Honeywell AS907 Standart Practices Manual

Engines, Systems & Services Phoenix THE ATTACHED STANDARD PRACTICES MANUAL, 72-05-14 IS ISSUED FOR USE IN SUPPORT
OF THE FOLLOWING AIRCRAFT. ENGINE PART NUMBER 3030001-4 ENGINE MODEL NUMBER AS907-1-1A AIRCRAFT APPLICATION BOMBARDIER CHALLENGER 300
This publication is distributed by: Honeywell Aerospace Services Technical Data Distribution M/S 64-03/2101-201 P.O. Box 52170 Phoenix, AZ 85072-2170 Inquiries of a technical nature regarding this publication should be directed to: Honeywell Aerospace Services Customer Support Center M/S 26-06/2102-323 P.O. Box 29003 Phoenix, AZ 85038-9003 Phone: (Domestic) 800-601-3099 Phone: (International) 602-365-3099 Fax: 602-365-3343
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Copying, use or disclosure of information on this page is subject to proprietary restrictions.
Dec 01/03
Engines, Systems & Services Phoenix
VOLUME I STANDARD PRACTICES MANUAL
PART NUMBER 3030001-4
MODEL NUMBER AS907-1-1A
STANDARD PRACTICES MANUAL
This document and all information and expression contained herein are the property of Honeywell International Inc., are provided in confidence, and may be used by persons required by Federal Aviation Regulations Part 21.50 to comply with any of the terms of these instructions. Except as set forth above, no person may, in whole or in part, use, duplicate or disclose this information for any purpose without the prior written permission of Honeywell International Inc.
This publication was prepared by Honeywell International Inc. Engines, Systems & Services Cage Code (99193) Technical Publications
FAA APPROVED
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Copyright 2003 Honeywell International Inc. All rights reserved.
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Engines, Systems & Services Phoenix
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STANDARD PRACTICES MANUAL AS907-1-1A SAFETY ADVISORY
WARNING:
BEFORE THE MATERIALS CALLED OUT IN THIS PUBLICATION ARE USED, KNOW THE HANDLING, STORAGE, AND DISPOSAL PRECAUTIONS RECOMMENDED BY THE MANUFACTURER OR SUPPLIER. FAILURE TO COMPLY WITH THE MANUFACTURERS OR SUPPLIERS RECOMMENDATIONS CAN RESULT IN PERSONAL INJURY OR DISEASE.
This publication describes physical and chemical processes which can make it necessary to use chemicals, solvents, paints, and other commercially available materials. The user of this publication must get the Material Safety Data Sheets (OSHA Form 20 or equivalent) from the manufacturers or suppliers of the materials to be used. The user must know the manufacturer/supplier information and keep to the procedures, recommendations, warnings and cautions set forth for the safe use, handling, storage, and disposal of the materials.
WARRANTY/LIABILITY ADVISORY
WARNING:
HONEYWELL ASSUMES NO RESPONSIBILITY FOR ANY HONEYWELL EQUIPMENT WHICH IS NOT MAINTAINED AND/OR REPAIRED IN ACCORDANCE WITH HONEYWELLS PUBLISHED INSTRUCTIONS AND/OR HONEYWELLS FAA/SFAR 36 REPAIR AUTHORIZATION. NEITHER DOES HONEYWELL ASSUME RESPONSIBILITY FOR SPECIAL TOOLS AND TEST EQUIPMENT FABRICATED BY COMPANIES OTHER THAN HONEYWELL. INCORRECTLY REPAIRED COMPONENTS CAN AFFECT AIRWORTHINESS OR DECREASE THE LIFE OF THE COMPONENTS. INCORRECTLY FABRICATED SPECIAL TOOLING OR TEST EQUIPMENT CAN RESULT IN DAMAGE TO PRODUCT COMPONENTS OR GIVE UNSATISFACTORY RESULTS. EQUIPMENT OR PARTS THAT HAVE BEEN REPAIRED OR FABRICATED BY OTHER THAN HONEYWELL-AUTHORIZED FACILITIES CAN INCREASE RISKS OF DEATH OR PERSONAL INJURY, COMPONENT FAILURES, AND SECONDARY DAMAGE AND CAN VOID WARRANTIES UNDERWRITTEN BY HONEYWELL.
WARNING:
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STANDARD PRACTICES MANUAL AS907-1-1A
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STANDARD PRACTICES MANUAL AS907-1-1A LIST OF EFFECTIVE PAGES CHAPTER/ SECTION Title Page CHAPTER/ SECTION Service Bulletin List
PAGE T-1 T-2
DATE Dec 01/03 Dec 01/03
PAGE SB-1 SB-2 LOC-1 LOC-2 TC-1 TC-2 1 2 3 4 5 6 7 8 9 10
DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
Safety/Warranty/ Liability Advisory
SWLA-1 SWLA-2
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List of Chapters
List of Effective Pages
Table of Contents LEP-1 LEP-2 Dec 01/03 Dec 01/03 Introduction
Record of Revisions
RR-1 RR-2
Dec 01/03 Dec 01/03
Record of Temporary Revisions
TR-1 TR-2
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STANDARD PRACTICES MANUAL AS907-1-1A RECORD OF REVISIONS ISSUE DATE DATE INSERTED ISSUE DATE DATE INSERTED
REV NO.
BY
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BY
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STANDARD PRACTICES MANUAL AS907-1-1A RECORD OF TEMPORARY REVISIONS CHAP/SEC/ SUBJ TR NO. PAGE NO.
ISSUE DATE
DATE INSERTED
BY
DATE REMOVED
BY
INCORPORATED INTO MANUAL BY REV NO.
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STANDARD PRACTICES MANUAL AS907-1-1A SERVICE BULLETIN LIST NOTE: A date listed in the "SERVICE BULLETIN INCORPORATION DATE" column is the latest date this report was revised to include changes to text/illustrations caused by the Service Bulletin or its revision. When the words "No Effect" are listed, the Service Bulletin caused no changes within this report. SERVICE BULLETIN NUMBER SERVICE BULLETIN REVISION NUMBER SERVICE BULLETIN INCORPORATION DATE
SUBJECT
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LIST OF CHAPTERS
Chapters 70 STANDARD PRACTICES
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INTