinse until part is free of Neutra-Rinse 40 residues.

See details

Ambient

--i

0

Dry

8.

BakeOut

z

Air blast hot air

Until dry

7.

1

I

I

Water

Rinse

seconds

(160 ~20)

I

I

Optional

(Maanesium Castings only)

I

I

I

I

I

or

other,

process. Bake out

constituents in

O O (fperating Conditions are

Sulfuric Acid:

Temperature: (:athodr (:urrent Density: Kate:

Plating Tank: Anode (’urrent I)c´•n~ity: Anodes: Anode Hooks:

Filtration: Kt´•clifirr:

Agitalion:

O 09

C~

I

r/3 ct

c3 cl

Tin PlatinR Rework.

O 56

3j

water.

O 15 +1.5

d1(2.0

+0.2

oz/gal)

ll).r, +1.5 by volume 21 tl)"(: (7i) +15"F) (1Xo(: (65"F) preferred) 1r,-2r, amps/sq ft (barrel) O.r, to 40 amps/sq ft track) :1.5 minutes per 0.1 mil at 15 amps/sq ft

Folyvinyl chloride, polyethylene 25 ampsiscl ft. max

or

t~

(:opper

or

monel

keep hook

C

Cd Cd

~e ~p

C~

%i

ecluivalent

out of

c z

plating bath

(:ontinuous

(:ontinuous voltage control with 5’k~,

Al,~,roximately

10

ft/nlin

or

cl

CI

I’ure tin

max

ripple

equivalent solutil,n

movement

BI, mi (1.7 n ori af l.inFlil(.ulmo Kq,icni*hmm~: Main~in bulh i,, Nidin~ Itr. (1()() gal, t,asrd on HIIII (:ell Trst8. I,er:(7X.T, ~,riyhtenc.t. Tin)rll,-(.lllmo

lialh

O

O

Plating bath:

Tin Metal:

m Cd

if used, must precede any further processing. See times and temperatures in

NOTES (:oncentrations

56 O

6i4

?1 ~11

a.5 +7.5 gil (5 ii oz/gal)

n C3

Water must be flowing. Rinse until part is free of plating bath residues.

See details

JAmbient

ma

a

4~ W CC

(70 f15)

(Sp. Gr. 1.84)

V)

seconds

21 +9

30 +0.8 g/l (4.0 t0.1 oz/gal

Stannous sulfate

Water should be flol.´•ing

15 ,5

IAmbieot

Cd r

DETAILS

C1 O

3

1 noll 25 mi lil.Xi ii oil Of

r

Q

C. c

z i ;3

.~d 3-;1 z c

V

r

5~

ey c~

3tw Cd z r

c3

cn c~

r,

Table 5.

Type II

Tin

Plating SOLUTION

OI’EKATI<)N

1.

o

1

2.

O

4.

5. m

Flux

Zinc Chloride

3.60

Ammonium Chloride

g/l (48 oz/gal) 36 g/l (4.8 oz/gal)

Water

Remainder

Dry

"C ("F)

27

(80)

max

Ambient

Hotdip

Tin, per &&-T-371

Reflow(see

Hydrofol Tinfat

details)

No. 50

BakeOut

(Magnesium Castings Only)

302 +22

I

1 (576.6 i40.j)l 254 ~6

(490 f10)

ta

p

m

e

r n

TEMP. CONCENTRATION

CONSTITUENTS

(Partial) 3.

f

DETAILS

Immerse part in flux bath until surfaces wet by flux.

are

sufficiently

Allow flux to drain from part and dry until surfaces of part is "tacky".

Sufficient time to heat surface and allow

3j O M Cd O ct

d

wettingand freeflo~ingof molten tin, Reflow if necessary to improve appearance. Sufficient time should be allowed for excess tin to drain from part surface.

O ~d

Optional process. Bake out, if used, must precede any further processing. See times temperatures in Tin Plating Rework.

O c3

and

td

nCd

m r

Z

Z II

A

O

O O ~o

-I

o

z

a

SR-76-023 CORROSION CONTROI, MANIJAI,

HARD CHROMIUM PLATING 8tr’il,pinlS

(;ENERAI, This section gives the chromium plating,

requirements for electrodeposited

Removal of chromium plating from ferrous base allov~ heat treated over 100,000 psi must be accomplished with reverse current in an alkaline bath.

APPLI%ATION NOTES FINISH

Appearance

Hydrogen Embrittlement Relief hydrogen must be in duration, tem peratures, and timeliness for the metal and process in use. Baking

following inspection and testing must be conducted to conformance to the requirements of this specification The

The chromium plating must be uniform in appearance and free from frosty areas, pits or blisters. When plating is performed on only a portion of the surface of parts, the plated areas must be finished in such a manner that they will blend smoothly with the adjacent unplated areas.


Appearance The appearance of chromium plating must be in APPLICATION NOTES above.

as

required

TESTS

su i table

Hardness The hardness of the chromium R(: 05.

plate

must be

no

less than

Hardness

The hardness requirement give in APPLICATION NOTES must be verified by direct measurement using Diamond Pyramid Hardness numbers or Knoop Hardness numbers equivalent to R~: 65 as a min value.

Adhesion

Adhesion

The adhesion of the chromium plating must be such that it shows no separation from the basis metal when tested

Adhesion tests must be performed using test coupons of 4130 Condition A plated with 0.0015-0.003 in. chromium per side concurrently with production items.

according

to TESTS below.

Thickness

The thickness of the chromium plating on finished parts must be 0.0015 in, min and 0.0030 in. max or all significant surfaces unless otherwise specified on the drawing.

Preparation

For

The test coupon must be bent thru an angle of 180" on a diameter equal to the thickness, straightened and examined for non-adhesion. Flaking, except at interface of chrom ium and basis metal, or formation of cracks i n the plating, is not cause far rejection.

When parts

Plating

are

chromium

quently ground to dimension, to adhesion.

Stress Relief All ferrous base ailoys.having a hardness of Re 40 or a heat over 180,000 psi shall be stress relieved by a suitable process, as applicable, after completion of all gri nding operations and prior to shot peening and plating. treat range

Shot Peening

plated oversize and subsetest coupons

are

not

required

Thickness

The thickness of chromium plating must be determined by one of the following methods i.

Micrometer Method

2.

Magne-Gage Measurement

alloys having a hardness of Re 40 or a heat over 180,000 psi must be shot peened.

All ferrous base treat range

Scale and Oxide Removal

(Over 180,000 psi)

Scale and oxide removal prior to plating must be restricted to abrasive blasting or anodic pickling (reverse etching). During anodic pickling, the current must be on prior to immersion and remain on until after removal

from the

electrolyte.

20-40-60 o


Page 1/~ Blank Aug 31/84

COKKOSI()N CONTROL MA~IIAI,

COPPER PLATING NOTE’

(;ENEKAL

On parts with recessed ureas, it ma~y be plate up to 0.004 in. on so~lu areas in order to th.rou~ the regze irerI thiek-

gives the materials and procedures to be used i n clectr´•otlositing copper on carbon and low alloy steels, (:I~ES and heat resistant alloys, or´• Series 400 stainless steclls for´• carburizing andlor nitriding stop-off purposes.

’1’ h is section

(:ar´•bon and low alloy steels heat tr´•eated to ultimate tcnsi It! strengths of 240 KSI and above must not be copper

I,lated. bronze deposits of 10-12% tin) solutions are acceptable if the recluirements of APPI,ICATION NOTES of this section art! complied with.

(:opper electrodeposits (or fr´•om

I,.yrophosphate-type

MATERIALS

of these materials are! haxardous chemicals and must he handled with due rc?gard for their lethal potential 62Q-A-673 Commercial Commercial 0-A-86

MacDermid, Inc. Commercial

(I’lxtinR (;rade)

~’hosphor´•ic Acid (sp. Ir;r. 1.69) IJolassium Cyanide (Plating (.:rade) I>ot.assium Copper Cyanide Pot;lssium Carbonate

I’otassium Hydroxide

(:yanide (I’latinff (;rade) Sulphuric Acid (66" Be~) Sotlium

ness

into the

recesses.

Nitriding (Malcomizing) Stop-Off The min copper plating(or bronze) thickness for nitriding stop-off is 0.0015 in. All sur´•faces not to be nitrided must be covered with a copper plating (or bronze) unless Escess stock of at least the case depth required plus 0.010 in. of material will be removed by machining aftel´• the sul´•face

hardening operation, Adhesion

Most

Col,pc!r Anodes (:ol,per Cyanide (Plating Grade) Epsclm Salts (MgSO4 ´•7Hz0 Hydrochloric Acid (20" Be’) Meter Strip-Aid (or chemical equivalent Nickel Chloride Hcxahydrate

necessayl to

0-P-313 Com mercial

Commercial Commercial Commercial Commercial O-A-SO1

The adhesion of the copper plating must be such that it does not evidence separation from the basis metal when applied thereon nor must separation occur betnlet‘n the ~’hen copper plating and any previously applied plating, tested as in FINISH of this section.

Stripping of Copper Platings Copper piatings (or bronze) must be stripped in accordance with STRIPPING PROCEDURE of this section. Acid stripping solutions are prohibited. SURFACE PREPARATION Prior to copper plating(or bronze), all metal surfaces to be plated must be properly cleaned or prepared in accordance

with the following 1.

procedures.

Carbon and Low Alloy Steels (Kefel

to

section

20-10-10.) 2.

CRE:S and Heat Resistant Alloys, Series 400 Stainless Steels (Refer to section 20-10-20.)

APPLICATI()N NOTES

COPPER PLATING PROCEDURES

Appearance

The copper plating, procedures for various basis metals are contained in the following tabulations.

must be adherenl, smooth, rlatt!d copper (or´• uniform in appearance, free from pinholes, blisters, nodules, pits or other defects, Lack of brightness and/or luster, or slight staining and discoloration is not cause for

i.

2´•

Sleels

C’es and Heat Resistant Alloys, Series 400 Stainless Steels

table 1 table 2

rejection. Thickness

~:arburizing Stop-Off The min copper plating (or bronze) thickness for carburizina stop-off is 0.001Ei in., except parts to be pack carburized must have a min of 0.0002 in.

20-40-65 0


Page 1 Aug 31/114

x iv 3C ~p

QI

t3

b a

Procedure for

Table 1.

:I

()PE:RA1’ION

i. Reverse ISlc´•h

Q) 01

I

~bcs

Copper Plating Carbon and Low Alloy Steels

APPLICAHLE

SOLUTION (:ONSTITIIENTS

TEMP.

PAKTS

1 AND(:ONCENTRATIONSO I

DEF. "F

Sulphuric Acid (660 Be) Epsom Salts

Carbon and Low Alloy Steels

32-40

I

I

RE:MARKS

Make parts anodic at 4()-50 amp/sq ft O

6-7 minutes

40-60

34 +4Wwt.

3 Z

TIMIS

oz/gal

O

(MgS0,.7H,O) 1.1 Alternate

Reverse Etch

3.

Carbon and I~ow Alloy Steels

Sulphuric

80

25 f2X

Water

"Strike" Plate

O

c,,metal

2.0-~.0

"Free" Potassium Cyanide Potassium Carbonate Potassium

1.0-8.0

Make parts anode, enter sol. current on at 200 +25

80-90 seconds

max

I I

wt.

I

All

Copper

Acid

by

All

2. Rinse

Room

~Oseconds min

120-140

1-:i minutes

Overflowingwater

All

4. Rinse

5.

Copper Plate

I

All

O

Water

oz/gal 2.0-8.0

metal

O

Hydroxide ~a

C) I --1

m

I

I

1

I

I

I

O

O IO 73

O n

O Z

1

14Fj-160

1

Until required deposit thick-

oz/gal oz/gal

A1I

Forced oil-free air

density mavrange I from 5-60 amp/sq ft

I

C~ C~ 3

by

vendors1

or oven

60seconds min

Watertobefreeflowing

a

drr

NOTES

01

Concentrations are by weight or by volume as noted of the constituents in softened. distilled or deionized water. Maint~nance-ot-volume water and water used to dissolve chemical additions must be of the same quality.

O

To avoid smut on the work piece, it is necessary to have the rectifier before the parts are immersed in the solution.

p

water must be free

O

Copper metal may be added as either copper cyanide or concentrations of copper and "free" potassium cyanide proper complexinp: factor when copper cyanide is used complex salt is used.

flowing tap

C1

O

Room

7. Dr~

OFHC copper anodes ball and/or oval may be used. Use cathode rod and/or air agitation. Constant solution fi´•ltrati~n preferred. Cathode

(preferred) forged

current

1

max

’d r

30 seconds min

4.0-6.0

O

Water

r

m n

Room

ness is obtained.

As recommended

All

m

Z

I

oz/gal

Wetting Agent and/or Brighteners (optional)

Cd Cd m

~d

0..5-1.0

8.0

VJ

13

5.0-8.0

Potassium Carbonate

6. Rinse

O

I

oz/gal

"Free" Potasslum Cyanide Potassium

n

C1

I

oz/gal pH 12.5

3 C p

I

freely

o

’

p

Make parts cathodic at 4-6 v. Parts should "Ras"

oz/gal

to

5=

I with lasf

I I

Hydroxide

p

3

on

and its voltage set

at 3-5

v

water.

potassium are

copper

cyanide complex salt. The

controlled by making allowance for the

no

factor allowance is necessary when the

O

O a

a

O I

Table 2.

400 Stainless Steels

Copper Plating of CRES and Heat-Resistant Alloys,Series

(D

TEMP

CURRENT DENSITY

TIME

OF

Amp/S4Ft

(MINUTES)

03

P


APPLICABLE

a

PARTS

OPERI\TIO~

cr,

1. Anodic F,tch

CRES and Heat

Phosphoric Acid

Resistant. Series

sp Rr. 1.69

1

a a m

5 I

o

I 4

o 3D a

6. Nirkrl Strike

80

If.~columr

I

O

li2-1

mau

30 ’P ozi

1~ iX fl

I

80

g.al

I

.5R125

max

Water to be flo~ina

freely

Mab pnrl~ csthodz:

enter

I solution

with electrical . Use lead (Pb)

Rmm

Nickel Chloride Hydroehlorie Acid

Icathodes.

j0

I

Water~

All

I

Room 2"

Make parts anode: enter solution with electrical . Use lead (Pb)

1-1/2

75

1

I

O

I All

Rin~

max

I

gulluric *cid

All

R. (:arhalic Etuh

m so

Water

All

2. Rinse

80

75 i2’B: \-ol

ADDITIONAL DETAILS

Janodes. to be

flowine ireely

l/e mill

Water

1/2

Do not let parw dry upon remavai

liemin

Do

fromrinsewater.lO

oz´•gal

(20" Be)

a Water

All

fi. Kinat´•

I

O

I

I

Room

I

not

~d Cb

M ’d r

let parts dry upon removal

c~

from rinse water.

-I

O

ct

g

7.

(.upl"r.Slnkr~

All

I

S~*taille

Z r~

iOperafiona

Plate X.

All

Rinse

All

11.

Rinx´•

Al

1,1´•?

All

Water

See table i.

I

I

O ()pc´•ration

I

I

liemin

I

Water

or ~lven

to

be flowinp freely

------l

5

I

I Forced oil-frre air

Room

R’x."’

I

I

L/E

min

laLrr

1 r=

~lr?´•

in soflenrci. (.l,llcelltl´•ations :Il.t. by wripht o,. b?. \-ol u me as notfcl l,f tht´• rl,n~tituent8

O

Watcl´•

O I(~irl’a"it

1,1´• I’rc´•r i,,, nic´•l\el strikr

water.

Maintr´•nance-of-volume

water

and water used todissolve

pi v

C1

same.

O

tal, a’atel´•. bPromP~ ~larii snll/ur

O

be fiuuinp Ireely

NOTES

chrl,lir;ll s~iditions shall I,e of the

h

~4

Ix,u.~ii´•l´•i.

thP nickt´•l l´•SLI´•ikl´•´•´• I*~IUli(ln Jhall br

purifip,l

or

c z c:

c

1\3 C’ t~m

sP

C7

E

34

3;

e~cU1 s

g 9

%Q,

r76 ~tU r 03

SR-7Ci-023 C()KROSI()N CONTROL MANUAL,

COPPER PLATING

(Continued)

STRIPPING PROCEDURE

Adhesion

The

Test for adhesion must be made on 4 x 1 x 0.040 in. separate specimens(which have been plated concurrently with the articles being inspected) in the anneaied condition and must be of 4130 steel (representing carbon and low alloy steels) or 350 CRES (representing CRE:S and heat resistant or Series 400 Stainless). The test speci mens must be ~nt repeatedly thru an angle of 180" on a diameter equal to the thickness of the specimen and then exam i ned at 4 diameters magnification for evidence of non-adhesion of (1) the copper to the basis metal or (2) copper to the nickel "strike" or (3) nickel strike to the basis metal.

stripping of copper platings land nickel "strike" platings beneath the copper plating) must be done according

to

table 3.

FINISH

Appearance The appearance of the copper plating must be smooth, uniform in appearance, free from pin holes, blisters, noclu Ics. I,its or other defects. I,ack of bl´•iRhtness or luster, slight staining or discoloration is not cause for rejection. Thickness Th e t h ickness of copper plati ng must be as required i n the app I icable section of APPLICATION NOT% S. The thickness must be measured by a non-destructive method.

Table 3.

Procedure for

BASIS METAL 1. Carbon and Low

Alloy Steels, CRES Heat Resistant,

Stripping Copper Plating

SOLUTION CONSTITUENTS Meter Strip-Aid (or equivalent) Sodium Cyanide

CONCEN´• TRATIONS 8

oz/gal

TEMP OF Room to 140

OTHER DETAII,S

Immerse until

stripped. Discard 12-16

oz/gal

when exhausted.

RL Series 400 Stainless Steels 2. Rinse

Water

Room

Water to be free

flowing

20-40-65 Page 4 Aug 31/84

o

CO-PYRIGHT, 1984 BY SABRELINER CORPORATION


BRUSH CIUM PLATING MATERIAI,S

(;ENERAI, ’I’his section

covers

the process and mstcl´•ials for brush

cium plating. l’he selective

plating")

is

a

plating process (sometimes called "brush method of depositing metal from concen-

trated electrolyte solutions on selected areas without immersion tanks. In this process, metal is deposited from material attached to an an electrolyte held in an absorbent int!r´•l anode. l’lating is made l,y l:,rushing or the (cathode) to be plated with the electro-

part

sw;l~,t,ing

lyte-bearing

Selective plating can be used effectively to perform functions as bath plating, e.g., corrosion protection, resistance, repair wear resistance, lower electrical

damaged machine parts,

etc,

DESCRIPTION of this process is determined by the individual The areas to be repaired will normally be limited to reasonably small areas, but in some cases it will be use

case.

practical

to

plate large

areas.

All solutions must be clean and free from contamination, ~;x Ira care should be taken to insure that the solutions are solunot contaminated by used anodes or other plating lions, or grease and oil from surrounding areas. It r´•u ah

I,I ati ng. solutions

are

not

designed

to remove

large

amollnts c,f scale, oxide, oil or gl´•casc!. 1Tse mechanical ch(lmical rnelhotls to r´•enlove large amounts of scale oxide. I~se solvents to remove large amounts of grease

or ol´•

or

oil.

Selective plating solutions are 5-Fj0 times as concentrated densities used range from as tank solutions. The current Fi00-10,000 amps per sq ft. The voltages listed on the solution containers have been precalculated to give proper the current densities. Too high a current density burns stressed produces density current low Too a plating. deposits and low efficiencies. Agitation is provided by anode to cathode motion. Too slow a motion causes buring. Too fast a motion results in low efficiencies and stressed deposits. Too dry a tool results in burned plate, course

grain structure, and unsound deposits. During operation the solution reaches temperatures of 100 to 1500F.

Matel´•ials that normally have a ive surface (stainless steel, chromium, nickel, and aluminum) require an activating operation. The activating operation removes the ive surface. E tch i nlS

for

Cylindrical

1´• 2.

_

plating inside diameters.

for outsitle di;lmeters.

bloc´•lt

shaped

for flat

shal,es.

3.

Flat

4.

Rulk bloclts of graphite material is available fol´•

or

manufacturing special shapes.

same

The

of The removable anodes are available in a wide I´•anffe fol lows: as are They basic th and r´•ee shal,es. stand ard si zcs

anode. the

worn or

Anodes

opc!r;ltions someti mes

resu

It i n the formations of

high purity dense graphite, and platinum, platnium-plated titanium or 900/0 platinum 10’)/o iridium unless otherwise required. Separate anodes should be kept for use with each plating solution. Anodes

The anodes must be of

that have been used for reverse current cleaning and etching operations should be marked for identification as such, and should not be used with forward current.

ToolCovering The tool covering is used to hold and distribute the solution uniformly. The tool can be covered by any of the b. following; surgical grade USP long fiber sterile cotton; or e. dacron d. Scotch-Briaht; c. dacron batting; pelon; felt.

Sleeving

lonaer´• tool-covering lil’E is tlesil´•ed, surgical t,e used. cotton, dacron, ol´• cotton/dac´•I´•on sleeving c´•an When

Solutions The solutions used in selective plating include solutions for cleaning, etching and activating the surface to be plated, plating solutions for depositing pure or alloy metals, stripping solutions, and special purpose solutions such as anodizing, chromate treatment, etc. Listed below are some sources.

Brooktronics solutions

Brooktronics Engineering

Corp. North

Dalic solutions

CA

Hollywood,

S’IFCO Metachemical Cleveland, OH or

Piddinfflon and Associates. Ltd.

Selectron solutions

Monrovia, CA Selectronics, Ltd. New York, NY

cx;tml,le: carbon on carbon steels.’l’hese layers can interfere with adhesion; therefore, i 1, i s i m po r lan t th at these fi Im s are removetl i n the pi al;i nR

Vanguard I’acific:

~,r´•oc´•ctlurc.

Red~vood (:ity, (’A

an

insoluble surface film, for

or

Sant;~ Monica

Inc´•.

ol´•

20-40-70 0


Page 1 Aug 31/84

SR-76-023 COHROSION CONTROL MANUAL

BRUSH CIUM PLATING

(Continued)

Solutions (Cont’d)

Rotary Power Head

Solutions of any manufacturer may be used provided they meet the applicable plating specification, and are qualifled by p,´•ocedure tests. However, plati nff and preparatory solutions of different manufacturers should not be intermixed or substituted in lo a pl;t~ting procedure.

Rotary power anodes are used to rotate the anode for the plating of internal diameters or to reduce operator fatigue on large areas. A stepless speed control from 0-90() rpm and a reversing switch are recluired.

EC)I~IPMENT

IRTRTAI,LATION NOTES

Power´• Unit

The t!lectroplated deposits m ust meet the

A suitable powel´• sourc´•tl is required.’I~he unit must be! capable of producing direct current having smooth charactel´•istics with controlled ripple (about 38~). The power

Anode Selection

unit must be able to output at least 2Fj amperes at 25 volts. Min instrumentation includes a voltmeter, ammeter, ampel´•ehour meter, variable de output, and ac and de cil´•cuit breakers.

Plating Tool Handles

Anode Selection for Plating Steps Metal is deposited essentially only in the area of the tool to work . As a result of this, the following must considered when selecting an anode. The anode must have optimum

The handles must be able to hold anodes of various sizes and configurations. The handles must be designed for rapid cooling, and be insulated for safety reasons. Containers The

dishes, beakers and flasks required to hold the plating solutions and catch the runoff must be inert to the solutions and of the appropriate shape and size.

Accessory Equipment I)t~l,c’ntlinR upon the tyl,e m;~y I,e n,cluircd.

req u i rements of

specification QG~-P-41A.

of work

being done other items

Ulasting E~luipment and Abrasive

Motorized Turning Head A m otor i zed turn i ng head is used for rotati ng com ponents such as shafts, bearings, etc., to assure concentric and uniform plating. The motorized turning head must have a speed control from 0-600 rpm, and have an on-off-reverse conll´•ol in either direction of rotation.

with the

The anode must be selected which most nearly conforms to the configuration of the part; for example, flat anodes for flat parts, cylindrical anodes for internal diameters, and concave configurations for outside diameters, etc. The anode must cover the full length of a diameter or the flat area being plated, unless mechanized to insun! uniform coverage. When plating large areas the max tool to work conlac´•l will depend on the pl;ltinR solution and power pack used. The max area may be computed using the following formula.

The size of the cabinet must be adequate for the part to be plated. Air lines must be suitably trapped and filtered to

prevent in-process contamination of the parts to be cleaned. The blast material must be aluminum oxide (AleOQ) or silica (SiOZ). The material must be of a size or grit that will not affect the micro finish or dimensions of the part.

area

workpieace, approximately 1/3-1/2 the total area to be pioted when used in manual operations. For automated ol´• mechanized flow plating, up to 100% is allowed.

CA

C:

Where: CA= A

C

max

area, sq in.

amperage output or power pack current density for solution, optimum conditions

After the anode has been selected, it must be fitted to the a´•p3~ropriate stylus, wrapped with batting, and sleeved, w~e" necessary.

20-40-70 Page 2

Aug

3

L/X4

o

1984:BY

S~ELINSR CO:RPO:RATION


(Continued)

BRUSH CAD1MIUM. PLATING Anode Sclec´•lion (~:ont’d)

Ilnr~lel´•sion

Anode Selection for Plating Steps ((:ont’d)

Immersion deposits will form with no current flowing from certain solutions on certain base materials. Immrrsion deposits have poor adhesion to the base matel´•ial.

NOTE Sleeves are used to increase wear resistance, and to decrease overplate on the edges and sides.

Preplates

preplates Build-up

To insure that thorough and uniform preparatory operations have been carried out, it is desirable to use adequate size tools for these operations.

,,n

Plating Solution Selection

etc.

Solution Usage

Alkaline and neutral solutions are preferred an porous base metals, white metals, high strength steel, and for

iml,r´•ovctf throwing ability, generally used

deposits thereby improving adhesion. Common nickel, gold, and palladium. often used to prevent immersion

are

Selective plating generally is limited in the thickness that be

deposited

in

one

because of stress

cracking

and roughness of the deposit. As a general rule, the thickness for one of cium is 0.005 in.

max

Characteristics of Selective Plating Solutions.

Rrush plating solutions can be used to perform the same functions as bath plating, e,g. corrosion protection, wear resistance, lower electrical resistance, buildup,

are

are

from forming

Anode Selection for Preparatory Steps

Acid solutions

I)el,osils ;Inct I’rcl,lulcs

The solution manufacturers have prepared comprehensive literature on their solutions. This information must be rev iewed when selecti ng a solution and the i nstruc tion s

followed when using the solution. The solution cantainel´•s fol´• various anodes and are labeled as to range of voltage solution factor. This information should he used during operating. The brush plating solution chHractrl´•isti~s given in tables 1, 2, and 3 are presented as a Kuitle for solution selection and use.

for rapid build-up and conjunction with

in as a laminating structure material alkaline-type solutions.

Table 1.

Characteristics of Dalic Plating Solutions

ANODE-CATHODE PLATING SOLUTION Cium Cium Cium Cium Nickel Nickel Nickel Nickel Nickel

Code Code Code Code Code Code Code Code Code

2020 2021 2022 2023

2080 2085 20116 2087 2088

VOLTAGE

MOVEMENT

(VOLTS)

FT/MINUTE

SOLUTION FACTOR AMPERE HOURS FOR 0.0001IN. ON 1

SQ IN.

6-20 5-20 10-22 6-20

30-130 20-80 30-100 30-100

0.007 0.007 0.007 0.007

8-25 8-20 8-25

20-100 50-100 20-100 20-100 20-100

0.021 0.015

8-25

8-25

0.085 0.025

0.021

20-40-70 a


Page 3 Aug 31/84

SR-76-023 CI()KR()SION CONTR<)I, MANUAL

BRUSH CIUM PLATING Table 2.

(Continued)

Characteristics of Selectron Plating Solutions

ANODE-CATHODE PLATING SOLUTION

VOLTAGE

MOVEMENT

(VOLTS)

FT/MINUTE

Cium Acid (SPS 5050) Cium LHE (SPS 5070) Cium (Alk) (SPS 5100) Nickel(Acid) H.R. (SPS 5640)

8-20 8-20 8-20 6-18

Nirkcl(Acid)(SPS 56()0)

6-18

Nickel (I-I.T.) (SPS 5610) Nickel (Low Stress) (SPS 5621)

6-18 6-20

Nickel(Special) (SPS 5630) Nickel(Semi Brt.) (SPS 5642) Nickel (H.S.) (SPS 5644) Nickel (Neutral) (SPS 5650) Nickel ’M’ (SPS 5647)

Table 3.

30-120 30-100 20-80

27-37 2()-50 20-50 20-50 20-50

6-20 6-20 8-20 10-25 10-25

20-50 30-60 20-80 20-40

SOLUTION FACTOR AMPERE HOURS FOR 0.0001IN. ON 1 sQ IN. 0.006 0.006

0.006 0.045 0.()25,

0.025 0.038 0.021 0.020 0.017 0.025 0.050

Characteristics of Brooktronics Plating Solutions

PLATING SOLUTION Cium (BEC 301) Cium (BEC 302) Cium (BEC 304)

Nickel(BEC: 360) Nickel(RE:(’ 361)

VOLTAGE

ANODE-CATHODE MOVEMENT

(VOLTS)

FT/MINUTE

SOLUTION FACTOR AMPERE HOURS FOR 0.0001 IN. ON 1 SQ IN.

8-20 8-20 8-20

35-140 20-80 30-100

0.007 0.007 0.007

10-25 10-26

50-100 20-80

0.01/1 0.014

20-40´•70 PaRe 4 Aug 31/84

o

COPYR1GHT,

1984 BY ~AsRELINER CORPORATION


BRUSH CIUM PLATING Controlling Thickness of Electrodeposit Measuring the ampere-hours during plating is the most the plating thickness com man method used for controlling during plating. This technique is independent of area and time. However, the computed amperehour figure only measures the amount of metal deposited, the distribution of which will depend time on all areas being plated.

on

uniform

Calculation of Required Ampere-Hours i.

Each selective plating solution has a solution factor which is equal to the ampere-hours required to deposit 0.0001 in, on 1 sq in. of surface.

2.

Multiply this figure by the number of sq inches involved. This gives the ampere-hours required to deposit 0.0001 in. of deposit on the number of sq inches involved.

Multiply the figure calculated above by the multiples of 0.0001 in. to be deposited. The result is the required ampere-hours. Area times thickness times solution factor equals ampere-hours; i.e., plate two

R.

solution factor of 0.020 to a thickness of 0.001 in. (2 x 10 x 0.020 0.4 ampere-hours).

sq in. with

a

General Plating Procedure

procedure is given for general discussion. For specific applications and the solution manufacturer’s instructions. Refer to Surfaces Preparation below.

This

Prior

Preparation

are not designed to remove large amounts of grease, oil, oxides, and scale. Mechanical methods must be used to remove large amounts of scale or oxides. Solvents must be used to remove large amounts of

Selective plating solutions

grease or

oil.

Electroclean Electroclean to remove residual amounts of oil, grease, and light oxide films. Forward current is normally used but reverse current can be used to prevent hydrogen embrittlement. Electroclean an area larger than the area to be plated.

(Continued)

Etch Etch the surface as required. Small amounts of oxides of many materials after may still remain on the surface electrocleaning. "Flowed" metal is often present on the surface from machining, grinding and polishing operations or thru usage of the part. The etching operation is used with reverse current and is continued until the oxide films, flowed metal, and contaminated surface material have been removed and a uniform "grainy" surface appearance is obtained. Rinse

Activate

Activate the surface as required far plating on aluminum aluminum alloys, high alloy steel, stainless steel, chromium, nickel or nickel alloys. The purpose of the activation step is to remove the characteristically ive surface of these metals.

or

Rinse In the

cases

preplating

or

where the activating and the following are compatible, this rinse

plating solution

may be eliminated.

Preplate obtain max as required. In many cases to preplates of a suitable metal are deposited prior to deposition of the metal desired. Usually the preplate deposit is just a flash.

Preplate

adhesion

Rinse

Electroplate The final preparatory operation must be followed as soon in as possible by the plating operation. Electroplate accordance with the solution manufacturer’s instructions. Rinse

Dry Dry using a dry lint-free

warm

air blower, paper towelling,

or

clean

rags.

Rinse Rinse thoroughly with water. If water breaks on the and should be repeated. su rf ace, cleaning was insuff icient

Surface Preparation The selective plating solution manufacturers have prepared and made available comprehensive literature on the use of their solutions. This literature must be reviewed when planning a selective plating repair. The following selective procedures for plating on some of the

plating

more common

basis

are

presented

as a

guide.

20-40-70 a


Page 5 4ua 31/84


BRUSH CIUM PLATING Surface Preparation (Cont’d)

Plating On Aluminum and Aluminum Base Alloys I.

2.

E lectroclean

using forward

not break

surface.

on

Activate with reverse current until a uniform gray to black surface is obtained. I)O NOT over activate. 4.

Rinse

2.

Rinse

3.

Reverse current etch with appropriate solution for base material until uniformly etched surface is obtained.

4.

Rinse thoroughly in clean tap water.

5.

Activate surface using forward current and appropriate solution for base material.

6.

DONOTRINSE

7.

Immediate nickel flash surface to a thickness of 0.00005-0.0001 in. with one of preplate nickels.

8.

Rinse thoroughly.

9.

Continue plating with cium to proper thickness.

current until water does

Rinsethoroughlywith cleantapwater.

thoroughly. NOTES

Certain Aluminum Alloys will exhibit improved adhesion iffollowing are added to

procedure.

19.

Activate withfonoard current until uniform light surface is obtained. Rinse 5.

water.

Rinseand dry.

These procedures are not applicable to steels heat treated above 180,000 psi. to

color

with

preplate

nickel. 6.

Rinse

7.


thoroughly.

1.

Electroclean using forward current until water does not break on surface.

2.

Rinse thoroughly in cold tap water.

3.

Reverse current etch with appropriate activating solution until a uniform gray smut is obtained.

4.

Rinsethoroughly.

5.

Reverse current activate with appropriate activati nR solution until smut is removed.

6.

Rinse thoroughly.

7.

Electroplate part

8.

Rinseand dry.

Rinse and dry.

Plating On Copper and Copper Base Alloys 1.


2.

Rinse

3.

thoroughly in clean tap

Plating On Iron and Carbon Steels

thoroughly.

Immediately electroplate

(Continued)


water.

Electroplate part with cium plating solution.

with cium.

NOTES

Plating On Ultra High Strength Steels

If adhesion problems develop, following must be added to procedure.

These procedures are applicable to steels heat treated to 180,000 psi and above.

Etch with reverse current until clean copper colored surface is obtained.

Rinse thoroughly. 4.

Rinseand dry.

Plating On

300 Series and 400 Series Stainless

Steels,

Nickel Base Alloys, Chromium Base Alloys, High Nickel Ferrous Alloys, Cobalt Base Alloys, Nickel Plate and (:hl´•omium Pliltcl i.

i.

Electroclean using reverse current until water does not break on surface.

2.

Rinsethoroughlyin cleantapwater.

3.

Electroplate part with cium. Plate initially highest voltage recommended for solution so as develop an initial barrier layer, then reduce standard voltage.

at

to to

E: lectroclean using forward current until watel´• does not break on surface.

20-40-70 Page 6 Aug 31/84

o

~YRIGHT, 1984



BRUSH CIUM PLATING Surface

Preparation (Cont’d)

Plating On Ultra High Strength Steels (Cont’d)

(Continued)

4.

Rinse thoroughly.

5.

Activate chrome surface using fol´•ward curr´•ent and appropriate solution.

4.

Rinseand dry.

6.

nonotrinse.

5.

lakettartfor~ hoursat:~75f2ftOFwithin4hoursof

7~

immediate nic´•kel flash surface to a thickness of 0.()0005-(1.0001 in, with one of prepl;lte nickels.

8.

Rinse

9.


plating. Plating ()n I~ltra Iliffh Strength Steels These

procedures

are

applicable

to steels heat treated to

180,000 psi and above. i.

10.

Electroclean using reverse current until water does not break on surface.


water.

2.

Rinse

3.

F,lectroplate part with cium. Plate initially highest voltage recommended for solution so as develop an initial barrier layer, then reduce standard voltage,

to to

Rinse and

5.

Bake part for 4 hours at 375 +25"F within 4 hours of

dry.

plating. NOTES

plated with DALIC Cium

Code "No

I>ALIC Cium Code Haka" or Seleetron Cium LHE SPS 507(3 will not reguire a post plate bake.

Acidetchingshouldbe avoidedifpossible. Where etching is absolutely necessary it must be done with

reverse

Rinse and dry.

PLATING FINISH

Appearance at

4.

1Darts

thoroughly.

current.

Plating On Dissimilar Metals and Changing Base As a general rule with two dissimilar metals to plate on, follow plating procedure for one with most steps of activation. If activating steps have to be mixed, use reverse current activation steps prior to forward current activation steps. Example: To touch up a pit in chrome

plating must be smooth, fine grained, adherent, and of visible blisters, pits, nodules, porosity, excessive edge build-up and other defects that would affect the functional use of the plated part. The free

Adhesion Test All plated surfaces must be tested for adhesion of the electrodeposit. The tape test is the genel´•ally accepted test. Shot peening or machining is a more severe test.

Apply a 1 in. wide strip of masking tape No. 850. or equivalent, with the adhesive side to the freshly plated surface. Apply the tape with heavy hand pressure and remove the tape with one quick motion perpendicular to the plated surface. Any plating adhering to the tape is cause for rejection. Shot Peen Test Shot peen using Minnesota Mining and Manufacturing

rotary peening tools. These tools consist of a rotary flap loaded with No. 330 tungsten carbide shot. The flap is used in a mandrel and rotated by an air or electric motor between 2000 and 3500 rpm. The intensities obtained by this method can be correlated to the Almen Standards.

plated aluminum. i.


2.

Rinse

3.

Activate aluminum surfaces using reverse current and appropriate solution until uniform gray to black surface is obtained.

thoroughly with

clean tap water.

20-40-70 0



SR-76-023 C<)RROSION CONTROL MANI~AI,

NICKEL-ZINC ALLOY PLATING GENERAL covers the materials and procedures used in electrodepositing a nickel-zinc alloy (16-30% nickel and balance zinc) for corrosion protection of carbon and low alloy steels, copper and copper-base alloys, and all CRES alloys whose service temperatures are up to 9000F.

This section

The nickel-zinc alloy deposit is applied over a thin nickel film (approximately 0.00005 in. thick) which has been previously deposited on the base metal after all welding, brazing and machining have been completed.

MATERIALS

Some of these materials are highly toxic or corrosive and must be handled properlll.

Anodes, Nickel (75 Zinc-25 Nickel) Alloy Anodes Acetic Acid, Glacial Nickel Chloride (Hexahydrate) Zinc Chloride Sulphuric Acid (66" Be) Boric Acid Hydrochloric Acid (200 Be)

Epsom Salts (MgS04.7H20) Enstrip "A" (or chem equivalent) F,nstrip "S" (or chem equivalent) Sodium Cyanide ’ITdylite Non-Fitter No. 22

QQ-A-677 Commercial Commercial Harshaw Chem. Co. Commercial Commercial Commercial Fed. Spec. 0-A-86 Commerciai

No separation of the composite coating from the base metal must occur when subjected to the bend test of this section. The formation of cracks occurring as a result of the bend test shall not be cause for rejection.

Thickness

Auxiliary electrodes must be used as required to provide sufficient coating to meet the salt spray requirement of Corrosion Resistance in those areas which would normally receive less than the min and which

protected by drawing.

’I’he nickel-zinc alloy plate must be smooth, fine-grained and free from pits, blisters, nodules, i ndications of burning and other visual defects when examined according to Visual Examination of this section. Superficial staining or discoloration resulting from rinsing or baking are not cause

for

rejection.

Adherence The adhesion of nickel-zinc alloy deposits must be such that no flaking or chipping from the nickel "strike" film nor composite coating from the base metal must be evident when examined per Adhesion

Testing of this section.

not otherwise

specified by

the

recesses, and internal threads where a controlled deposit thickness cannot be normally obtained or which cannot be touched by a sphere 3/4 in. in diameter is not subjected to a thickness requirement.

1.

Holes,

2.

Parts, whose dimensional tolerances do not permit 0.0003 in, composite plating thickness, must be

given the max composite coating thickness patible with dimensional toleances.

Udylite Corp.,

Appearance

are

alloy plus nickel "strike" film composite coating thickness must be 0.0003 in. min and 0.0007 in. max unless otherwise specified on the governing drawing or controlled by the following exceptions:

Commercial

REQUIREMENTS

as

The nickel-zinc

Enthone, Inc. Enthone, Inc.

Harshaw Chem. Co. Harshaw Chem. Co. Fed. Spec. 0-A-88

organic coating

Prior to the electrodeposition of the nickel-zinc allo~: a thin film (or "strike") of nickel approximately 0.00005 In. thick must be electrolytically deposited directly upon the base metal.

3.

Detroit, MI Nickel Carbonate (Plating Grade) Ammonium Bifluoride Nitric Acid (42" Be)

an

com-

Bolts, studs, washers and articles with externally threaded portions must have a min total deposit thickness of 0.0002 in.

Corrosion Resistance No corrosion of the base metal must be evident on parts plated with a composite nickel-zinc alloy-nickel "strike" film thickness of 0.0002 in. to 0.0007 in, when subjected to a 24 hour salt spray test as in the paragraph on Salt Spray Test. Test s, plated with the same composite plating thickness as above, shall show no corrosion of the base metal when

subjected

to

a

48 hour salt spray.

Hydrogen Embrittlement Relief The hydrogen embrittlement relief method used must be suitable in duration, temperature, and timeliness for the metal and process in use.

Stripping of Composite Electrodeposit Procedures and chemicals covered in the paragraph on Stripping of Defective Composite Coating should be used to chemically strip defective composite nickel-zinc alloy nickel "strike" film platings to the base metal.

20-40-75 o


Page 1 Aug 31/84


NICKEL-ZINC ALLOY PLATING (Continued) SURFACE PREPARATION P1´•ior to nickel-zinc plating, all metal surfaces must be cleaned or preconditioned in accordance with the follow-

ing procedures. Ultra High Strength Steels (260 KSI And Above Or R,50 And Above)

Scale or oxide must be removed from the parts prior to plating by vapor blasting or grit blasting not to exceed 150 grit particle size. Anodic (reverse etch) pickling or ’ther suitable non-embrittling methods may be used for removal of discoloration, light oxidation, etc. Soak pickling is prohibited. A non-electrolytic acid dip of greater than 10 seconds constitute a soak pickle. Cathodic cleaning or cathodic pickling must not be used. Acid pickling of parts heat treated above 240 RSI is not permitted for any duration of time. Parts must be free of grease, oil, scale, or any other foreign adjudged harmful to the success of the plating

matter

operation. (:arbon And Low

Alloy Steels (180 KSI To 240 K8I)

Surface

preparation method of steels other than ultra high strength steels must be suitable for the steel in question. Corrosion Resistant And 400 Series Stainless Alloys Corrosion resistant steels and 400 series stainless must be cleaned by a suitable method. (Refer to section 20-10-20.)

Copper And Copper Alloys These metals must be

properly cleaned before plating. Plating must immediately follow surface preparation, beginning with table 3. NICKEL-ZINC PLATING PROCEDURES Nickel-zinc plating are listed below.

procedures for various base metals

Carbon and Low Alloy Steels CRES and Series 400 Steels (:ol~pcr and Copper Alloys

table 1 table 2 table 3

26´•40175 Page

2

Aug 31/84

o

1064 BY

~B;RELIN.ER CORPORATION

O

Table i.

O

Carbon and Low Alloy Steels

a

D I --I

PARTS

i. Reverse Etch

Carbon and Low Alloy Steels. Ineluding 11-11 a.

m r

5. Nickel-Zinc Alloy Plate

a

by Water

Nickel Chloride

30 f2

X

Hydrochloric

13 f3

Pre-Dry

m

water

r

Make parts cathode; sol. with current on at 50-125 Amps/Sq

enter

1-1/2-3

125 f10

minutes

oz/gal

CI

oz/gal

I

All

Nickel Chloride Zinc Chloride Acetic Acid

I

C~

i Dump when solution

5-10 seconds

125 +10

becomes green

r r O

Plate at 80-200 Amp/Sq Ft. Use cathode rod agitation. Filter as necessary. Use bagged anodes (auxiliary anodes ex~pted). Make daily acetic acid additions. Q e~

150 +5

32.0-40.0

oz/gal 14.0-16.0

oz/gal

CC Cd r

2.0-3.01 by vol

1.00k, by vol 3.0-3.5

Non Fitter No. 22

7.

C~

Amps/Sq Ft

Overflowing

30 seconds min

Room

O

Water with 1.5 +0.5% by volume of acetic acid

Z

80-120

2-4 minutes

wt.

All

O

6. Rinse

1:

80 f2%

(20"F Be)

O

Make parts anode, enter sol.

30-90 seconds

max

bywt.

Acid

13 a

80

2512%

I

a

4. Rinse

Make parts anodic 8 40-50 Ft O

ct

m

O O

5-7 minutes

32-40 oz/gal

Sulphuric Acid

All

3. Nickel Strike

Z

40-50

Amps/Sq

s

All

2. Rinse

34 i4Vwt.

Sulphuric Acid

Carbon

b. H-ll Steels

a

TIME

(MgSO,.’iHPO)

Steela

Cn

Acid

(66" Be) Epsom Salts

Alloy

Reverse Etch

a

Sulphuric

REMARKS

I

"F

AND CONCENTRATIONS

OPERATION

1.1 Alternate

P

TEMP.


APPLICABLE

a

pH

C3

All

Water

Room

All

Water

1.50-180

O

Until free of plating solution

W

Remove and allow to dry

1-2

G~

minutes in air

A

C3 8.

Dry (Alternate)

9. Bake

Forced

warm

air

or oven

dry

O

I

1 For part

requirinR hydrogen embrittlement relief.

use

I

I

correct temperature and time for metal involved.

~t

1 ;c

NOTES

O

(:oncentrations are by weight or by volume as noted of constituents in softened. distilled or deionized water. Maintenance-of-volume water and water used to dissolve chemical additions must be of same quality.

O

To avoid snlut solution.

O

Non Fitter No. 29 may be added to 25’Uwt, sulphuric acid etch bath at removal of smut from etched metal surfaces.

O O O

Rinse water must be either softened. tiistilled

on

work

piece. it is

necrssary to have rectifier

on

and its voltage set at:1-5

v

before parts

are

immersed in

E

a v

Z

ri a

concentration

not to

exceed I’h by volume to aid in

Z i

a-a

b E

r

3q

Maintain

pH of nickel

PlatinR baths

must

strike and nickel-zinc

be kept free of

Krmove zinc-nickel an~,des from

cn

partic´•les

or´•

deionized.

alloy bath with hydrochloric acid and/or nickel carbonate.

or

sludye bg c~ontinuous

I,lating tank durinp I,roll,n~rtl

idle

or

3: ~a

batch filtration.

I,eriods

to

I,rt´•vent excessi\´•cl anode cclnsumption.

ZQ,

b

r: 3P3 r 03

´•e r

F~

C~M

C~ O

a

LY

Table

~b

CKES and 400 Series Stainless Steels

3

P

1

I)PGRATION

1. clean

C:IIHKENT

TEMP

SOLI]’I’ION CONSTITUENTS

’4~

~)KCGNTRITIUNSB

C: REMARKS

TIME

AMPSi~l FTI

’B

2. Anodic etch

(66" Be)

Make part the anode. Do not rinse prior to operation 3. O

2-3 minutes

40-.50

40-.50

Sulfuric acid 34 +4’h by at

3. (’athodir

Etc´•h

Room

5. Nickel

Nickel chloride 32 +2 oz/gal Hydrochloric acid (200 Re) 13 f3 fl oz/gal

Strike

6. Rinse


O

~I

Water

O

O

Water with 1.5 f 0.55h/vol of acetic acid hj

Nickel chloride 32-40 oz/gal Zinc chloride 14-16 oz/gal Acetic acid 2-3% by vol Non-pitter 1% by vol

2.5-:10

40-.50

Epsom Salts (MgS()4.7H´•1()) :12-4(1 ozig.al

4. Rinse

I

125 f10

I

I

I

1

150 f5

80-200

Make part the cathode.

15-30 seconds

Transfer immediately to nickel strike after rinsing. Make

1-1/2-3minutes

.50-125

125 +10

I

1

30-90 seconds

1

partcathode.

I

8. Rinse

Water

O

C~

jZ:

Plate at 80-200 AmpiSq Ft. Cse cathode rod agitation. Filter as necessary. Use bagged anodes (auxiliary anodes

Until free of solution

Room

oroven

10. Bake

For parts

requiring hydrogen embrittlement relief,

use

correct

L1

Concentrations are by weight or by volume as noted of constituents in softened, distilled or deionized water. Maintenance-of-volume water and water used to dissolve chemical additions must be of same quality.

C3

To avoid smut on work piece, it is necessary to have rectifier on and its voltage set at 3-5 solution.

O

Rinsewater mustbeeithersoftened. distilledordeionized.

m r

Z

Z

O CC

C~

G~ A

C~

J

NOTES Il a

O

r r

temperature and timeformetalinvolved.

v,

SD

C~

O

m i

D

1

plating

Clean, dry compressed air

9. Dry

P

O

r

I

on.

acetic acid additions.

~b

9

M

Immerse part with

I~a

I

O

c~

ercepted).

C)

C)

~Z:

current

Transfer immediately to nickel-zinc alloy bath. Dump when solution becomes green.

5-10 seconds

pH 3,0-3.5

9 i I)

X

Part must be free of water breaks

Use correct method for alloy

being cleaned

m ~D

to

Z"

1

I

v

before parts

are

immersed in

O Maintain pH of nickel strike and nickel-zinc alloy bath with hydrochioric acid and/or nickel carbonate. O Plating baths shall be kept free of particles or sludge by continuous or batch filtration. a Remove zinc-nickel anodes from plating tank during prolonged idle periods to prevent escessive anode consumption.

(P

Q

9

r

O

O 73

Table 3.

II

Copper and Copper-Base Alloys

n

APPLICABLE

I

PARTS

OPERATION

P

m

1. Clean

All

2. Rinse

All Al or silicon bronze only

3. Etch

V)

O

4.

r

Rinse

5. Nickel Strike

z m ~D

Water

O

Nitric Acid

100 fl

(42" Be) Ammonium Bifluoride

11

oz/gal

B

Overflo\n´•ing

Room

O

All

30 f 2

Hvdrochloric Acid (200 Be)

1R tX

All


1-1:2-~ minutes

125 +10

fl

I

oz/gal

Water with 1..5

i-10 seconds

125 -t10

of acetic

r

Make parts cathode: enter sol. with current on at 50125 Amps/Sq Ft

32.0-40.0

Zinc Chloride

14.0-lfi.0

Plate at 80-200 Amp/Sq Ft. Use cathode rod agitation. Filter as necessary Use bagged anodes (auxiliary anodes excepted). Make daily acetic acid additions. O,I~ I~

1FiO ~´•i

I

8. Rinse

C CC CII

by vol 1.0’1;, by vol. PH X.O-:i.T,

Non Fitter No. 22

r r

Cd

Acetic Acid

I

C:

Dump when solution becomes green.

p

NickelChloride

rz: I

oz/gal Z

C;

water

I

ozipal

O

cc

X

NickelChloride

All

2:

I

I

I

I

Water

acid

O

Room

oz/gal

water

Use a plastic (PVC) lined tank. Provide adequate fume ventilation.

2-5 seconds

ozigal

6. RinSe

~D 73

Overflowing

Room

O

All

o

REMARKS

TIME

"F

Use correct method for metal being cleaned.

(NH,F-HF) m

TEMP.

SOLUTION CONSTITUENTS AIVD CONCENTRATIONS

C~

All

Water

O

Room

All

Water

O

1.50-180

cc

I!ntil free of plating solution 1-2 minutes

Remove and allow to in air.

dry

Z O C:

Forcrcl

10. I)rv

warnl

ait´•

I,I’ oven

C

~lr?´•

1

(Aitel-nate) For ~,art recluirinp

11. Bake

hydrogen embl´•ittlement relief.

use

correct teml,erature and time for metal involved.

NO?’E’S

O

O

C~

b E

3q

O O III

Maintain Th~´•

pH

I,latinp

v

before I,arts

are

immersed in solution.

of nickel strikr and nirkelzine allo?i bath with

baths mt~at ~,t´• kt’l,t fr~.t‘ of

Krmove zinc-nickel anotlc´•s l’rom

I,articles

I,latin)r t;tnk

or

hyclroc~hloric

t,y continuous

I,rolon)red

2

8

in softened. distille(l or deionized water. (:oncent!ations are by weight or t,?~ volume as noted of constituents must be of the same qualit~´•. Maintrnance-of-volume water and water used to dissolve chemical ad(litions work I,iece. it is necePzar?- to have eithe,´• aoft~netl. distilled or deionized. To avoid smut on Kinse water must be rectifirl- on and its voltag~f set at :(-6

a

1 e

idle

C C?

S

acitl and/or nickt´•l ca,´•l,onate.

or

3, v

J

hatc´•h filtrati~,n.

I,~´•,´•icltls

to

Ilrevrnt er;cc´•ssive Rn~,de c~onsuml,tion.

r

T~=d

ZQ, ’C

~p:

~B ’4)

~b 3t´•5


NICKEL-ZINC ALLOY PLATING (Csntinued) STRIPPING OF DEFECTIVE COMPOSITE

surement, Magne-Gage

COATINGS

Defective nickel-zinc alloy-nickel "strike" film coatings stripped from the base metal according to the

must be

applicable

section of table 4.

FILM ADHESION

or Permascope. The thickness measured must meet the thickness requirements of this Section.

Verification of the nickel "strike" film must be done by the Koeour electronic instrument method or by other approved methods. Protect test spot on production parts.

(Refer

The

to section

20-40-85.)

following inspection and testing must be conducted to assure conformance with the requirements of this section.

SJt Spray Test

Visual Examination

The following test must be conducted to determine conforinance to the requirements of Corrosion Resistance of

Visual examination for conformance to Appearance and Adherence paragraphs must be performed under 7x to IOx binocular

microscope magnification with an illumina2000-8000 ft-candles on the part(s) at the time of

tion of examination.

this section. The salt spray test must be conducted according to

S?1;D-1~1,

Plated parts must be exposed for 24 hours. Test s, ddcribed below must be exposed for 48 hours.

Adhesion Testing

Initial

Plated parts must be visually examined as described above for adherence. The bend test for adhesion to test s (or specimens) must be made in accordance with the requirements of the following paragraph´•

plating facilities

The bend test for adhesion must be performed as follows: One or more separate specimens, 1 in. wide by 4 in. long and 0.04 in. thick which are in the hardened condition and which are of a base metal equivalent to that of the articles

represented, must be used. "Equivalent" base metal includes chemical composition and surface finish prior to plating. The specimens must be introduced with each group of parts and I,rocessed simultaneously thru the cleaning and plating cycle. The plated specimens must be bent thru an angle until the base metal breaks and the plating examined for conformance to the adherence requirements of this section.

FED-

Method 811.1.

qualification

as

and quarterly evaluation of any

to meet the salt spray requirements of Corrosion resistance must be done in the following manner:

Test s, of basis metal equivalent to that of production articles and of a size 3 in, wide by 6 in, long a’nd 0.04 in. thick and in the hardened condition and with a surface finish of 125 RHR or better prior to plating with a total plating thickness (nickel-zinc alloy plus nickel "strike" film) of 0.0002-0.0007 in., must be exposed to the salt spray test. Control of Alloy Deposit Metal Ratio

Close control of the plating solution constituents, pH, ca;thode current dens ity and pi ati npt solution tem peratu re aS listed in tables 1, 2, and 3 will be necessary for control

fd

the 16-30% nickel and balance zinc alloy deposit. The

nickel-zinc alloy deposit must be checked quarterly for the actual metal ratio to determine conformance with listed controls.

Thickness Measurement

Measurement of the composite nickel-zinc alloy-nickel "strike" film thickness must be made on plated parts or test s using one or more of the following techniques: Kocour electronic instrument, microscopic section meaTable 4.

Stripping Defective Composite Coatings

APPLICABI,E PARTS Carbon and low alloJr steel or CRF,S alloys

(‘ol,l,c’r and (lol´•,l,erbasc;llloys

STRIPPING SOLUTION

Enstrip "S"

TEMP. "F

8

REMARKS

oz/gal sodium cyanide 16-24 oz/gal

140-170

Enstrip "A"

140-170

As above

180-2()()

As;lbove

F,nstl´•ip 165S (IJsr 1-2 Ih/Ral in a

at

Immerse until stripped. Discard stripping solution when spent. Use tap water for solution

makeup.

100~volume sulfuric solution)

acid

NOTE

After parts

are

stripped, rinse in

clean tap water and

d~

as

required.

20-40-75 Page

6

Aug 81/8$

o

COPYRIGHT,

1984 BY SABRELINER CQRPORATION


ELECTROLESS NICKEL PLATING (;ENERAL l’his section covers the engineering recluirements for chemical reduction deposition of nickel plating.

Stripping

APPLICATION NOTES Appearance Electroless nickel plating must be uniform in appearance but not in color, free from pits that expose parent material and free from blisters.


Stripping of electroless nickel plating must not subject the part to hydrogen embrittlement nor cause pitting of the basis metal. FINISH

Appearance

Hydrogen Embrittlement Relief Baking

Copper. copper alloys, and CRFES and heat resistant alloys must be prepared in accordance with section 20-10-’L5 or 20-10-20, as applicable.

hydrogen

must be

suitable in duration, temperature, and timeliness for the metal and process inuse. Adhesion The adhesion of electroless nickel plating must be such that it shows no separation from the base metal, when tested under the ar,plicable section of FINISH below.

The appearance of electroless nickel plate must be described under APPLICATION NOTES.

as

Adhesion Adhesion tests must be performed using test coupons of 4130 condition A, plated concurrently with production items. The coupons are bent once thru an angle of 180" an a 1/2 in. diameter mandrel. It must then be impossible to detach any appreciable area of the coatings on the outside area of the 180" bend.

Thickness The thickness of electroless nickel plating must be 0.0008 in. min and 0.0012 in. max unless otherwise specified on the applicable drawing.

Thickness The thickness of electroless nickel plating must be determined by one of the following methods.

Corrosion Resistance thickness of 0.0010 +0.0002 in. must withstand a 48-hour salt spray exposure without evidence of corrosion of the basis metal.

Test

s plated

to

a

1.

Micrometer measurement

2.

Microscopic measurement Permascope NI, Type N2E3

3.


Corrosion resistance to salt spray must be determined in the following manner.

Preparation for Plating Stress Relief

Ail ferrous base alloys with a hardness of Re 40 or heat treat range of 180 KSI must be stress relieved after completion of all mechanical operations and prior to shot peening and plating.

Test s, 6 x 3 x 0.040 in., of 4130 heat treated to 125-140 KSI plated concurrently with production items. These s must be exposed to salt spray in accordance with ASTM-B-117 for 48 hours. Corrosion of the basis metal is cause for rejection of the parts and requalification

of the process.

Shot Peening All ferrous base

alloys with

a

hardness of Rc 40

treat range above 180 KSI must be shot

Scale and Oxide Removed

(Over

180

or

heat

peened.

KSI)

Scale and oxide removal is restricted to abrasive blasting During anodic or anodic pickling (reverse etching). pickling, the current must be on prior to immersion and remain on until after removal from the electrolyte.

20-40-80 0



SR-76-023 C()RKOSI()N CONTROL MANLAL

REPAIR AND REFINISHING OF ABRADED, SCRATCHED, REWORKED, OR CORRODED METAL SURFACES

1’ h i s section covers procedu n~s to be followed i n the rel,ai r I,sinlsd, c´•hcln ic;llly Ireatetl.or :Intl/ol´• I´•efi,lish ing of Inanufzlctured pal´•ts which have,´•c´•c´•eived minor´•

I,l;lted

corrosion not ser´•ious enough to warrant the part. of scr´•appinff

tlamage

unpainted pal´•ts, clean the;trea thoroughly with Mil, C-5410 cleaner. If all signs of corrosion are removctl, the p,,´•t may be used without fu r,ther rc~work. t(owevcr, i i’ al~y evidenc´•c´• (,r corrosion (I,it´•s, stains, etc.), t.he I,;~rt

On

(;ENE:RAL,

or´•

’I’he applicable refinishing procedures may also be used for touch-up on reworked parts,

Whenever practicalbe, refinishing must be in accordance with the applicable finish requirements or detail drawing. When this cannot be accomplished, the applicable substitute finish system detailed in this section must be used.

Itecluired organic finishes practical after rework.

must be

applied

as

soon

as

with any

or

areas

Iw~ louc´•hctl uI,´•

KEW()KH PR()CEDURES FOR AI,UMINUM Clad Aluminum, Base Metal Not Exposed Excel´•nal sul´•faces of bare, chemical film treated or anodi~ed clatl parts which have been abraded or scratched must ~,e used without rework. However, when the

evctn

or

function of the part is seriously affected, may be required

replacement of assemblies though structurally sound.

r´•ewor´•k

or

to or

NOTE

required for electrical practicable, bondina must be provided by masking prior to the finishing opel´•ation. After bonding, terminal areas shall

al,l,earance

to be painted. (Refer application of Iridite No. 14

areas

Re-finish painted parts according to detail dl´•awing. Parts which originally were not painted must I,eceive one coat of wash pri m er (Refe r´• to sect ion 20-RO-10.) one coat of zinc chromate primer, and two coats of aluminized lacquer (Refer to section 20-30-20.).

Whenever a previously unpainted left hand right hand part reguires painting, consideration should be given to painting the corresponding right or left hand part for or

hlldrogen perozide. bare

Whenever

areas

Apply chemical film to section 20-40-35.) (Brush Alodine 1200).

Organic finishes must not be applied to areas that will subsecluentl21 liguid oz~ygen

followina additional treatment ;IlonK being reworked. painted

must receive the

i’ainted sul´•faces which have been abraded or scratched must be touched up, (Refer to section 20-30-20.) (:ol´•roded areas on either painted or unpainted parts must be reworked as described below.

Strip off all paint. (Refer to section 20-10-45.) If not painted, scrub free of any grease, corrosion products of other for´•eign matter with a rag wet with stoddard solvent of the soil. If neither or water, depending upon the nature is effective, Bon Ami or fine aluminum wool may be used.

balanced appearance, The following Spot Test must be used when base metal exposure is questionable. ’rhe area to be tested must be cleaned in acc´•or´•tlnncle with section 20-10-10.

One drop of caustic soda solution (100 R1´•ams caustic´• soda, P-S-GR1, in 900 milliliters of water) must be applied to the scratch and allowed to remain 5 minutes. It is advisable to apply a drop of the caustic solution in an adjacent area where there are no scratches, using this spot test as a comparison with the scratched area fol´• detel´•mininR

scratch

penetration,

Rinse the area carefully to remove the caustic solution and observe the scratched area. Black residue at the bottom of the scratch indicates penetration to the base metal. If the residue is white, the scratch does not extend thru the

cladding, The area exposed to the caustic test solution must be touched up with either 5% chromic acid solution or MILC-5410 cleaner´• (see below) to insure complete removal of all caustic residue.

Steel wool must not be used.

20-40-85 0


Page 1 Aug 31/84

SR-76-023 C()KH()SI()N CONTROI, MANUAL

REPAIR AND REFINISHING O% ABRADED, SCRATCHED, REWORKED, OR CORRODED METAL SURFACES (Continued) Non-(:lad Aluminum, C:orrosion Resistant (1100, 3003, 5052, 6001) Corl´•oded parts on which evidence of corrosion cannot be completely removed by MIL-C-5410 cleaner applied as detailed below, and scratched parts (except where scl´•atches ar´•e limited to superficial abrasions which do not affect the proper function of the part), should not be reused.

Application Procedure

For MIL-C-5410

I)ilute cleaner 1:1 (by volume) with water and apply to the cor´•l´•oded surface with a stiff brush or aluminum wool. Keel, surf ace of pal´•t wet for 5-10 minutes. Repeat once, if necessary.

Rinse by spl.aying, wiping with a cloth saturated with clean water, or immersion in running water. Rinsing should he thorough, especially at faying surfaces or other points where solution can be trapped. or

with

an

air

blast. Non-Clad Aluminum, Anodized 7075, 2024, 2014, 356 etc.

If no pitting is apparent on the cleaned part, refinish per either the detailed drawingorthe applicable sub-paragraph under Non-Clad Aluminum, Anodized and/or Painted above.

R%WORK PROCEDURES FOR UNFLATED COPPER AND FERROUS ALLOYS

Type II Cleaner

I)i´•y 1,3’ wiping with clean, lint-free cloths

Remove corrosion stains either with M IL-C-4f,lO, Type II cleaner as detailed above under Non-Clad Aluminum, Corrosion Resistant, or by rubbing with Bon Ami.

Lightly scratched

or abraded parts where the damage does not affect the proper function of the part shall be used without rework other than paint touch-up. (nefer to section 20-30-20.)

Corroded bare or painted parts, and parts where the function is affected by scratch or abrasion damage shall be reworked as described below.

Strip off paint. (Refer

to section

20-10-45.)

S:mooth out all scratches with abrasive cloth o~´• paper. as necessary to meet the surface

using 150 grit or finer finish requirements.

and/or Painted

e´•ff.

Process and refinish in accordance with requirements.

When scratch damage is limited to minor abrasions not damaging the aluminum, the following finish systems may be substituted for these called out on the detailed drawing,

Oiled

exposing, but

or preservative coated phosphate treated ferrous alloys with minor isolated mars or scratches must be used

without rewoi´•k unless

Non-functional External Surfaces

proper function of the part is affected. Phosphate treated parts which have corroded or have closely grouped scratches or abraded areas shall he reworked as described below.

Apply chemical film

Degrease. (Refer

treatment (Refer to section 20-40primer (Refer to section 20-30-10.), one coat of zinc chromate primer and either two coats of appropr´• i ately colored lacquer or one coat of appropriately colored enamel. (Refer to section 20-30-10.)

35.),

one

coat of wash

Non-functional Internal Surfaces Touch up (Refer to section 20-30-20) when not immersed in oil. When immersed in oils such paris must either be c)lrnlical film treated (Kefer to section 20-40-:35) or

anotlixetl. (Refer to secltion 2()-40-10.)

to section

10-20-10.)

Strip off phosphate coating. (Refer Smooth out all scratches

or

using

20-40-:-30.)

pits with abrasive cloth

150 grit or finer surface finish requirements. paper

to section

as

or

necessary to meet the

Phosphate treat (Refer to section 20-40-30.) and reapply or preservative as applicable.

oil

REWORH PROCEDURES FOR MAGNESIUM EXTRUSIONS, CASTIN~S OR F<)RGINGS These procedures al,ply to unassembled detai I parts with minor scratch, abrasion, or corrosion damage.

F’ll~lc´•lion;ll Surfacc!s I~el’inish in accordance with the tietail

drawing for the

I,art.

Mildl~´• col´•r´•oded parts

must be reworked

as

described

bclo\\´•.

Stl´•il,

off all

paint. (Refer

to section

20-10-46.)

20-40-85 I’aac 2 Aug 31/84

o

COPYRIGHT,


SR-76-023 C()HR()SI()N C()NTHOL MANIIAI,

REPAIR AND REFINISHING OF ABRADED, SCRATCHED, REWORKED, OR CORRODED METAL SURFACES (Continued) Apply three coats of zinc chromate primer and any required finish color coats. (Refer to section 20-30-20.)

Having A Smooth Surface (E.(;. Sheet, Extrusions Etc.) Must Be Reworked Parts

As I)escribed Below

paint or primer. (Refrr to section 20-10-46.) MaRnesium protective treatment need not be! removed.

Remove all

Smooth out all scratches paper (320 grit

or

or

pits with abrasive cloth

Corroded magnesium parts must be removed from assemblies and either I´•cworked, or 1´•eplacrd with ntlM´• detail ~al´•ts. Itcasscmbly ~nust l,e with tal,e or 8c~alant barriers between magnesium and other metals.

or

finer).

REWORK OF PLATED SURFACES

Refinish the entire part with the chemical treatment and paint system called out on the detail drawing.

Bright Alloy Plating

Having Rough Or Porous Surfaces (Castings, Forgings, Etc.) Must Be Reworked

Bright alloy plated capper or copper alloy parts damaged by isolated minor scratches and/or abrasions may be used without rework even though minor base metal exposure has occurred in a few of the damaged areas.

Parts

As Described Below Remove as much paint as possible from the damaged area either by stripping (Refer to section 20-10-45.) or with

abrasive cloth

or

paper.

corrosion pits with abrasive

Smooth out all scratches or cloth or paper (320 grit or finer). chrome

Apply

pickle

treatment.

(Refer

to

section

zo-10-05.) A pply

one

coat of wash

primer.(Refer to section 20-30-10.) NOTE

A 1107AI ’UlcrSh primer to dr:y ons hour p~rior to appllling xine chroma.te pr´•i~ner. coats of zinc chromate primer and any color coats. (Itefer to section 20-30-20.) finish I´•eclu i r´•ed

Al,[,ly thr´•ee

Assembled Parts With Minor Scratch Or Abrasion L)amage May Be Reworked As Described Below

Smooth scratches with abrasive cloth or paper (320 grit or finer) keel,ing the reworked area as small as possible.

Cium Plating Cium plated parts damaged by isolated minor scratches and/or abrasions may be used without rework has occurred in a even though minor base metal exposure few of the

damaged

Whenever practicable, parts showing any signs of corrosion must be stripped and replated. (Refer to section 2040-70.) This includes superficial corrosion of the plating Corrosion of the base as well as corrosion of the base metal. metal is evidenced by discoloration on the plate (brown red for steel, bluish-green for copper alloys).

no not destro21 tape or sealing compound ba´•rrier ´•required between dissimilar metal

faying surfacQ.

procedure. Remove corrosion products by first washing with (damp cloth), then rubbing with abrasive paper (:$20 grit or

finer).

Treat with MIL-C-MIO Type II cleaner (diluted with an equal volume of water) for 2-3 minutes; then wipe dry. coat of wash primer (Refer to section one coat of zinc chromate primer and two coats of MIL-L-7178 aluminized lacquer(Refer to

pickle touch-up (Refer to section 20-30-20.) getting solution between faying solution cannot be su rfaces or into pockets where excess and drying. water rinsing removed by thorough A I,l,ly

care

one

to avoid

coat of wash

one

20-30-10.) followed by section 20-30-20.)

Chromium Plating

A r,r,ly chrome

taking

or

Where it is not practicable to replate superficially corroded parts (i.e., white corrosion products only), the part may be reworked in place using the following

Finish with

IW!nlan~

areas.

pri mer. (Refer to section 20-30-10.)

Chromium plating is applied chiefly to provide a hard, smooth bearing surface. Its corrosion properties are generally of a secondary nature. Consequently, parts from which the plating has been removed, or which have corroded due to cracking, scratching or peeling of the ch ram i u m pi ati ng are not acceptable and m ust be str i pped

(12efer

to section

20-40-60.) and replated.

20-40-85 0


Page 3 Aug 31/84

SR-76-023 COKROSION CONTROL MANUAL

REPAIR AND REFINISHING OF ABRADED, SCRATCHED, REWORK%D, OR CORRODED METAL SURFACES (Continued) Chromium Plating (Continued) Scl´•atch or abrasion damage which does not expose the base metal may be removed by buffing, providedthat the required smoothness can be obtained without taking the plating below the min thickness specified on the drawing. Parts which cannot be reworked in this manner must be stripped and replated per drawing requirements. Nickel

Plating

After the second coat is dry to the touch (about 10 minutes) bake the painted area for 15 minutes with infra-red lamps placed 2 in, from the painted surface.

NOTE Where nickel plating is used to prollide a smooth bearing surface, the above paint system is not applicable.

Nickel plating is primarily used to provide corrosion to temperatures above the upper limit far cium. Protection is obtained only as long as the plating is free from cracks, pinholes, or other discontinuities. Whenever practicable, parts on which the base metal has beerl exposed by corrosion, physical damage or rework shall be stripped (Refer to section 20-

protection for parts exposed

40-45.) and replated When it is

procedure

per

impractical

drawing requirements.

to

may be used to

replete the part, the following salvage the part in place.

NOTE Heat discoloration (tl/pically blue-grey to blade) of nickel plating should not be considered as corrosion and will not normally u,arrant refirLishing of such parts. Remove any foreign matter (grease, metal chips, corrosion products, etc.) from the affected area by wiping with

cle;tning solvent (NA~-Ii062) or water depending on the nat.ure of the spoil, If neither is effective, fine abrasive paper (No. 320 or finer)or wire brushing may be used to expose the bright lustre of the base metal.

Wipe the exposed area with undiluted MIL-C-5410 Type II phosphoric acid cleaner until the surface is water break-free. Rinse thoroughly with water (spray or wet cloth) and dry immediately. NOTE Care should be taken to remove all MIL-C5410 cleaner from seams, lapped ts, etc.

Immediately after cleaning, apply two coats of Glidden Angeles, CA) 43~-740 high heat aluminum paint ~,3’ I,1´•ushing or spraying. Feathel´• the paint so as to ovrl´•lap into the nickel plated portion. Allbw 20 minutes dl´•.vinR time between coats. (:O. (IuS

20-40-85 PalSc´•4 Aug 31/84

o

COP~´•IC3MT,


C H A PT E R

ELECTRICAL POVVER

SR-76-023 COKROSION CONTROL IMANUAL

CHAPTER 24 ELECTRICAL POWER TABLE OF CONTENTS Chapte r/Sectio n/Subject

Su hiect

Hattt,rv

Compartment

Page

LOC

’;!4-70-00

Inspect ~attery Compartment

~01

24-CONTENTS o

COPYRIGHT, 1984 BY SAt;r7=LINER CORPORATION

GRID


3B06

SR-76-023 CORROSI()N CONTROL IMANUAL

CHAPTER 24 ELECTRICAL POWER LIST OF EFFECTIVE PAGES THIS ENTIRE CHAPTER HAS BEEN~ REVISED.

Chupteri Section

Page

Date

Chnl,ter d4-L.E.P.

1/’2 Blank

Aug 17jX4

Chapter ~´•1-T.O.C.

t/2 Blank

Aua 17/84

201 and 20;!

Aug 17/84

24-L.E.P. 0

C.OPYRIGHT, 1984 BY SABRELINER CORPORATION



BATTERY COMPARTMENT MAINTENANCE PRACTICES C.

INSPECT BATTERY COMPARTMENT On ~Iodel NA 2(iTj-40 and -60, the batteries are located in the aft fuselage on the lower centerline between FS 369 to the batteries is throu gh the aft fuselage and :itfO. between FS access tlool´•s located on the lower centerline anti ´•1 12.

D,

5.

B.

C,

2.

to

battery

area

Remove masking paper and tape,

F.

Reinstall batteries. (Refer to applicable maintenance

6,

If corrosion is detected, determine the extent and

depth of corrosion damage. If damage exceeds acceptable damage limits, a structural repair of the damaged area must be accomplished. If corrosion damage is within acceptable limits, proceed as follows:

Clean corroded area with alkaline waterbase cleaner. (Refer to Chapter 20,)

inspection aids,

D.

~F3emove corrosion

E.

Sponge area ~vith a mi~uture of ~j ounces of sodium bicarbonate mixed with 1 gallon of water. Keep applying solution until bubbling stops, Allow solution to remain on corroded area for Fi-fi minutes after bubbling has jtopped.

F.

Flush

area

Brush

or

to

T!sina

a

flashlight and mirror

are

indications of

Sponge the

spillage

spilled electrolyte:

area

with clean water.

mixture of ~i ounces of area with sodium bicarbonate mixed with 1 gallon of water. Apply generously until bubbling stops, Allow solution to remain

S1~onRe

on area

for .5-6 minutes after

manual.)

C,

(Refer

B.

E.

Remove

batteries from battery retaining trays applicable maintenance manual.i

If ther´•e

Brush or spray two coats of Everlube No, 1:3~Fill Special on damaged area allowing 10 minutes between coats,

B,

inspect the battery area for evidence of corrosio~, tlanlaKerl or deteriorated paint, or spilled electl´•olvte. -I.

Wipe the entire surface with methyl ethyl ketone (MEK), or equivalent, and dry

Mask off all componentsiareas that could be affected bv corrosion removal chemicals or corrosion residue.

by opening applicable

as

Lightly abrade the damaged or deteriorated with 320 grit emery cloth.

i~.

door.

Remove

Mask all componentslareas adjacent to damarea which could be affected by paint removal solutions or paint residue,

D.

Loo172.

access

access

deteriorated:

thoroughly.

i´•n

C;ain

or

area

Visually inspect the battery compartment/area (See fiKur´•e ~01) for corrosion as follows:

i.

applicable main-

aged

On ~Iodel NA 26Ti-6.i and -80, the batteries are located in the nose of the airplane forward of the bulkhead at FS FjO. Access to the batteries is thru access doors on each side of the fuselage nose section between FS 1:2 and 50.

S/1.~.ILld he

to

manual.)

If paint film is damaged A,

On ~loclel NA dfi.i-70, the batteries ar´•e mounted in a I´•etl´•actuble shelf which is located on the lower centerline aft f F S ~Oti. Access to the batter ies is th rough the! access dool´• on the lower´• centerline between FS ,’()6 and 201i+lS.

cold wnter or a weale solution ofborie ac´•id, If the eyes are involved leash with a stream of luater and consult a physician immedia´•tulU. When ha7tdling potass´•i´•urr~ gloves and np7´•o´•ns idr, f~Lce shields,

Reinstall batteries, (Refer tenance

Access

a The potass´•ill~rrL hydrozide electrolyte rLic/cel cacllnizcm battenJ is uerzJ corrosive. electrolyte is sp´•illed on the hands, the affeceed eloth´•i~iy, ol´• other area should be flooded immediately ´•loZtte

Sponge area again with clean water, then dry surfaces with clean cloths.

bubbling stops,

G,

paint from corroded

ar´•ea.

using chemical and/or mechanical methods, I Refer to Chaptel´• 21).)

511

with clean

water

and dry thoroughly.

spray two coats of Everlube No, 13on damaged area allowing 10 min-

Special

utes between coats.

H,

I.

Remove masking paper and tape,

Reinstallbatteries, (Refertoapplicable mainte,ance

manual.)

24-70-00 0

COPYRIGHT, 1984 BY SABRELINER CORPORAT!~N

Page 201 Aug 17/84


08

-C FS 390

Model NA 265-40 AND -60

FS 357

51

8

Ci3

\I,

FS 206

Model NA 265-70

~T/" oio o;o

o

Fl 36.5

Model NA 265-80 926823-57-14

Battery Compartment Figure 201

24-70-00 Page 202 Aug 17/84

COPYRIGHT,


C H A PT E R

LANDING GEAR


CHAPTER 32 LANDING GEAR TABLE OF CONTENTS Suhjecl LandingCear

Chapter/Section/Subject

Page

$2-00-00

!;rneral Wheel Wells ~Maintenance Practices

1

:32-80-00

In~l,ect ~Iain and Nose(;ear Wheel Wells

201

~P-CONTENTS 0




CHAPTER 32 LANDING GEAR LIST OF EFFECTIVE PAGES ChaDter/ Section

Date

Page

32-I,.E.P.

1/2"

38-CONTENTS

1/2

32-00-00

1" 2" 3" 4"

32-80-00

201/202

Jan 16/87

Aug 17/84 Jan Jan Jan Jan

16/87 16/87 16/87 16/87

Aug 17/84

32-L.E.P. 0


Page 1/2 Blank Jan 16/87


CHAPTER 32 LANDING GEAR GENERAL Exterior surface material and corrosion damage limits on Sabreliner main and nose landing gear are covered in this

chapter. Figure 1 shows the nose the main landing gear.

landing gear and Figure 2 shows

Refer to chapter 20 for general cleaning, sealing, and surface coating procedures.

32-00-00 16/87Psge I 1

o


Jan

SK-7fi-023 (:()RI1()SI()N C()N’I’HOII MANI:AI,

4

s

rO:

c’

h 5

v

O

9

CHROME PLATE

ITEM

NO.

NOMENCLATURE

MATERIAL

MAXIMUM ALLOWABLE CORROSION DEPTH

1

NOSE GEAR PISTON

HIGH H.T. STEEL

0.006

2

NOSE GEAR PISTON (CHROME PLATED AREA)

HIGH H.T. STEEL

0.003

3

NOSE GEAR OUTER CYLINDER

ALUMINUM D.F.

0.015

4

NOSE GEAR ACTUATING CYLINDER

ALUMINUM

0.020

5

NOSE GEAR ACTUATING CYLINDER PISTON

CHROME PLATED STEEL

0.003

TRUNNION

HIGH H.T. STEEL

0.008

ALUMINUM

0.020

6 7

8 g

1 STEERING CYLINDER TOROUE ARMS NOSE GEAR WHEELS

Nose

ALUM FORGING

0.020

ALUMINUM

0.020

Landing Gear Corrosion Damage Limits Figure 1

32-00-00 Page

2

Jan 16/87

o

COPYRIGHT,



i\ 1

i

’6’ i

j

Ii

4

ia

5

6

d~

r

ui

ii

CHROIWEPL~TE

MAXIMUM ITEM

NOMENCLATURE

NO.

MATERIAL

ALLOWABLE

CORROSION DEPTH

i

MAIN GEAR WHEELS

ALUMINUM

0.020

2

TORQUE ARMS

STEEL

0.020

3

MLO TRUNNION AREA

HIGH H.T. STEEL

0.006

4

1 MLOACTUATOR CYL.

ALUMINUM

01020 0.003

5

MLO ACTUATOR PISTON

STEEL

6

MLO OUTER CYL.

HIGH H.T. STEEL

0.006

7

MLO PISTON

HIGH H.T. STEEL

0.003

(CHROME PLATED)

NOTES REFERENCE NUMBERS 2, 3, 6 AND 7 ARE HIGH-HEATTREAT STEEL, 3

280,000 PSI AND ABOVE.

ANY CORROSION DAMAGE ON REFERENCE NUMBERS 5 AND 7 EXCEEDING DEPTH OF THE PLATING SHOULD BE REMOVED FOR STRIPPING, REPAIR. AND RE-

PLATING.

APPLICABLE TO MODEL NA 265-40, -40A, -60, -60A, -60SC, AND -65 Main

Landing Gear Corrosion Damage Limits Figure 2 (Sheet 1 of 2)

32-00-00 a


Page 3 16/87

Jan

SK-76-023 C()KK()SI(I~V (’ONTROL MANUAL

-eI~

ze

v

if

C-1

\e

1/i

3

4

s~ra s

r

3 i´•l

~I

~7

,,-~3C;I I

1’1 i

CHROME PLATE

ITEM

~10.

NOMENCLATURE

MATERIAL


1

MAIN GEAR WHEELS

ALUMINUM

0.020

2

TORQUE ARMS

STEEL

0.020

3

MLO TRUNNION AREA

HIGH H.T. STEEL

0.008

4

MLG ACTUATOR CYL

ALUMINUM

0.020

5

MLO ACTUATOR PISTON

STEEL

0.003

(CHROME PLATED) 6

MLG OUTER CYLINDER

HIGH H.T. 6TE6L

0.008

7

MLG PISTON

HIGH H.T. STEEL

0.003

NOTES

i

REFERENCE NUMBERS 2, 3, 6 AND 7 ARE HIGH-HEATTREAT 5

STEEL, 260,000 PSI AND ABOVE.

ANY CORROSION DAMAGE ON REFERENCE NUMBERS 5 AND 7 EXCEEDING DEPTH OF THE PLATING SHOULD

BE REMOVED FOR STRIPPING, REPAIR, AND REPLATING.

APPLICABLE TO MODEL NA 285-70, -80, -80A, AND -80SC Main

Landing Gear ~orrosion Damage Limits Figure 2 (Sheet 2 of 2)

32-00-00 Page

4

Jan 16/87

o

COPYRIGHT,



WHEEL WELLS MAINTENANCE PRACTICES INSPECT MAIN AND NOSE GEAR WHEEL WELLS

Visually inspect the nose and/or main landing gear wheel wells for corrosion as follows: i.

(;ain

2.

Using an inspection mirror and flashlight as inspec tion aids, visually inspect interiors of landing gear wheel wells for indications of corrosion and deteriorating or damaged protective finishes. Pay particular attention to areas of moisture entrapment and areas where mud and other foreign materials have a tendency to collect.

8.

if cor´•rosion is detected, mask all components/areas which could be affected by corrosion removal chemicals or corrosion residue.

1.

Sti~ip primer/paint from corroded

access

to

landing

(:leun corl´•oded

area

inn solution. Refer

gear wheel well.

area.

using alkaline waterbase cleanto

Chapter 20.)

R.

Remove corrosion using chemical andior mecht~nical methods. (Refer to Chapter 20.)

7.

Apply chemical conversion coating to areas where colrosinn has been removed. (ReEer to Chapter 80.i

Y.

ing

applicable primer/paint to (Refer to Chapter 20.)

match surround-

areas.

Remci\~e maskinR paper and tape.

32-80-00 0



C H A PT E R

DOORS


CHAPTER ~2 DOORS TABI~E OF CONTENTS

Chapter/seetion/subject

Subject Main Entrance Door Corrosion

Inspection

Innight Escape Hatch Removal, Inspection andInetsllatian

Page

62-10-00

201

52~’20-00..............´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•´•

2011

SB-CDNTENTS o


Page 1/2 Blank 9ep g/gl


CHAPTER 52 DOORS LIST OF EFFECTIVE PAGES

Chapter/

Page

Section

Date

62-L.E.P.

1/2’

Sep 6/91

SE-CONTENTS

1/2’

Sep 6/91

52-10-00

201’

Sep 6/91

202

Jan 16/87

201’ 202"

Sep 6/91 Sep 6/91 Sep 6/91 Sep 6/91

62-20-00 Added

203’

Added

204*

52-L.E.P. cc


Page 1/2 Blank Sep 6/91

SR-76-6Z3 CORROSJON CONTROL MANUAL

MAIN ENTRANCE DOOR MAINTENANCE PRACTICES MAIN ENTRANCE DOOR CORROSION

E.

Apply applicable primer/paint finishes to match surrounding area. (Refer to chapter 20.)

F.

Remove masking paper and tape.

G.

Install batt type insulation per dwg. 282530007.

H.

Reassemble mainentrancedoor.

INSPECTION

NOTE Under certain geograpi~ical and enuironmental conditions will ~igR´•-tempemture, salt water or lli0b i~Edustrial conta~ilcation, it may be nectkis essary to increase tke frelFcency of be e~all determination TCris inspection. made by t~e aircraft Owner and/or

10.

Opemtor.

limits, proceed

Visually inspect the interior of the main (see Figure 201) for corrosion as follows:

entrance door

Open main

2.

Carefully lift-up and

3.

Remove

access

remove

stair tread coverings.

s from S/B 86-1 installation

(2 ea.). Remove screws securing stair treads to structure of main entrance door, then remove stair treads from door. Save screws for reinstallation.

Remove all insulation from door

6.

Usingexternal lightsource, inspection mirror, magnifying glass, and any other inspection aids necessary, visually examine all interior areas of the main

entrance door. Carefully examine the interior side of the entrance door outer skin for areas of moisture

entrapment and the faying surfaces between the

door structure and the door outer skin for indications of corrosion between the faying surfaces.

follows:

Mask all components/areas which could be affected by corrosion removal chemicals or corrosion residue.

B.

Strip all paint/primer from corroded

C.

Clean corroded areas using alkaline waterbase cleaner. (Refer to chapter 20.)

D.

Remove corrosion using chemical and/or chanical methods. (Refer to chapter 20.)

E.

Apply chemical conversion coatings where corrosion has been removed.

prior to inspection.

5.

as

A.

entrace door.

1.

4.

If corrosion is detected, determine extent and depth of corrosion damage. If corrosion exceeds damage limits given in chapter 20, a structural repair must be accomplished. If damage is within acceptable

area.

to

me-

areas

(Refer

to

chapter 20.) F.

Apply applicable primer/paint to match rounding area. (Refer to chapter 20.)

G.


H.

Install batt type insulation per dwg. 282530007.

I.

sur-

Reassemblemain entrancedoor.

entrance door for deterioration primer/paint and for cracked or missing sealant between faying surfaces.

7.

Inspect interior finish of main

8.

If no corrosion or damaged paint films are detected, install bat type insulation per dwg. 282-530007 and reassemble door.

9.

If damaged paintfilms are found, proceed asfollows:

adjacent to damaged

A.

Mask off

B.

Removeall

paintfromdamagedarea.

C.

Clean

using alkaline waterbase cleaner.

areas

area

area.

(Refer to chapter 20.) D.

Apply chemical conversion coating area. (Refer to chapter 20.)

to cleaned

52-1 0-00 Page 201 a


Sep 6/91


00000 80008800000

c~S)PI

(AEF. 8/8 861)

O o

NOTE All doors are ilcs~peeted iderttically, regardless of ai~lane model or door collfiguration.

5265-23-37-11

Main Entrance Door Corrosion Inspection Figure 201

52-1 0-00 Page 202 Jan 16/87


83~-76-023 CORROSION CONTROL MANUAL

EMERGENCY EXIT MAINTENANCE PRACTICES INFLIGHT ESCAPE HATCH REMOVAL, INSPECTION AND INSTALLATION

12.

Removal

13.

sump drain and drain closeable container.

Open forward fuselage fuel residual fuel into Remove

access

a

doors and speed brake close out

s. (See Figure 201.) Do;not allow speed brake to swing free. It can result in daneage to tlcfuselage skin at tLe speed brake kinge poi~ct. 1.

For NA

265-60A/SC, -80A/SC and

port the speed brake and

-65 models, supremove

Remove bolts

15.

escape hatch and

16.

Before removing escape hatch, open half way and fuel bladder.

17.

Remove escape hatch from airplane making tape does not stick to fuel bladder.

screws,

securing speed brake closed; then slowly lower the .

seeuring mounting pins.

14.

remove

pins.

sure

Inspection inflight escape hatch (see removal).

v114atllll~Ill

1.

Remove

Clear w~eel well area of equipment and Do not enter speed bmJee area w~en electrical and Icydr&ulic power is applied, or ground safety locks not installed. Anyone stncck by a moving c~eed brake can be serioacsly mfatally injured

2.

Withhatchremoved, carefullyexaminethe infiight escape hatch opening in the fuselage and the hatch

personnel.

2.

For NA 265-40, -60, -70 and -80 models lower brake.

3.

Install

4.

On airplanes S/N 306-142, -143, -145, -146, S/N 38070 and all -65 models go to step 11, otherwise continue with step 5.

5.

Remove floor covering over inflight escape hatch inner door located on fuselage centerline between FS 174 and 206.

speed

itself for indications of cracks and corrosion. 3.

If no cracks or corrosion are noted, install escape hatch per installation instructions.

4.

If cracks and/or corrosion follows:

are

located repair

as

A.

Remove all primer/paint from cracked and/or corroded area(s).

B.

Clean

C.

Remove corrosion chanical methods.

D.

Fabricate

ground safety locks.

area using alkaline waterbsse cleaner. (Refer to chapter 20.)

using chemical and/or (Refer to chapter 20.)

me-

repair parts using approved repair procedures.

6.

Remove all hatch area,

soundproofing and/or insulation from

E.

7.

Drill out rivets around periphery of inflight escape hatch securing pressure seal to hatch.

Apply chemical conversion coatings to repair parts and to areas of inflight escape hatch where primer/paint has been removed.

F.

8.

Remove safety wire securing hatch mounting pins in place,

Prime all repair parts and areas where corrosion has been removed using epoxy polyamide primer. (Refer to chapter 20.)

9.

Remove

G.

Install repairs using cedures.

mountingpinsfrom receptacles infuselage

structure at FS 174.

approved repair

pro-

10.

Allow forward end of hatch to drop down to clear fuselage structure, then move hatch forward to remove from airplane,

H.

Apply epoxy polyamide primer followed by a costing of high impact resistant polyurethane top coating. (Refer to chapter 20.)

11.

Defuel forward fuselage fuel tank on S/N 306-142, -143, -145, -146, S/N 380-70 and all -65 models per applicable Sabreliner Maintenance Manual.

I.

Reinstall inflight escape hatch in airplane per installation instructions.

ILT I IQ

52-20-00 a

COPYRIGHT, 1991 t3Y SABRELINER CORPORATION

Page 201 Sep 6/91

8B-76-023 CORROSION CONTROL ~ANUAL

EMERGENCY EXIT MAINTENANCE PRACTICES INFLIGHT ESCAPE HATCH REMOVAL, INSPECTION AND INSTALLATION (Cont’d)

17.

Apply talc to tack free sealant.

18.

Install secess doors and forward fuselage fuel sump drain. (899 Figure 201.)

Installation 1.

2.

On airplanes S/N 306-142, -143, -145, -146, S/N ~8070 and all -65 models go to step 11, otherwise continue with step 2.

Clear

Make

personnel. Do

sure

sl4ru~

drain is clear and assembled properly.

3.

Lubricate mounting pins with Lubri-bond A.

4.

Slide escape hatch aft on to hinge fittings then push up and install mounting pina, aatety eap~

5.

If any of the

Rubstrips or retainers are in need of replacement, see figure 201 for part numbers.

wLcel well

area

not enter

and of speed bralcc area

udisla sdsch´•ical actd potosr t aplolied. Anyone 8tmcck by a Ioovng speed brake can be seriously or fatally

(9ee Figure 201.)

6.

(Continued)

injureQ 19.

Remavegroundsafetylocka.

20.

Secure

speed brake.

Seal around pressure seal P/N 282-311214-11 and using PR1422GB Sealant.

escape hatch

7.

Install

rubstrips and retainers using rivets P/N

MS20600AD4W4 sized 8.

use

or CR3213-4-4. If holes rivets CR3243-4-4.

Install inaight covering.

Clear

are over-

escape hatch inner door and floor

well

of eqnipnrent and speed brake area when electrical and hydraulic power is applied Anyone struck by a movilcg speed

wheel

personnel. Do brake i~tiured. 9.

area

not enter

can

be seriously

or

fatally

Removeground safety locks.

10.

Secure speed brake.

11.

Apply newtapeP/N 427-2"toescapehatch iftape is worn or

damaged.

12.

Slide escape hatch aft on to hinge fittinffs.

13.

Carefully close

14.

Lubricate mounting pins with Lubri-bond A and install mounting pine and bolts. (599 Figure 201.)

16.

fuel bladder and apply tape around interior perimeter of escape hatch.

16.

Top

escape hatch making bladder does not get pinched.

cost

sure

that fuel

taped perimeter with sealant PR1422GB

and allow to

cure

until tack free.

IIBla8ru;wl8E~´•

52-20-00 Page 202 Sep 6/91

(P

COPYRIGHT, 1991 BY SABRELI’NER CORPORATION

CORROSION CONTROL ~ANUAL

PRESSURE SEAL P/N 282-31121911

RETAINER,

PACKING ANOnlOO

IRm

MOUITIIG

fS 114

PIN

(LOWLRI

RUBSTRIP P/H 202-31121958 RETAINER P/H 9031121939

MOUNTING PIN 285300084

R~CLPTACLLS

14 PLACESI

50887812

I2PLA0E81

(2

(RL9

PUCES)P/I

h

12 PUC9

CAP PACKING

INFLIRHT ESCAPE HATCH

PPLAGESI INACTIVE ESCAPE HITCH ON AIRPLANES

IREF)

WITHOUT FORWARD fUSLLAGE FULL TANK

RUBSTRIP /I 28291141968 RETAINER P/N 202-81121348

RUBSTRIP P/H 2112-31121353 RETAINER P/N 28231121347

RURSTRIP P/N 20231121957 RETAINLR P/N 28231121345

PPLACLS)

12 PLACES)

0/

NOTE

\I,RUBSTRIP P/N 282311213-4~ RETAINER

Inspect all shaded areas for cracks and corrosion.

P/12~2311P1991

fS 208.25

BOLT (2 PLACESI WASHER

I INFLIOHT ESCAPE HATCH

NUT

OUTER DOOR HINGE FITTIIIOS

FS174

(LOWER)

)I

I, I,

HATCH ON AIRPLANES WITH FORWARO

Sj-O-

FUSELAOEFUELTANK IS/H’s 302´•142, -143, -145. MOUNTING

-145. 380-70 AHO ALL ´•65 MODELS)

blN RECEPTACLES

MOUnTIBrlW P/N 26&9#1084

I2 PUGBI

Meun

201-

InfllLht Escape H´•toh ((lheet

1 oi

2)

Isma

52-20-00 cD


Page 208 Sep 6/91

SR-76-02S CORROBION CONTROL YANUAL

$i

t:´•:´•:´•:

ACCESS DOOR 80RWARD FULL CELL ACCESI :2´•:S

FORWIRORSELABI FUEL SUMP DRAII

SPLEO BAAI(I PAWEL

0

r’ 7

II’

I I

IWFLIBHT IIELPE HATCH

FWD

SPEEO BRAWE CLOSE OUT PAIELS

(AcCESS L

SCREWS

IWOT APPLICIBLE 01 S/W 3O8-142. -143. -145. ´•146 AHO S/W 380´•89 AIR SUBS)

ACCESS ODOR FORWARD FULL CLLL IITLRIAL COMPOIERT ACCESSI

IBOTTOM VIEW) MO DEL NA 265-60; S/N 306-1 42. -143, -145, -146 MODEL NA 265-80; S/N 380-69 AND SUBS MODEL NA 265-65; S/N 465-1 AND SUBS

IlalA~

Figun 201

Infli~ht E~ape Hatch (8hect 2 of 2)

52-20-00 Page 204 Sep 6/91


CHAPTER

F USE LAG E

SR-76-023 CORR()SION C()N’I~ROL MANUAL

CHAPTER 53 FUSE LAGE TABLE OF CONTENTS Sut,ject

Chapter/Section/Suhiect

(;enel´•al

:3~-00-00

Page

Foi´•wai´•ti

53-10-00 Fuselage Insl,ect Dulkhead at FS 13 [n~l,ect Lower Longeron anti c,ckpit Interior Belo~v Pilots Slitling Window

CcnterFuselage ~nspectADF LoopAntennaMount

801 401

In~pectCabin Floor Under Main Entrance Door ft Fusela~e Diain Holes In Vertical Hat Section ~iilkheact at FS X:I:i

~01 201

rj3-30-00 on

53-CONTENTS Page 1/2 Blank COPYRIGHT, 1984 BY SABRELINER CORPORATION

Ai~g 17/84


CHAPTER 53 FUSELAGE LIST OF EFFECTIVE PAGES THIS ENTIRE CHAPTER HAS BEEN REVISED.

Chapter/ Section

Page

Date

!:haptel´• .S:-i-I,.E.P.

1/2 Blank

Aug 1784

Chal,ter :i:-:-T.O.C.

1/2 Blank

Aug 17/84

1 thru 10

Aug 17/84

201 and 202

Aug 17/84

201 and 202

20~/204 Blank

Aug 17/134 Aug 17/X4

201/202 Blank

AuR 17/84

53-L.E.P. 0

~OPYRIGHT, 1984 BY SABRELINER CORPORATION

Page ~/2 Blank Aug ~7/84


CHAPT7ER 53 FUSELAGE

GENERAL Materials used on the fuselage external surfaces and the corrosion damage limits for these surfaces are provided in this chapter. Also provided in this chapter are instructions far the examination of specific areas of the fuselage which may be susceptible to corrosion.

Fuselage exterior surface material is shown

on

figure

i.

Corrosion damage limits for the forward fuselage, center fuselage, and aft fuselage are shown on figures 2, 3, and 4 respectively. Refer to Chapter 20 for general cleaning, sealing, and surface coating procedures.

53-00-00 0


Page 1 Aug 17/84


auSs oR PLnsne

ALUMINUM ALLOYS

FleReoLAas UYINITES

CORROSION RES18TANT´•8TECL

APPLICABLE TO MODEL NA 265-40, -40A, -60, -60A, -60SC, AND -65

53-00-00 Page 2 Aug 17/84

Fuselage Exterior Surface Material Figure 1 (Sheet 1 of 2)

o



OLAS[I OR PLASTIC

I:

1

FleREaLASS LAMINATfS

*LUYINUM ALLOYS

CORROSION RESISTI\NT-STEEL

APPLICABLE TO MODEL NA 265-70, -80, -80A, AND -80SC

Fuselage Exterior Surface Material Figure 1 (Sheet 2 of 2)

0

COPYRIGHT,

1984 BY SABRELINER CORPORA.I iuN

53-00-00 age 3

Aug 17/84


FS 206 FS

118.625 FS

1

13

A

MIN

OF

2

IN.

MUST

SEPARATE

CORROSION

ALONG

SPLICE

DAMAGED AREAS.

P

CORROSION

2.

I

2

1.

4

1

50

FS

CORROSION DAMAGE IS LIMITED TO THE FOLLOWING: 5

X

DAMAGE

A

OR

FASTENER ROW MUST NOT INCLUDE MORE THAN 3 FASTENERS IN EACH DAMAGED AREA.

i;l: 8

7

A

3.

MIN

OF 3 UNDAMAGED

L

8

91011

121314

1518

i:´•--t

17

192021

13

22

MAXIMUM ITEM

MATERIAL

NOMENCLATUAE

GAGE

NO.

1

UPPER SKIN

FS 13 TO 50

7178-’76 BARE

0.050

2

UPPER SKIN

FS 50 TO 98

2024-T3 BARE

0.050

3

UPPER 8K!N

FS l?e.cas To 205

4

SIDE SKIN

5

ENTRANCE DOOR SKIN

6

LOWER SKIN

7

SIDE SKIN

FS 13 TO 50

7178-T5 BARE

8

SIDE SKIN

FS 50 TO 76

117~TB BARE

9

EQUIPMENT ACCESS DOOR

7178-T8 BARE

FS 134 tO 158.5

FS 13 TO 50

BARE

OF

AFFECTED

DEPTH

SURFACE

0.004 0.002

0.092 0.005

2024-T3 BARE

0.050

0.002

7178-T6 BARE

P 0.050 10 0.050 M 0.050 O 0.050 D 0.050 m 0.125 m 0.050 m 0.050 m 0.050 O 0.125 Q 0.050 m 0.050 O 0.05y B

7178-t62 BARE

EOUIPMENTACCESSDOOR

7118-78 BARE

11

I

ACCESSDOOR

7178nr BARE

12

1

SIDE SKIN -FS76T0155.25

2024-T3 BARE

2024´•t3 BARE

0.004 0.004 0.004

0.002 0.002 0.002 0.002 0.002 0.002

SIDESKIN-FS98TO134

7178-T6 BARE

15

ENTRY DOOR CENTER LINK COVER

7075-T8 BARE

16

LOWER SKIN

II

SIDE SKIN

18

LOWER SKIN

19

SPEED BRAKE CLOSE-OUT

7178-T8 BARE

0.032

0.003

20

SPEED BRAKE OUTER SKIN

7178-T6 BARE

0.083

0.004

21

LOWER SKIN

FS 158.25 TO 166.25

7178-t6 BARE

0.032

0.003

22

LOWER SKIN

FS 102.813 TO 151

7178-T8 BARE

0.050

23

NOSE GEAR DOORS

2024-T3 BARE

0.032

24

LOWER SKIN

7178-T6 BARE

0.050

14

1

FS 164 TO 206

FS 158.5 TO 206

FS 190 TO 208

FS 25.75 TO 50

7075-T8 BARE 2024-T42 BARE

m

0.005

0.003 0.002

0.003

Lil ii] m P [il Lil O O [il O m m O [il O

50

[iJ Iii M O lil fiI

10

20

ii)

10

10

10

10 10 50

50 50

10 10 to lo

10 to 50

´•co 10

10 to

io

0.003 0.003

O

PERCENT

CORROSION

0.050

1

fS 91.44 TO 159.25

0.050

m m O

24

ALLOWABLE

2024-73 BARE

10

SIDE SKIN

MUST

FAStENERRoWS.

18

13

FASTENERS

SEPARATE CORROSION DAMAGED AREAS ALONG

0.005

20

NOTES D

CHEM-MILLED PART

O

INDIVIDUALCORROSION DAMAGEDAREAS MUST NOT EXCEED 2 SQUARE IN.

O

INDIVIDUALCOAROSION DAMAGEDAREAS MUSTNOT EXCEED 4 SQUARE IN.

APPLICABLE TO MODEL NA 265-40, -40A, -60, -60A, -60SC, AND -65

53-00-00 Page 4 Aug. t7/84

Forward

Fuselage Corrosion Damage Limits Figure 2 (Sheet 1 of 2) o

COPYRIGHT,

i

~B4 BY SABRELINER CORPORATION


CORROSION DAMAGE IS LIMITED TO THE FOLLOWING: 1.

206+17 FS FS

1

50

’B

1

I

3

MIN

OF

2

IN.

MUST

SEPARATE CORROSION

2.

CORROSION DAMAGE ALONG A SPLICE FASTENER ROW MUST NOT INCLUDEMORCTnAN 3 FASTENERS IN EACH DAMAGED AREA.

3.

A MIN Of 3 UNDAMAGED FASTENERS MUST SEPARATE CORROSION DAMAGED AREAS ALONG FASTENER ROWS.

118.625

FS

A

DAMAGED AREAS.

FS

S

4

OR

or

6 7

8 91011

121314

ITEM

1516

17

Is

NOMENCLATURE

NO.

Is 20

MATERIAL

212223

GAGE

1

UPPER SKIN

FS 13 TO 50

7175-T8 BARE

0.050

2

UPPER SKIN

FS 50 TO 98

2024-73 BARE

0.050

3

UPPER SKIN

FS 118.825 TO 206+17

2024-742 BARE

0.050

2024-T42 BARE

0.050

4

1 SIDE SKIN- FS´•134 TO 158.5

24

ENTRANCE DOOR SKIN

1024-T3 BARE

0.050

6

LOWER SKIN

7178-76 BARE

0.050

I

SIDE SKIN

FS 13 TO 50

n7e-ra BARE

o.oso

8

SIDE SKIN

FS 50 TO 76

Tile-re BARE

o.oso

9

ACCESS DOOR

FS 50 TO 78

7178-Te BARE

0.050

D m O

10

ACCESS DOOR

FS 50 TO 78

7178-78 BARE

0.050

O

I ACCESS DOOR-FS76TO90

7178-Te BARE

0.115

2024-73 BARE

0.050

2024-T3 BARE

0.025

14

1 sIDESKIN-FS91.44TO 159.25 1 SIDE SKIN FS 98 TO 134

7178-T8 BARE

0.050

15

I

O O D O D D D D

11 12 13

SIDE SKIN

FS Is TO 155.25

ENTRYDOORCENTER LINKCOVER

2024-742 BARE

0.190

is

LOWER SKIN

2024-73 BARE

0.050

17

SIDE SKIN

2024-T42 BARE

0.050

FS 161 TO 208

FS 158.5 TO 508+17

18

ACCESS DOOR

FS 208

2024-t42 BARE

0.050

19

ACCESS DOOR

FS 190 TO 208

2024-T42 5c~RE

0.050

20

ACCESS DOOR

FS 208+17

2024-742 BARE

o.oJo

21

1

SPEED BRAKE CLOSEOUTSKIN

7178-76 BARE

0.032

22

SPEED BRAKE

7178-Te BARE

0.064

23

ACCESS DOOR

24

LOWER SKIN

25

7178-Te BARE

0.050

7178-78 BARE

0.050

NOSE GEAR DOOR

2024-T42 CLAD

0.032

26

LANDING LIGHT DOOR

2024-T42 CLAD

0.071

27

ACCESS DOOR

8081-T4 BARE

0.050

FS 150 TO 158.55

FS 102.8 TO 15.1

FS 24.6 TO 35.5

m P

2627

MAXIMUM ALLOWABLE CORROSION

OF AFFECTED

DEPTH

SURFACE

m O m

5

FS 13 TO 50

25

PERCENT

0.004

o

so

0.002

[il

10

o.oonm aocs Cil o.ooz

R

D D 0.004 rs 0.002 O 0.002 O 0.001 O 0.002 O 0.002 m 0.002 [il 0.005 D 0.003 O 0.002 Iii 0.003 O 0.003 1~ 0.003 O 0.003 lil 0.004 [jl 0.003 O 0.050 O 0.003 D o.oos [il o.oos Iii

to to ´•lo

o.oM

50

o.oos

so so

10

10 10 10 to

10 50 10 10 10 10 10 10 10

20 10 to

20 to

NOTES O

CnEM-MILLED PART

Iii

INDIVIDUALCORROSION DAMAGEDAREASMUSTNOT

D

INDIVIDUALCORROSION DAMAGEDAREAS MUSTNOT EXCEED4SQUAREIN.

EXCEED 2 SQUARE IN.

APPLICABLE TO MODEL NA 265-70, -80, -80A, AND -80SC Forward

o

COPYRIGHT, 1984

Fuselage Corrosion Damage Limits Figure 2 (Sheet 2 of 2)


53-00-00 Page 5 Aug 17/84

SR-7fi-02:-3 C()KK()SI()N C()NTROL MANUAL

CORROSION DAMAGE IS LIMITED TO THE FOLLOWING: i.

A

MIN

MUST

Of 2 1N.

SEPARATE CORROSION

DAMAGED AREAS. 2.

CORROSION DAMAGE ALONG A SPLICE OR FASTENER ROW MUST NOT INCLUDE MORE THAN 3 FASTENERS IN EACH DAMAGED AREA.

3.

MIN OF 3 UNDAMAGED FASTENERS MUST SEPARATE CORROSION DAMAGED AREAS ALONG A

FASTENER ROWS.

,--’7 I

D

II

3 I

o

ITEM

NO.

MATERIAL

NOMENCLATURE

2024-T3 BARE

O.oJo

2024-t3 BARE

0.050

DORSAL FIN SKIN

7178-T8 BARE

0.032

4

LOWER SKIN

2024-T3 BARE

0.050

5

LOWER SKIN -FS258.4T0308.1

7178-’768486

O.oJo

6

LOWER SKIN FS 308.1 TO 357

2024-T3 BARE

0.050

i

UPPER SKIN

2

SIDE SKIN

3

FS 206 TO 357

GAGE

FS 206 TO 357

FS 206 TO 258.4


13 o

0.001 0.002 o.oos

0.003

O O

0.003 0.003

O o O O O O

8

PERCENT OF AFFECTED SURFACE 10 lo so

50 10 10

NOTES O

CHEM-MILLED PART

O

INDIVIDUALCORROSION DAMAGEDAREASMUSTNOT

EXCEEDPSQUAREIN. INDIVIDUALCORROSION DAMAGEDAREASMUSTNOT

EXCEED4SQUAREIN.

APPLICABLE TO MODEL NA 265-40

53-00-00 Page ~ua 17/a4

Center Fuselage Corrosion Damage Limits

Figure

3

(Sheet 1 of 3)

6

o


SR-76-023 CORROSION CONTROL MAWUAL


CORROSION DAMAGE MUST NOT EXCEED 10% OF AFFECTED SURFACE AREA.

2.

INDIVIDUAL CORROSION-DAMAGED AREAS MUST

3.

A

NOT EXCEED ?SOUARE IN. MIN

OF

2

IN.

MUST

SEPARATE

CORROSION

ALONG

SPLICE

DAMAGED AREAS. 4.

CORROSION

DAMAGE

A

OR

FASTENER ROW MUST NOT INCLUDEMORETnAN 3 FASTENERS IN EACH DAMAGED AREA. 5.

A

MIN

OF

3

UNDAMAGED

FASTENERS

MUST

SEPARATE CORROSION DAMAGED AREAS ALONG FASTENER ROWS.

0‘ 3

MAXIMUM ITEM

NO.

NOMENCLATURE

1

UPPER SKIN

2

SIDE SKIN

3

LOWER SKIN

4

FS 206 TO 359

MATERIAL

GAGE

O O

ALLOWABLE

CORROSION DEPTH

2024-73 BARE

0.050

2024-73 BARE

0.050

FS 298 TO 333

2024-73 BARE

0.050

0.003

LOWER SKIN

FS 333 TO 357

2024-73 BARE

0.050

0.003

5

LOWER SKIN

FS 257.5 TO 298.5

7178-78 BARE

0.050

0.003

8

LOWER SKIN

FS 206 TO 257.5

2024-73 BARE

0.050

0.003

I

LOWER SKIN

FS 206 TO 206+17

7075-78 BARE

0.050

0.003

FS 208 TO 298.5

0.002 0.002

NOTE D

CHEM-MILLED PART

APPLICABLE TO MODEL NA 265-60, -60A, -60SC, AND -65 Center Fuselage Corrosion Damage Limits Figure 3 (Sheet 2 of 3) m

COPYslC-HT. 1984 B’,’ "ABRELINER CORPORATION

53-00-00 Page 7 Aug 17/84

SR-76-0~3 C()RK()SI()N C()NTROL MANUAL

CORROSION DAMAGE IS LIMITED TO Tn E FOLLOWIN G: i.

A

OF 2

MIN

IN.

MUST SEPARATE

CORROSION

DAMAGED AREAS. 2.

CORROSION

DAMAGE

ALONG

A

SPLICE

OR

FASTENER ROW MUST NOT INCLUDE MORE THAN 3 FASTENERS IN EACH DAMAGED AREA. 3.

A

MIN

OF 3

UNDAMAGED

FASTENERS

MUST


D

a

S

MAXIMUM ITEM

MATERIAL

NOMENCLATURE

NO.

GAGE

OF

CORROSION DEPTH

AFFECTED

2024-73 BARE

0.050

2024-73 BARE

0.050

DORSAL FIN SKIN

7178-78 BARE

0.032

0.005

1

UPPER SKIN

2

SIDE SKIN

3

FS 206+17 TO 357 F.C "06+17 TO 357

n O

PERCENT

ALLOWABLE

0.002 0.002

4

LOWER SKIN

FS 298.5+21 TO 333.625

2024-742 BARE

0.050

0.003

5

LOWER SKIN

FS 298.5 TO 333.825

2024-742 BARE

0.050

0.003

8

LOWER SKIN

FS 298.5 TO 298.5+21

7178.78 BARE

0.050

0.003

7

FAIRING SKIN FS 208+17 TO 284.25

2024-73 BARE

0.050

0.003

tit [il M O (il m O

SURFACE 10

10 50 10 10 10 10

NOTES m

CHEM-MILLED PART

o

INDIVIDUALCORROSION DAMAGEDAREASMUSTNOT EXCEED 2 SQUARE IN

B

INDIVIDUALCORROSION DAMAGEDAREASMUSTNOT EXCEED 4 SQUARE IN.


53-00-00 Page

Center

Fuselage Corrosion Damage Limits Figure (Sheet 3 of 3)

X

17;X´•L

o



CORROSION DAMAGE IS LIMITED tO THE FOLLOWING: 1.

A

MIN

OF 2 IN.

MUST

SEPARATE CORROSION

DAMAGED AREAS. 2.

1

CORROSION

DAMAGE

ALONG

A

SPLICE

OR

FASTENER ROW MUST NOT INCLUDEMOAETHAN 4

3

3 FASTENERS IN EACH DAMAGED AREA.

5

3.

A MIN OF 3 UNDAMAGED FASTENERS MUST SEPARATE CORROSION DAMAGED AREAS ALONG FASTENER ROWS.

10

11

ITEM

NOMENCLATURE

NO.

MATERIAL

GAGE


DORSAL FIN SKIN

T07J-T8 BARE

2

UPPER SKIN

FS 357 TO CANT STA 457.408

7178-T6 BARE

0.031m 0.040 O

0.003

3

UPPER SKIN

FS 118.625 TO 206+17

7178-T6 BARE

0.040

0.005

4

UPPER FAIRING

FWD

7178-78 BARE

0.040

s

UPPER FAIRING

AFT

7178-To BARE

0.040

8

UPPER SKIN

7

AFT SKIN

8

LOWER SKIN

g

SIDE SKIN

10 11

I

FS 485 TO 505

o.oos

so

m O I~j O O O O

0.005

13

PERCENT OF AFFECTED SURFACE

0.005

to 50 so 50

MAGALLOYSHT

0.040

0.005

7178-78 BARE

0.040

0.005

717a-T6 BARE

0.040

CANT STA 451.408 TO FS 505

MAGALLOYSHT

0.050

0.005

50

SIDE SKIN


MAGALLOYSHT

0.050

0.005

50

SIDE SKIN


7178-T8 BARE

0.040

7178-78 BARE

0.040

0.003

iii ii]

INNER SKIN

2024-T42 CLAD

0.025

0.005

O

50

OUTER SKIN

2024-T42 CLAD

0.025

0.005

O

50

FS 504 TO 519

CANT SfA 457.406 TO FS 505

1?

LOWER SKIN

13

AFT FUSELAGE ACCESS DOOR


IP

m

0.005

0´•003

50 50 50

10 10

NOTES CHEM-MILLED PART

O

INDIVIDUALCORROSION DAMAGEDAREASMUST NOT EXCEEDPSQUAAEIN.

O

INDIVIDUALCORROSION DAMAGEDAREAS MUSTNOT EXCEED 4 SQUARE IN.

APPLICABLE TO

~ODEL

NA

265-40, -40A, -60, -60A, -60SC, AND

Aft Fuselage Corrosion

Figure

4

Damage Limits (Sheet 1 of 2)

5265-23-53-6

-65

53-00-00 Page

0

COPYRIGHT, 1984 BY SABRELINER

9

CORPORA’;Aug 17/84

SR-7fi-02.3 C()KR()SI()N CONTROL MANUAL

2

a,

_

~/S CORROSION DAMAGE IS LIMITED tO THE FOLLOWING: 1.

A

OF

MIN

2

IN.

MUST SEPARATE

CORROSION

DAMAGED AREAS. 2.

6 7


3.

i

MIN OF 3 UNDAMAGED FASTENERS MUST SEPARATE CORROSION DAMAGED AREAS ALONG A

FASTENER ROWS.

J

ITEM

MATERIAL

NOMENCLATURE

NO.

1

DORSAL FIN SKIN

2

UPPER SKIN

3

UPPER FAIRING

4

12

1

FS 357 tO CANT STA 457.406 FWD

UPPER FAIRING-ACT FS 485 TO 509

GAGE


7075-78 BARE

0.032

m

o.oos

2024-73 BARE

0.040

0.003

2024-73 BARE

0.040

O 81

2024-742 BARE

0.040

2024-T42 BARE

0.040

2024-742 BARE

0.040

2024-742 BARE

0.040

2024-742 BARE

0.040

o.oos 0.005

D

0.005

s

UPPER SKIN

6

AFT SKIN

7

LOWER SKIN

B

SIDE SKIN

9

ACCESS DOOR


2024-742 BARE

0.040

0.005

1 ACCESSDOOR

FS485

2024-742 BARE

0.040

0.005

2024-T3 BARE

0.040

m

0.003

7178-T6 BARE

0.040

O

0.003

INNER SKIN

102eT42CLAD

0.025

0.005

OUTER SKIN

2024-T42CLAD

0.025

0.005

10

FS 509 TO 522.5



11

SIDE SKIN

12

LOWER SKIN

13

1



0.005

D D

0.005

PERCENT

OF AFFECTED

SURFACE

o O

so

o O O

so

O 1~

50

0.005

10

50 50

50 50

O O D O

50

N O

50

50 to

10

AFT FUSELAGE ACCESS DOOR

50

NOTES CHEM-MILLED PART

iii

INDIVIDUALCORROSION DAMAGEDAREAS MUSTNOT EXCEED 2 SQUARE IN.

[R

INDIVIDUALCORROSION DAMAGEDAREAS MUSTNOT

EXCEED 4 SQUARE IN.


53-00-00 Page LO Aug 17/84

Aft Fuselage Corrosion Damage Limits Figure 4 (Sheet 2 of 2) c

COPYRIGHT. 1984 BY SABRtlil\jER CORPORATION


FWD FUSELAGE MAINTENANCE PRACTICES INSPECT BULKHEAD AT FS 13

4.

corrosion i.

2.

as

follows:

Remove

access

s from inboard sides of left and

right hand consoles in cockpit.

Visually inspect the bulkhead at FS 13(see figure 201) for 5.

Remove

access

doors

fuselage between FS

on

left and right sides of

76 and 90.

Gain access to bulkhead at FS 13 by removing radome on forward side of bulkhead and electrical bay access doors on both sides of fuselage aft of bulkhead at FS 13.

6.

Remove reveal below the pilot’s sliding window.

7.

Using an inspection mirror and flash light as inspection aids, visually inspect both forward and aft sides of bulkhead paying particular attention to lower portion of bulkhead.

Using a flashlight and mirror as inspection aids, inspect the lower longerons between FS 98 and 143, and the area below the pilot’s sliding window, for

8.

evidence of corrosion.

Inspect all exposed areas for damaged primer/paint films.

or

deteri-

orated

NOTE

9.

Remove any componentlequipment interfering with visual inspection of either side of bulkhead. If there is no indication of corrosion attack, reinstall removed components, radome and access doors, 4.

5.

Ifcorrosion isdetected, mask all components/areas which could be affected by col´•rosion removal chemicals or corrosion residue.

Strip primer/paint from corroded

If

no

corrosion is found,

paint films

as

repair damaged primer/

necessary and reinstall

removed

components. 10.

If corrosion is found, determine extent and depth of corrosion damage. If corrosion exceeds acceptable damage limits, a structural repair of the damaged area must be accomplished. If damaged is within acceptable limits, proceed as follows: A.

Mask off all coitlrJonenis,lareas

damaged by corrosion or

area.

which could be

removal chemicals

and/

corrosion residue.

B.

Remove all primer/paint from corroded

cleaning solution. (Refer

C.

Clean corroded

7.

Remove corrosion using chemical and/or mechanical methods. (Refer to Chapter 20.)

area using alkaline waterbase cleaner. (Refer to Chapter 20.)

D.

8.

Apply chemical conversion coating

Remove corrosion using chemical andior mechanical methods. (Refer to Chapter 20.)

E.

Apply chemical conversion coating to all areas where corrosion has been removed. (Refer to

F.

Apply epoxy polyamide primer followed by a coating of high impact resistant polyurethane top coating. (Refer to Chapter 20.)

G.


6.

Clean corroded

area

using alkaline waterbase to Chapter 20.)

to areas where

corrosion has been removed. 9.

10.

Apply applicable primer/paint ing area. (Refer to Chapter 20.)

to match surround-

Remove masking paper and tape; then reinstall removed components, radome and access doors.

INSPECT LOWER LONGERONS AND COCKPIT INTERIOR BELOW PILOT’S SLIDING WINDOW

Inspect the lower longerons between FS 98 and 143 and the cockpit interior below the pilot’s sliding window for

evidence of corrosion

as

follows:

1.

Remove both the pilot’s and copilot’s seats.

2.

Remove carpet and pac’ from cockpit floor.

3.

Remove floor s from cockpit floor to gain

to lower

area.

Chapter 20.)

H.

Reinstall access

on left side of cockpit: floor s, s on inboard sides of consoles; pads

and carpet; seats: and the two the outside of the airplane.

access

doors

on

access

longerons.

53-10-00 o

COPYRIGHT,


Page 201 Aug 17/84

SR-76-023 C()IIII()SI()N C()NTROL MANUAL

ooo""

FS

~ii8:i fifi

INSPECT SH*DEI)

(BOTH SIDES)

SZ66-2557LO

Bulkhead of FS 13 F;rr~re 201

53-1 0-00 Page 202 Aug 17/84

o



CENTER FUSELAGE MAINTENANCE PRACTICES

INSPECT ADF LOOP ANTENNA MOUNT

1.

Lift-up floor covering to expose area to be inspected. Start at out-board corner (adjacent to bulkhead at

Examine edges of ADF LOOP ANTENNA bonded doubler (see figure 201) and areas of fuselage upper skin adjacent to the bonded doubler on fuselage upper centerline between FS 224.5 and 242 for evidence of corrosion as fol lows:

2.

Examine exposed

3,

Remove sealant, using a non-metallic scraper, from periphery of ADF Loop Antenna and doubler

If corrosion is not detected, re-cement floor in place.

4.

If corrosion is found, determine extent and depth of damage. If damage is beyond acceptable limits, install approved structural repair over damaged

1.

FS 143). Use caution to not

installed under antenna, 2.

Inspect edges of antenna doubler and fuselage skins adjacent to doubler for evidence of corrosion. A.

If

corrosion is found, reseal using sealant (PR-341, Pro-Seal-730, EC-1547 or equivalent), prime and finish using applicable primer and topcoat. (Refer to Chapter 20 for application no

5.

If corrosion is within acceptable limits, proceed follows:

as

Using methyl ethyl ketone (MEK)or any other acceptable solvent, remove floor covering cement remaining on cabin floor.

If corrosion is found, remove antenna to determine severity of corrosion damage.

B.

Mask off all areas which could be damaged by corrosion removal chemicals or corrosion residue.

If corrosion damage is less than 0.010 in. depth, a structural repair will be required within the next 100 fliyhi ilours, providing corrosion control measures are

C.

accomplished immediately. (2)

If damage exceeds 0.010 in.

immediately. Remove all corrosion, using chemical mechanical methods, (Refer to Chapter 20.)

D.

Apply chemical

conversion

coating. (Refer

Remove all

damaged

paint/primer from corrosion

area.

D.

Clean corroded area using alkaline waterbase cleaner. (Refer to Chapter 20.)

E.

Remove corrosion using chemical mechanical methods. (Refer to Chapter 20.)

F.

Apply chromate conversion coating to areas where corrosion has been removed. (Refer to

depth, repair

C.

or

or

Chapter 20.) to

G.

Apply primer applicable to existing paint Chapter 20.)

Apply epoxy polyamide primer followed by a coating of high impact resistant polyurethane top coating. (Refer to Chapter 20.)

H.

Remove masking paper and tape; then cement floor covering in place.

Chapter 20.) system. (Refer to F.

covering

A.

(1)

E.

damage floor covering.

for corrosion.

area.

procedures.) B.

areas

Apply finish top coat to match surrounding area.

(Refer

to

Chapter 20.)

INSPECT CABIN FLOOR UNDER MAIN ENTRANCE DOOR Cot´•rosion of the cabin floor inboard of the main entrance door (see figure 202) may be caused by moisture entering through an open main entrance door and/or by foot traffic during wet weather conditions. This could saturate the floor coverings; thereby providing all the ingredients for corrosive attack. To

visually inspect the cabin floor inboard of the main door between FS 143 and 174, proceed as

entrance

follows:

53-20-00 0


Page 201 Aug 17/84


INSPECTION FOR CORROSION REOUIRED AROUND THE AFT LOOP ANTENNA ONLY. AFT ADF LOOP ANTENNA FWD ADF LOOP ANTENNA

,FS 242

(008)

o

AFTADFLOOPANTENNA FS 224.5

REMOVE SEALANT FROM THIS AREA.

DO NOT REMOVE THIS SEALANT

USE A NONMETALLIC SCRAPER.

REMOVE SEALANT FROM THIS AREA. USE A NONMETALLIC SCRAPER.

INSPECT FOR CORROSION AROUND THE ENTIRE EDGE OF THE 882-911207-)15 OOUBLER AND ON THE FUSELAGE SKIN

282-311207-25

DOUBLER (REF)

NEXT TO THE DOUBLER.

FUSELAGE SKIN

FUSELAGE FRAME

(REF)

(REF)

FS 224.50

O

O

AFT ADF LOOP ANTENNA

O

O

282-311207-25 DOUBLER

O

O

INSPECT fOR CORROSION AROUND THE ENTIRE EDGE OF 282-311201-25 DOUBLER AND ON THE FUSELAGE SKIN NEXT TO THE DOUBLER.

FUSELAGE SKIN

(REF)

S26.5´•9%-57-15

ADF Loop Antenna Mount Figure 201

53-20-00 Page 202 Aug 17/84

o

COPYRIGHT, 1984 BY SABHELINER C0;103RATION

SR-76-023 COKROSI()N C()NTROL MANUAL

an´•´•´•~

~1

B 3

FWD IFWI)

FLOOR LINE FS

VIEW LOOKING OUTED At MAIN

143

ENtRYDOOR

FLOOR LINE FS 174

8266-23-67-11

Cabin Floor

FS 143 to 174

Figure

202

53-20-00 0

COPYRIGh

i,




AFT FUSELAGE MAINTENANCE PRACTICES

DRAIN HOLES IN VERTICAL HAT SECTIONS ON BULKHEAD AT FS 333

Drain holes through the web below the vertical hat sections have been provided on Model NA 265-40, S/N 128 a"d SUbs; -60, S/N 126 and subs; -65, all S/N’s; and -80, S/N 380-55 and subs to eliminate moisture entrapment in the vertical hat sections. On airplanes which do not have the drain holes in the lower webs, drain holes may be drilled through the lower webs; using the applicable dimensions shown below to locate the drain holes.

Because of the continuing temperature variations between the cabin and the aft fuel cell area, the vertical hat sections on the aft side of the bulkhead at FS 338.625 have a tendency to collect and retain moisture (condensation)

inside the hat.

Use estreme care in locating and drilling drain holes. Make certain holes enter into hat section and not into fuel cell area.

BP 19 7/8

BP10

i__L

BP10

90197/9

FS 333.625

__

t

0.0g2

I

1.375

0.250 DIA HOLE

i

(5 PLACES)

VIEW LOOKING DOWN

FS 357

MODELS NA 265-40 AND -60

BP?O

BP10

0.160

2) I

c

BP 10

0.190

I~e 0.160

~cl

BP 20

0.190

II

ICc0.160 rl

FS333.625

~iZ 0.250 DIA HOLE VIEW LOOKING DOWN

(5 PLACES)

FS 357

MODELS NA 265-70 AND -80 Vertical Hat Section Drain Holes

Figure

o

COPYRIGHT,


201

53-30-00 Page 201/202 Blank Aug 17/84

CHAPTER

NACELLES PYLONS

SR-76-023 CORRL)SI()N C()NTROL MANUAL

CHAPTER 54 NACELLES AND PYLONS TABLE OF CONTENTS Suhject


(;eneral

54-00-00

Page

Rel,air Procedures

54-CONTENTS C,OPYRIGHT, 1984 BY SABRELINER CORPORATION



CHAPTER 54 NACELLES AND PYLONS LIST OF EFFECTIVE PAGES THIS ENTIRE CHAPTER HAS BEEN REVISED.

Chapter/ Section

Page

Date

Chapter 54-L.E.P.

1/2 Blank

Aug 17/84

Chapter

1/2 Blank

Aug 17/84

li4-00-00

Tj4-T.O.C.

1 thru 6

Aug 17/84

7/8 Blank

Aug 17/84 Aug 17/84

801/802 Blank

54-L.E.P. 0




CHAPTER 54 NACELLES AND PYLONS

GENERAL

Specific repair procedures peculiar to nacelle/pylon components are also included in this chapter.

Exterior surface material and corrosion damage limits for Sabreliner nacelles and pylons are covered in this chapter. (See table 1 for figure reference.)

Table

Refer to Chapter 20 for general cleaning, sealing, and surface coating procedures.

Surface Material and Corrosion Damage Limits Figure References,

MODEL

S/N EFF.

EXTERIOR

CORROSION

SURFACE

DAMAGE

MATERIAL

LIMITS

NA 285-40

All

Figure i

Figure

4

NA 265-40A

All

Figure

1

Figure

4

NA 285-60

All

Figure 1

Figure

4

NA 265-604\

All

Figure

1

Figure

4

NA 265-60SC

All

Figure

i

Figure

4

NA 265-65

All

Figure 2

Figure

5

NA 265-70

370-2 thru -6, -8, and -9

Figure

1

Figure

4

NA 285-70

370-7

Figure 3

Figure

6

NA 265-80

All

Figure

3

Figure

6

NA 265-80A

All

Figure

3

Figure

6

NA 265-80SC

All

Figure

3

Figure

6

54-00-00 o

CO’PYRIGHT,


Page 1 Aug 17/84


ALUMINUM ALLOYS

CORROSION RESISTANT STEEL

E~

BONEYCOMB

LOWER VIEW

UPPER VIEW setis-ea´•j´•1-a

Pylon and Nacelle Fabrication Material (JT-12 Engines) Figure 1

54-00-00 Pag,

4

Aug 17/84

o

COPYRIGHT,



LI

C

ALUMINUM ALLOY

E~l;

CORROSION RESISTANT STEEL

"~lon and Nacelle Fabrication Material (TFE 731 Engines) Figure 2

54-00-00 Page 3 0

COPYRIGHT, 1984 B1’

3~BRELINER

CORPORATION

Aug 17/84


t~l

*LUMINUMALLOYS CORROSION RESISTANT-BTEEL

I’:-

i--:---:-

’1

HoNevcoMe

/////X/////’/

/i/

:i z

z

;’/Lr

i

i

S285-2S54-~I

Pylon and Nacelle Fabrication Material (TF-700 Engines) Fiffure 3

54-00-00 Page

4

Aug 17/84

o

COP~HIGHT, 1984

BY SABRELINER CORPc/;iATION



A

MIN

OF 2 IN. MUST SEPARATE CORROSION

DAMAGED AREAS. 2.

CORROSION

DAMAGE

ALONG

A

SPLICE

OR 10

FASTENERROWMUSTNOTINCLUDEMORETnAN 3 FASTENERS IN EACH DAMAGED AREA.

3.

A

MIN

OF 3 UNDAMAGED

/j L57

9

FASTENERS

O-

MUST


2

3 18

14 14

‘7 o

1

~´•jr$

8

B s

c

15

11 13

MAXIMUM ITEM

NOiriENCiAViiRe

NO.

MATERIAL

dAOE

ALLOWABLE CORROSION DEPTH

1

PYLON L. E. SKIN

2024-T4 CLAD

0.040

0.008

2

PVLON UPPER FWD SKIN

7178-T8 EARE

0.050

0.002

3

PYLON t. E. SKIN

2924-742 CLAD

0.012

0.006

4

PYLON LOWER FWD SKIN

7178-78 BARE

0.100

O

0.002

5

NACELLE SKIN-LOWER FWD

7178-78 BARE

0.040

O

0.006

NACELLE SKIN LOWER INtERM.

7178-T6 BARE

0.040

0.008

17-7 PH ORES

0.020

0.002

6

7 8

9

I

NACELLE SKIN

UPPER AFT

NACELLE SKIN LOWER AFT

1 NACELLE INBOARDSKIN

17-7 PH ORES

0.020

17-7 PH ORES

0.040

0.002

O

0.005

ill

iii O O iii [11 O

10

1 NACELLE SKIN

7176-76 BARE

0.040

0.006

11

I NACELLE NOSE

FWD OUTED

2024-74 BARE

0.040

0.003

12

NACELLE NOSE

FWD OUTED

6081-T3 BARE

0.040

0.004

13

NACELLE DOOR: FWD OUTED

1’1-7 PH CRES

0.020

0.002

NACELLE DOOR FWD INBD

17-7 PH CRES

0.020

0.002

lil Iii O

17-7 PH CRES

0.050

m

0.004

m

17-7 PH CRES

0.050

El

0.004

iii

UPPER

INTERM.

14 15

I ENOINEBEAM-

18

1 ENOINEBEAM-

OUTER SKIN INNER SKIN

13 [11

NOTES m

CHEM-MILLED PART

iii

INDIVIDUALCORROSION DAMAGEDAREASMUSTNOT EXCEED 2

SdUARE

IN. szes-23-u-1

INDIVIDUALCORROSION DAMAGEDAREASMUSTNOT EXCEED 6 SQUARE IN.

Pylon and Nacelle Corrosion Damage Limits (JT-12 Engines) Figure 4

0


54-00-00 Page 5 Aug 17/84


Z

2

Is

/6

,’7

15

14

13

ri

i

UPPER SURFACE

S L

i"

21

I1

7

’1

/1

PYLON

11:

8

20

19

9 lo 11

NACELLE 22

12 27

28

?6

24

?5

23

LOWER SURFACE 32

31

30

29

MAXIMUM ITEM

NOMENCLATURE

NO.

MATERIAL

GAGE

ALLOWABLE

CORROSION DEPTH

1

NOSE COWL UPPER SKIN

2024-76 COS

2

UPPER COWL SKIN

2024-76 COS

3

AFt COWL UPPER SKIN

2024 OC

4

THRUST REVERSER UPPER DOOR SKIN

2024-76 COS

5

THRUST REVERSER LOWER DOOR SKIN

2024-76 COS

1

0.125

8

COVER, AFt COWL

2024 OC

1

0.050

7

AFT COWL LOWER SKIN

2024 OC

8

COVER, AFT COWL COVER, AFt COWL

2024-73 C

9

I

0.050 0.063

1

0.125

0.025

1

0.050

2024-T3C

0.050

10

1 LOWER COWL DOOR SKIN

2024-76 COS

0.063

11

1 NOSE COWL LOWER SKIN

2024-76 COS

0.050 0.050

12

NOSE COWL L.E. SKIN

302/321 CRES

13

UPPER PVLON T.E. SKIN

2024-T42CLAD

14

UPPER PYLON SKIN

301 CRES

0.050

15

UPPER PVLON SKIN

301 CRES

0.050

16

UPPER PYLON SKIN

301 CRES

0.050

17

UPPER PYLON SKIN

2024-742 CLAD

0.050

18

PYLON L.E. SKIN

2024-742 CLAD

0.040

19

i DOOR ASSEMBLY

2024-742 CLAD

0.040

20

1 UPPER AFT ENGINE ACCESS DOOR

301 CRES

0.050

21

1 UPPER PYLONDOOR

301 CRES

0.050

2024-T42 CLAD

0.040

301 CRES

0.040

22 23

DOOR ASSEMBLY 1 LOWER AFT ENGINE ACCESS DOOR

O

0.025

1

O

0.040

24

LOWER PYLON DOOR

301 CRES

0.050

25

LOWER PYLON SKIN

301 CRES

0.050

28

LOWER PYLON DOOR

2024-742 CLAD

0.050

27

LOWER PYLON SKIN

2024-742 CLAD

0.050

28

LOWER PYLON DOOR

2024-742 CLAD

0.050

29

LOWER PYLON T.E. SKIN

2024-742 CLAD

0.040

30

LOWER PYLON SKIN

301 CRES

0.050

31

LOWER PYLON SKIN

301 CRES

0.050

32

1 LOWER PYLON SKIN

301 CRES

0.050

NOTE O

CHEM-MILLED PART

Pylon and Nacelle Corrosion Damage Limits (TF Figure 5

731

Engines)

54-00-00 PaRr

6

Aug 17/84

COPYRIGHT.

1984 BY SABRELINER CORPORATlOh


078 CORROSION DAMAGE IS LIMITED TO THE FOLLOWING: 1.

A MIN


DAMAGED AREAS. 2.

CORROSION

DAMAGE

ALONG

A

SPLICE

OR

FASTENER ROW MUST NOT INCLUDEMORETHAN 3 FASTENERS IN EACH DAMAGED AREA.

5

3.

4

10

3

t

1;

MIN OF 3 UNDAMAGED FASTENERS MUST SEPARATE CORROSION DAMAGED AREAS ALONG

A

FASTENER ROWS.

11

MAXIMUM ITEM

NOMENCLATURE

I(O.

MATERIAL

CAGE


88

1

PYLON UPPER FWD SKIN

5AL-4V Ti

0.032

0.004

2

PYLON UPPER FWD DOOR

2024-73

0.050

0.005

3

PYLON UPPER SKIN

8AL-4V T1

0.050

0.005

4

PYLON UPPER AFT SKIN

2024-73 CLAD

0.050

0.005

5

PYLON T.E. SKIN

2024-73 CLAD

0.032

0.004

8

PYLON LOWER AFT SKIN

2024-73 CLAD

0.050

0.005

7

TRANSLATINGSTRUCTURE 2017-74 CLAD

0.025

0.003

5

AFT FAIRING SKIN

2017-74 CLAD

0.025

0.003

9

UPPER DOOR OUTER SKIN

2017-74 CLAD

0.025

0.025

2017-74 CLAD

0.025

0.003

8061-a BARE

0.050

0.005

5AL-4V T1

0.050

(il lil 0.004 O

CRES STEEL

0.025

0.003

2017-74 CLAD

0.032

0.004 18

201 7-74 CLAD

0.032

0.003 O

OUTER SKIN

10

LOWER INNER DOOR OUTER

11

PYLON LEADING EDGE

12

1 PVLONLOWERFWDSKIN

SKIN

13

TRANSLATINGSTRUCTURE

14

1 LOWEROUTERDOOROUTER

INNER SKIN

SKIN 15

NOSE SECTION OUTER SKIN

Ii] [il lil

ill ill

O

NOTES P

CHEM-MILLED PART

O

INDIVIDUALCORROSION DAMAGEDAAEASMUSTNOT EXCEEDZSQUAREIN.

O

INDIVIDUALCORROSION DAMAGEDAREASMUSTNOT EXCEEDGSQUAREIN.

slea´•n3´•sJ-I

Pylon and Nacelle Corrosion Damage Limits (CF-700 Engines) Figure 6

54-00-00 0

COPYRIGHT, 1984 t~Y SABRELINER CORPORATION



NACELLES AND PYLONS REPAIR PROCEDURES

REPAIR PROCEDURES

Repair of Cooling Air Inlet Duct Finish Fibreglass cooling air inlet ducts which exhibit evidence of erosion, chipping or finish separation may be repaired using the following procedure: 1.

Remove the existing finish from damaged areas of the air inlet duct.

the

2.

Fill all

deeply eroded

using a slow

setting

epoxy resin.

:3.

Using fine grit areas

or

chipped

emery cloth of the air inlet duct.

or

areas

eroded/

4.

Wipe all surfaces of the air inlet duct with a clean cloth moistened with methyl ethyl ketone (MEK).

5.

Mask surrounding

6.

Apply two coats of epoxy polyamide primer to surfaces of air inlet duct. Allow 1-2 hours drying time between coats.

7.

After final coat of epoxy polyamide primer has dried for 3 hours, apply a final coating of polyurethane top coating. allow top coating to cure for a minimum of 12 hours.

areas

not to be refinished.

paper, smooth all

GI

AIR INLET DUCT

Cooling Air Inlet Duct Location Figure 801

54-00-00 Page 801/802 Blank COPYRIGHT, 1984 BY SABRELIN ER CORPORATION

Aug

CHAPTER

STABILIZERS

SR-76-023 COKIIOSI()N CONTROL MANUAL

CHAPTER 55 STABILIZERS TABLE OF CONTENTS Su

t,ject

(;eneral


Page

.55-00-00

55-CONTENTS -~I

COPYRIGHT. 1984 B~ aABRELINER CORPORA;:S;J



CHAPTER 55 STABILIZERS LIST OF EFFECTIVE PAGES THIS ENTIRE CHAPTER HAS BEEN REVISED.

Chapterl Section

Page

Date

Chapter Fj5-L.E.P.

1/2 Blank

Aug 17/84

Chapter.55-T.O.C.

1/2 Blank

Aug 17/84

1 thru 6

Aug 17/84

5.5-0(3-0(3

55-L.E.P. e

COPYRIGHT. 1984 BY

SABRELINER

CORPORATION


CHAPTER 55 STABILIZERS

GENERAL Exterior surface material and corrosion damage limits for Sabreliner stabilizers are covered in this chapter. See figure 1 for exterior surface material.

Corrosion damage limits for horizontal stabilizers, elevators, vertical stabilizers, and rudders are shown in figures 2, 3, 4, and 5 respectively. Refer to Chapter 20 for general surface coating procedures.

cleaning, sealing,

and

55-00-00 o

COPYRIGHT. 1984 BY SABRELINER CORPORATION

Page

1

Aug 17/84

SR-76-023 COKHOSION CONTROL MANUAL

HONEYCOMB

FIBREOLASS LAMINATES

ALUMINUM ALLOYS

ELEVATOR TRAILING EDGE MAY BE HOLLOW

CORE OR HONEYCOMB CORE.

Exterior Surface Materials

Figure

1 sesj-raas-l

55-00-00 Page Aug t7/84

o



CORROSION DAMAGE 1S LIMITED TO THE FOLLOWING: 1.

CORROSION DAMAGE MUST NOT EXCEED 10% OF

AFFECTED SURFACE AREA. 2.


3.

A MIN

NOTEXCEEDZSQUAREIN. OF 2 IN.

MUST

SEPARAiE CORROSION

DAMAGED AREAS.

1

4.


5.

A

MIN OF 3 UNDAMAGED FASTENERS MUST SEPARATE CORROSION DAMAGED AREAS ALONG FASTENER ROWS.

2

3

TYPICALSABRELINER HORIZONTAL STABILIZER

S26F~-e:(-R5-8

MAXIMUM

ITEM

NOMENCLATURE

NO.

MATERIAL

GAGE

ALLOWABLE

CORROSION DEPTH

1

HORIZ STAB L.E. SKIN

2024-T3 BARE

0.032

2

HORIZ STAB UPPER SKIN

2024-T3 BARE

0.050

3

HORIZ STAB LOWER SKIN

2024-T3 BARE

0.050

2024-T3 BARE

0.050

B

0.002

2024-T3 BARE

0.050

P

0.002

(MODEL THRU

0.002

O

0.(i02 0.002

NA 285-40, S/N 282-001

-090)

HORIZ STAB LOWER SKIN

(MODEL NA 285-40, S/N 282-091 and suba, and MODEL NA 265-80 and -70) HORlt STAB LOWER SKIN

(MODEL

NA 285-65 AND

-80)

NOTE O

CHEM-MILLED PART

Horizontal Stabilizer Corrosion Damage Limits

Figure

2

55-00-00 0

COPYRIGHT,


Page 3 Aug 17/84



CORROSIONDAMAOE MUSTNOTEXCEED1O%OF AFFECTED SURFACE AREA.

2.

INDIVIDUAL CORROSION-DAMAGED AREAS MUST NOT EXCEED 2SOUARE IN.

3.

A MIN


DAMAGED AREAS. 4.

i

CORROSION

DAMAGE

ALONG

A

SPLICE

OR

FASTENERROWMUSTNOTINCLUDEMORETHAN

2

3 FASTENERS IN EACH DAMAGED AREA. 5.

A

MIN

OF

3

UNDAMAGED

FASTENERS

MUST


TYPICAL SABRELINER ELEVATOR sa;o´•r::-a~-e

MAXIMUM ITEM

MATERIAL

NOMENCLATURE

NO.

GAGE


ELEVATOR L.E. SKIN

’1

2

I

ELEVATOR SKIN

(UPPER 3

AND

1

1024-t42 BARE

0.050

2024-T3 BARE

0.032

2024-t3 BARE

0.010

0.002

O

0.002

LOWER)

ELEVATOR T.E. SKIN

0.002

NOTE O

CHEM-MILLED PART

Elevator Corrosion Damage Limits Figure 3

55-00-00 Page

4

Aug r7/84

o

COPYRIGHT, 1984 BY SABRELINER C~JnPORATION



A MINIMUM OF 2 INCHES MUST SEPARATE CORROSION-DAMAGED AREAS.

2.

CORROSION DAMAGE ALONG A SPLICE OR FASTENER ROW MUST NOT INCLUDE MORE THAN THREE FASTENE DAMAGED AREA.

3.

A MINIMUM

I

3\

4

OF THREE UNDAMAGED FASTENERS MUST SEPARATE CORROSION-DAMAGED AREAS ALONG FASTENER ROWS.

sr~isrcr,a.:t

ITEM NO.

NOMENCLATURE

MATERIAL

GAGE


1

VERT STAB FILLET

6061-T4

0.032

2

VERT STAB SIDE SKINS

2024-T3 CLAD

0.083

3

VERf STAB L. E. SKIN

2024-T4 BARE

0.032

4

VERT STAB T. E. SKIN

2024-T3 BARE

0.010

0.010

[il

PERCENT

Op AFFECTED SURFACE 25 10

0.002

O O

0.002

O

10

0.002

10

NOTES m

CI-IEM-MILLED PART

O

INDIVIDUALCORROSION DAMAGEDAREASMUSTNOT EXCEED2SQUAREIN.

O

INDIVIDUALCORROSION DAMAGEDAREASMUSTNOT EXCEED4SQUAAEIN.

Vertical Stabilizer Corrosion Damage Limits

Figure

4

55-00-00 0


Page 5 Aug 17/84


CORROSION DAMAGE IS LIMITED TO THE FOLLOWING:

2,

1

I I

1.


2.


3.

A

NOT EXCEED 23QUARE IN. MIN

OF 2 IN.

MUST SEPARATE CORROSION

DAMAGED AREAS. 4.

CORROSION

DAMAGE

ALONG

A

SPLICE

OR

FASTENER ROW MUST NOT ~NCLUDEMORETHAN 3 FASTENERS IN EACH DAMAGED AREA.

5.

A

MIN

OF 3 UNDAMAGED

FASTENERS

MUST


SZRR-2:(-T,T,-J

MAXIMUM

ITEM NO.

MATERIAL

NOMENCLATURE

GAGE

ALLOWABLE CORROSION DEPTH 0.002

1

RUDDCR L. E. SKIN

2024-73 CLAD

0.040

2

RUDDER SIDE SKINS

2024-73 CLAD

0.020

O

:.~iu2

0.032

O

0.002

3

RUDDER T. E. SKIN

2024-73 CLAD

0.010

0.002

4

RUDDER TRIM TAB SKIN

2024-73 CLAD

0.010

0.002

NOTES MODEL NA 265-40, -40A, -60, -60A. AND -60SC

ill

MODEL NA 265-65. -70. -80. -80A. AND -80SC

Rudder Corrosion Damage Eimits

Figure

5

55-00-00 Page 6 Aug r7/84

o


CHAPTER

VVINGS


CHAPTER 57 WINGS TABLE OF CONTENTS SLlhject


(;eneral

57-00-00

Wing Structure

57-10-00

Page

WingFuelDrainCavity

201 204

Wing Fuel Drain Valves WinKdoint Rib Assembly

1

COPYRIGHT, 1984 BY SABRELINER CORPURATION

57-CONTENTS Page 1/2 Blank Aug t7/84


CHAPTER 57 WINGS LIST OF EFFECTIVE PAGES THIS ENTIRE CHAPTER HAS BEEN REVISED.

Chapter/ Page

Date

Chapter 57-L.E.P.

1/2 Blank

Aug 17/84

Ti7-T.O.C.

1/2 Blank

Aug 17/84

57-0()-00

1 thru 8 9/10 Blank

Aug 17/84 Aug 17/84

Fj7-10-00

201 thru 206

Aug 17/84

Section

Chapter

57-L.E.P. 0

COPYR IGn r, 1984 BY SABRELINER CORPORATION



CHAPTER 57 WINGS

GENERAL This chapter provides exterior surface material, corrosion damage limits, and procedures for inspecting specific areas of the Sabreliner wing.

Wing exterior surface material is shown

on

figure 1.

Corrosion damage limits for the wing structure, slats, ailerons, and flaps are shown on figures 2, 3, 4, and 5

respectively. Refer to Chapter 20 for general cleaning, sealing, and surface coating procedures.

57-00-00 o

COr’,’;ilGHT, 1984


Page 1 Aug 17/84



ALUMINUM ALLOYS

IONEYCOM.

I~J

O NOTES

O

MODEL NA 265-40 AND -60

O

MODEL NA 265-70 AND -80

s2sa-za-511

.L.PPLICABLE Tu nnODELS NA 265-40, -40A, -60, -70, AND -80

57-00-00

Wing Exterior Surface Material Figure 1 (Sheet 1 of 2)

Page Aug 17/84

o

COPYRIGHT, 1984




I

:I_-:1

ALUMINUM ALLOYS

HONEYCOMB

APPLICA8LE TO MODEL NA 265-60A, -60SC, -65, -80A, AND -80SC

Wing Exterior Surface Material Figure 1 ~Sheet 2 of 2)

57-00-00 Page 3 0


Aug 17/84


7~

8

Ip

2

9


07~

c

CORROSIONDAMAGE MUSTNOTEXCEED1O%OF

o

AFFECTED SURFACE AREA. o

2.


3.

A MIN

NOT EXCEED PSQVARE IN.

13

15 (TYP)

14 3

OF 2 IN.

MUST SEPARATE

CORROSION

DAMAGED AREAS.

14

CORROSION

4. D

DAMAGE

ALONG

A

SPLICE

OR


i

~’a

ti

‘7

16

A

MIN

OF 3 UNDAMAGED

FASTENERS

MUST


1’211

FASTENER ROWS.

OUTED

INED

ITEM NO.

NOMENCLATURE

MATERIAL

GAGE


1

WING SKIN

LOWER

2024-7531

PLATE

INBD 0;006 OUTED 0.003

1

WING SKIN

UPPER

7178-t851

PLATE

INBD 0.008

3

WING SKIN

7075-78 BARE

0.125

4

WING SKIN

5

WING

8

WING SKIN

1

INBD T.E. SKIN

8 8

OUTED 0.003 INBD L.E. INBD T.E.

lD

0.008

7075-78 BARE

PLATE

0.003

7075-78 BARE

0.040

0.002

7075-78 CLAD

0.032

0.003

2024-74 CLAD

0.010

0.002

WING T.E. SKIN

2024-73 CLAD

0.080

0.003

WING T.E.

2024-73 CLAD

0.010

0.002

10

WING SKIN OUTED T.E.

2024-T42CLAD

0.040

11

WING OUTED T.E.

2024-73 CLAD

0.010

0.002

12


2024-T42CLAD

0.040

0.003

13

WING SKIN OUTED L.E.

2024-73 CLAD

0.083

14

WING L.E. SKIN

2024-73 BARE

0.083

15

WING L.E. SKIN DOOR

7075-78 CLAD

0.083

0.002

16

WING SKIN LOWER T.E.

2024-73 CLAD

0.020

0.003

17

WING SKIN

LOWER INBD T.E.

7075-78 CLAD

0.032

18

WING SKIN

LOWER

7075-78 BARE

0.071

INED T.E. INBD T.E.

O

0.003

O.OOP

O

0.002

0.002

O

0.003

NOTE P

CHEM-MILLED PART

APPLICABLE TO MODELS NA 265-40, -40A, -60, -70, AND -80 8265-23-572

Wing Structure Corrosion Damage Limits Figure 2 (Sheet’l of 2)

57-00-00 Page 4 Aug 17/84

o

COPYRIGHT,



MAXIMUM ALLOWABLE

ITEM

GAUGE

MATERIAL

NOMENCLATURE

CORROSION

NO.

DEPTH

WING SKIN

1

INBD

PLATE

2024-7531

LOWER

0.006

OUTED 0.003 WING SKIN

2

INBD

PLATE

7178-7651

UPPER

0.006

OUTED 0.003 3

WING SKIN

INBD L.E. TOP

7075-76 BARE

0.080

4

WING SKIN

INED T.E. INED,

7076-78 BARE

PLATE

0.003

FWD UPPER 5

SKIN, INBD, UPPER

2024-73 BARE

0.040

6

WING INBD T.E.

7075-76 BARE

0.040

7

FACE SHEET, UPPER

2024-73 CLAD

0.032

8

OVERWING FAIRING ASSY

LAMINATED

9

SPOILER, ASSY,

2024-7351

0.313


2024-742 CLAD

0.040

SKIN, UPPERSURFACE, EXTENDED

2024-73 CLAD

0.063

0.002

INBD AND OUTED 10

11

I 1

O

0.003

2024-73 CLAD

0.063

13

ACCESS DOOR

2024-73 CLAD

0.063

14

SKIN, LOWER

2024-73 BARE

0.040

FACESHEET,LOWER

2024-73 CLAD

0.032

SKIN, INBD, LOWER

2024-73 BARE

0.040

SKIN,L.E.LOWER

2024-T42-CLAD

INBD 0.068

SKIN, L.E.

2024-742 CLAD

12

15

SKIN,LOWERSURFACE.

I

16

17

1

EXTENDED

OUTED 0.063 18

INBD 0.068

OUTED 0.063

1.

CORROSION

DAMAGE

5

8

CORROSION DAMAGE IS LIMITED TO THE FOLLOWING:

2

6

4

7

9

2 10

INED

MUST NOT EXCEED 10% OF

OUTED

11


INDIVIDUAL CORROSION-DAMAGED AREAS MUST NOT EXCEED 2SQUARE IN.

3.

A

MIN

OF

2

IN.

MUST SEPARATE

CORROSION

DAMAGED AREAS. 4.

CORROSION

DAMAGE

ALONG

A

SPLICE

OR

18


A

MIN

OF 3 UNDAMAGED FASTENERS MUST CORROSION DAMAGED AREAS ALONG

FASTENER ROWS. 13

12

OUTED 14

IN~D

NOTE

1;

16

1

15

CHEM-MILLED PART

APPLICABLE TO MODEL NA 265-60A, -60SC, -65, -80A, AND -80SC

Wing Structure Corrosion Damage Limits Figure 2 (Sheet 2 of 2)

57-00-00 a

´•I"YRIGHT, 1984 BY SABRELINER CORPORATION

Page 5 Aug 17/84




2.


3.

A MIN

4.

CORROSION DAMAGE ALONG A SPLICE FASTENER ROW MUST NOT INCLUDEMORETHAN 3 FASTENERS IN EACH DAMAGED AREA.

3.

A

NOTEXCEEDPSQUAREIN.

1

OF 2 IN. MUST SEPARATE CORROSION DAMAGED AREAS. OR

MIN OF 3 UNDAMAGED FASTENERS MUST SEPARATE CORROSION DAMAGED AR EAS ALONG FASTENER ROWS.

TYPICAL SLAT

ITEM NO.

NOMENCLATURE

MATERIAL

GAGE


1

SLAT T.E. SKIN

2024-T3 CLAD

0.010

0.002

2

SLAT UPPER SKIN

2024-’73 CLAD

0.040

0.002

3

SLAT LOWER SKIN

2024-T3 CLAD

0.040

0.002

Slat Corrosion

Damage Limits Figure 3

526&29573

57-00-00 Page

6

Aug 17/84

O

COPYRIGHT.

1984 BY

SABRELINER CORPORATION




2.


3.

A

NOT EXCEED 1SQUARE IN. MIN


DAMAGED AREAS. CORROSION

4.

DAMAGE

ALONG

A

SPLICE

OR

FASTENER ROW MUST NOT INCLUDEMOREtHAN 3 FASTENERS IN EACH DAMAGED AREA. 5.

A MIN

OF 3 UNDAMAGED

FASTENERS

MUST


1

FAStENERROWS.

MAXIMUM ITEM

MATERIAL

NOMENCLATURE

NO.

GAGE

ALLOWABLE

CORROSION DEPTH

1

AILERON L.E.SKIN-INBD

2024-73CLAD

0.020

2

AILERON L.E. SKIN

7075-70 CLAD

0.090

0.002

3

AILERON TRIM TAB SKIN

2024-73 CLAD

0.010

0.002

4

AILERON SKIN

2024-73 CLAD

0.020

0.002

5

AILERON T.E. SKIN

2024-73 CLAD

0.010

0.002

6

AILERON SKIN

2024-73 CLAD

0.020

0.002

UPPER

LOWER

0.002

NOTE O

CHEM-MILLED PART

AIltron Corrosion Damage Limits

Figure

S?65-2J-67-L

4

57-00-00 o


Page 7 Aug 17/84



CORROSION DAMAGE MUST NOt EXCEED 10% OF AFFECTED SURFACE AREA.

2.

INDIVIDUAL CORROSION-DAMAGED AREAS MUST NOT EXCEED 2SQUARE IN.

3.

A

MIN

OF 2 IN.

MUST SEPARATE

CORROSION

DAMAGED AREAS. 4.

CORROSION

DAMAGE

ALONG

A

SPLICE

OR

FASTENER ROW MUST NOT INCLUDEMORETnAN 3 FASTENERS IN EACH DAMAGED AREA. 5.

1

A

MIN

OF

3 UNDAMAGED

FASTENERS

MUST


MAXIMUM ITEM NO.

NOMENCLATURE

MATERIAL

GAGE

ALLOWABLE

CORROSION DEPTH

1

FLAP L.E. SKIN

7075-T881 BARE

0.250

2

FLAP UPPER SKIN

2024-73 CLAD

0.040

0.002

3

FLAP T.E. SKIN

2024-73 CLAD

0.010

0.002

4

FLAP LOWER SKIN

2024-T3 CLAD

0.010

11.002

O

0.002

NOTE O

CHEM-MILLED PART

APPLICABLE TO MODELS NA 265-40,

-40A, -60, -70,

AND -80 S265-235i-5

Flap Corrosion Damage Limits Figure 5 (Sheet r of 2)

57-00-00 Page 8 Aug 17/84

o

COPYRIGHT,


SR-76-023 CORROSION CONTROL MAWUAL

MAXIMUM

ITEM

NOMENCLATURE

NO.

MATERIAL

GAUGE


0.040

1

FLAP L.E. SKIN

2024-142 CLAD

2

SKIN UPPER

2024-T3 CLAD’

0.040

SKIN LOWER

2024-13 CLAD

0.040

SKIN, UPPER

2024-13 CLAD

0.063

SKIN, LOWER

2024-T3 CLAD

0.063

3

1

3

2


CORROSION DAMAGE MUST NOT EXCEED 10% OF



3.

A

NOTEXCEEDZSQUAREIN. MIN

OF

2

IN.

MUST

SEPARATE

CORROSION

ALONG

SPLICE

DAMAGED AREAS. 4.

CORROSION

DAMAGE

A

OR


A

MIN

OF 3

UNDAMAGED

FASTENERS

MUST


APPLICABLE TO MODEL NA 265-60A, -60SC, -65, -80A, AND -80SC

Flap Corrosion Damage Limits Figure 5 (Sheet 2 of 2)

57-00-00 o

COPYRIGHT, 19~: SY SABRELINER CORPORATION



WING STRUCTURE MAINTENANCE PRACTICES

WING FUEL DRAIN CAVITIES

9.

The machined surfaces must be polished withabrasive paper, etched with Turco 5361 or equivalent, and then examined for corrosion.

10.

After inspection is completed, and corrosion removed, if required, wipe the cavity area with toluol and remove any trace of primer. Dry with a clean, dry cloth.

11~

Apply cleaning compound, Turco 4906, Cee Bee, CBA-301 or equivalent, with a soft bristled brush or swab, keeping the surface wet for 5 to 10 minutes.

Check the cavities of the fuel drain valves in the lower skin as follows:

(see figure 201) for corrosion 1.

airplane in accordance with existing instructions.(Refer to applicable Sabreliner MaintenDefuel the ance

2.

3.

Manual

Chapter 28.)

Remove access covers necessaryto gain access to fuel drain valves in LH and RH lower wing skins. Remove ten fuel drain valves from LH and RH lower

wing surface. 4.

5.

6.

Inspectthe ten cavities for the fuel drain valves for the presence of Cati-Coat primer (Cati-Coat primer is "Buff~’ in color same as inside of wing tank). If the cavities are covered with Cati-Coat primer, no further rework is required. Reinstall fuel drain valves. not covered with Cati-Coat primer, inspect the following areas for corrosion: ’I’he area (land) where the "0" ring seal makes with the wing skin, and the vertical sides of both inner and outer holes for the fuel drain valves.

If the cavity

areas are

To precent damage to CA TI-COA Tprimer, do not allow any cleaning materials to the CATI-COATsurface inside the

wing. 12.

droplets) must be obtained. Repeat cleaning process, if necessary, to obtain this condition.

on the land, remove corrosion end mill or counterbore (2.125 to 2.188 in. diameter with a 0.12.5 in. radius). The fuel drain valve mounting hole in the drain valve may be used as a pilot for the cutting tool.

If corrosion exists

using

Wear rmbber gloves when m´•i~ing and using solutions. Rags, sponges, swabs, etc., used for applying chemicalfilm solutions must not be allowed to dry. If allowed to dry, they constitute afire hazard. Immediately after use, they must be thoroughly rinsed in water, then they may be reused or discarded

an

Cut enough material to entirely remove all corrosion and leave a clean surface. Do not reduce the wing skin thickness to less than 0.100 in. A max of 0.015 in, of material may be removed without adding a spacer. If the material removed exceeds 0.015 in. it will be necessary to install a spacer under the fuel drain fitting to make it flush with the wing mold line. Remove 0.030 in. min material if spacer is to be used. 7.

8.

Rinse thoroughly with tap water to completely ’remove all cleaner. A water-break-free! surface (no

If corrosion exists on the vertical walls of the inner hole, it may be removed by using a bearing scraper or similar tool. It is not necessary to equally remove material from all sides of the hole; however, the hole may not be enlarged in any area to a point that would result in an inadequate land for the drain valve "O" ring seal.

13~

14.

Use Alodine Kit No. 22 (apply in accordance with directions contained in kit) or mix 6 ounces by weight of Iridite 14 and one fluid ounce of ARP No. 2 wetting agent and one gallon of water, or mix 3 ounces by weight of Alodine 1200 and 0.5 fluid ounces of nitric acid with one gallon of water. Cost the cleaned surface and keep wet from 3 to 5 minutes, then allow to dry. Rinse the coated surface with water, but do not rub brush, as the soft protective film will be damaged. If there is Do visible film color, repeat step 12. Apply Cati-Coat primer as indicated in Chapter 20.

or

The diameter of the inner hole may be enlarged from the original diameter of 1:375 in. to a max of 1.625 in. The diameter of the outer hole may be enlarged from the original diameter of 2.125 in, to a max

of 2.188 in.

57-1 0-00 0


Page 201 Aug 17/84

SR-76-023 CORROSION CONTROL MAhrWAL

MAINTENANCE PRACTICES (Continued)

Wing Fuel Drain Cavities (Cont’d) NOTE All equipment usedfor application of CatiCoat Primer may be cleaned with a 50-50 mQture oftoluol and butyl alcohol. 15.

When Cati-Coat primer is dry and if required, re-install drain valve.

no

spacer is

If spacer is required under drain valve to make it flush with the wing mold line skin, proceed with the

following steps. 16.

Fabricate spacer

as

shown, apply Cati-Coat to

spacer.

NOTE General PurpoSi Sealing Compound is required to seal spacer. 17.

Applying SealingCompound: A.

Wipe the surface to be sealed with a clean cloth dampened with naphtha or equivalent solvent. Before solvent has evaporated, wipe surface withacleandrycloth.

B.

Mix the base sealing compond and accelerator in the proportions recommended by the msnu-

facturer. N~OTE The sealing compound must be used within S;hours after being mized or after removal from cold storage, 18.

Usings clean wooden spatula or equivalent, apply a thin coat of sealing compound on the wing skin and spacer fayjng surface. Install spacer and apply a srinall bead n the upper surface around the inner l;oie as shown in figure 201.

19.

Reinstall drain valve while sealing compound is to provide pressure of the spacer on the wing skin to insure a fuel tight bond.

pliable

20.;..Air-dry..; sealing compound at room temperature (approximately 770F) for 24 hours prior to refueling airplane.

57-1 0-00 ’Pake

%02

.t~Auff 17/84

o

COPYRI~HT, 1984 BY SABRELINER CORPORATION


VIEW LOOKING UP WING FUEL DRAIN VALVES

2

LAND(REF)

INNERHOLE(REF)

i

WING SKIN

WING SKIN

INSPECT THIS AREA FOR CORROSION.

OUTER HOLE (REF)

(ENTIRE CIRCUMFERENCE) If AREA IS COATED WITH CATI-COAT PRIMER, NO REWORK RIQUIRED.

WING

SKIN1.825

MAXj/

WING SKIN

1.375REF

1_ .100 MIN

1~-1‘

2.125

(REF)

-I

2.188 MAX

MATEklALTWICKNESS AFTER

CORkOS1ON

REMOJAL.

SEAL ENTIRE

CIRCUMFERENCE bF

FAYINO SURFACE USING PRODUCTS RESEARCH RADIUS TO MATCH WING CAVITY.

SPACER

J

281223

WING SKIN

di~i;t

SEALING.COMPO;U~D,

SPACEROREQUIVALhNi

WING SKIN

SPACER THICKNESS AS REQUIRED TO MAKE DRAIN VALVE NEAR FLUSH WITH WING SKIN MOLD LINE

2.082

´•1

(.050 MIN) szes-23-57a

NOTE MAKE SPACER FROM ALUMINUM ALLOY 2024-T4

Wing Fuel Drain Cavities Figure 201

57-t 0-00 Page o


203

Aug 17/84

SR-76-023

C,i)RR()S~)N CONTROL MAN13AL MAINTENANCE PRACTICES (Continued) WING ~EL DBAIN VALVE S

Viaully~

the fuel drain valve s

202~ :f6x’idbrrcigion ~s.´•follows:

i~l;-.PTsmg´•´•a’ $ediiner

2.

Remove

two

i

securing eac~i fuel drain valve

C.

Apply Cati-Coat primer . Refer

to

areas

of the

to fuel drain valve

"Application

of Cati-coat

Primer".

each fuel drain valve for of corrosion. If no corrosion is found and Cati-Coat primer surfaces aielnbt damaged, reinstall’fuel drain valve in wing, Torque fuel drain valve fasteners to 20-25 in. Ibs, If corrosion is found and exceeds 0.010 in. depth, the fuel drain valve must be replaced.:lf corrosion is found, and is less than 0.010 in, depth, proceed as follows:

t~vide;ice

DRRIN

Brush cimum plate all bare fuel drain valve .

wing lower skin,

3."" 2fisqally examine

i’’;..’’7

B.

type wrench, unscre~v;the fuel

screws

to the

Using mechanical methods, remove all corrosion from the fuel drain valve . Blend reworked area to create a saucer shaped depression. The finished blended area must not exceed O.D10 in, depth.

(see figure

drain valve from the fuel drain val~ve L~pbrt. Refer :Wing.Skin Drain V´•slves" in Chapter 57 of :;the!applicable maintenance manual.

-;:~;nr*

A.

D.

Reinstall fuel drain valve fittings in

wings and screws

E.

secure

in place. Torque

attaching

to 20-25 in.-lbs.

Reinstall fuel drain valves.

V~LVI

117-481005-11 e:´•

SP´•

Is^ll

Wing Fuel Drain Valve Figure 202

SZB6-23-67-fi

’?r;i

17´•;1 0-00 ^PaE;e 804 Aug 17/84

COPYRIGHT,

1984 BY SABRELINER

CORPOAATION

88-’76-023 CORROSION’

MAINTENANCE PRACTICES 6.

WING T RIB ASSE~IBLY

Cutenough material tb entirely a

possible ezplosions during following procedures, make sure that To prevent

the all

airplane switches are at off or normally maintained safe positions, and that all sources of electrical power are removed

7.

Repair any wing t (See figure 203.)

follows:

Defuei the airplane in accordance with existing instructions. (Refer to Sabreliner Maintenance Manual Chapter 28.)

2.

Removeaccesscovers necessarytogain accesstotwo fuel drain valves in LH and RH lower wing skins,

8.

9.

must be

and ’"’a.

1

After inspection is completed, Bn‘d~:corrosion removed, if required, wipe the cavitS;1 area..-ith with a toluol and remove any trace of

1.:,.1...:

Apply cleaning dompound, Turco 4~306, Cee Pee, CBA-301 or equivalent, with a soft bristled brush or swab, keeping the surface wet for 5 to.O m’inutes.

To prevent damage to Cati-Coat primer, do not allow any cleaning materials to

the cati-coat surface inside the wing.

Remove four fuel drain valves from LH and RH lower wing surface next to wing t rib assembly. 10.

nana

C

clean’sur~ac;es

clean, dry cloth. as

i.

´•/3.

The

clean surface.

paper, etched with Tu~cb 5361 then examiried for corrosion.

from airplane bus system. rib assembly corrosion

(Continued):;r~i::.

Comply with necessary safety procedures workinginsidefuel tanks.

Rinse thoroughly with tap water to completely remove all cleaner. A water-break-free surface (no nroplet,9) muat be obtained. Repeat cleaningprocess, if necessary, to obtain this condition.

when

c~

NOTE Corrosion

and Wear rubber gloves when, solutions. Ra~Fs, sponges swabs etc., used for applying chemical film solutions must not be allowed to dry. I;fallowed to dry they constitute afire hazard. Immediately ~er use, they must be thoroughly rinsed in water, ULen theymay be reused or discarded

be detected ´•if paint has the metal surface is ezposed

can

bubbled up or through the paint.

If corrosion is detected on the edge of the flange (seefigure a03), corrosion should be suspected on the bottom offlange. Wings then must be separated and bottom wing skins removed from t rib assembly to

11.

check for corrosion, 4.

If corrosion

can

be repaired from the drain valve

holes, perform steps 6 through 12. 5.

If corrosion cannot be repaired from the drain valve holes, the wings have to be separated for access. Separate at the wing t rib assembly. Refer to applicable Sabreliner Maintenance Manual Chapter 57.

minutes, then allow

C

(apply

to

or

dry.

NOTE All equipment used for application of Cati-Coat primer may be cleaned with a 50-50 m´•i~ure of toluol and butyl alcohol,

NOTE

Separate the wings on the side of the t rib that has to be repairedfm access.

in accordarice with mix 6 ouncesby weight of Iridite 14 or one fluid ounce of APR No. 2 wetting agent with one gallori, of water, or mix 3 ounces by weight of Alodine’l200 and 0.5 fluid ounces of nitric acid with, one gallon of water. Coat the cleaned surface and keep wet from 3 to 5

Use Alodine Kit No.22

directions contained in kit)

12.

Ri nse the coated surface with water, but do not rub or brush, as the soft protective film will be damaged. If there is no visible film color, repeat step 10. Apply Cati-Coat primer as indicated in Chapter 20.

5j-1 OC~c

COPYRIGHT, 1984 BY SABRELINER CORPORA~ION

:Page i05 Aug 17~84

SR´•76-023. MANUA~L

SUSPECTED AREAS FOR CORROSION (tVPICAL ON BOTH SIDES OF RIB)

~TE\ SUSPECTED

CORROSION AREAS´•ARE INSPECTED WITH A SMALL MIRROR-OR BORESCBPE THAU DRAIN: VALVE HOLES

(4)

,s.151.

I

I

I

I

DRAIN VALVE

i$

C(10

HOLE (DRAIN ALVE AND BRACKET

REMOVED).

~n

CORROSION MUST NOT EXCEED~/84 IN.’ DEPTH 01~ TOP OF FLANaE

~-:IM SIDE OF CENTERLINE T 16 :’´•R’:LIN iSHOWN,-RH

SIDEliyPICA~L

la

;´•r

a

DRAIN VALVE

HOLE (DRAIN VALVE AND BRACKET

REMOVED),

IF CORROSION IS;SUSPECTED ON:BOrrOM OFFLANOE, nr MUST fjo~EXCGEbS133 IN1´• ;:1

iN DEPiH ~/NG SKldS

IVIU9~:’: :_´•

a

~ORROSION

WING SKIN

MUSTNOT EXCEED 1/32 IN. DEPTH ON EDaE OF

FLANtJE’

i r 82B5-2-97-7

Win~ t Rib Assenbly Corrosion Repair ;203

0-00 P~ge ~(j6 Aug 17/84

o


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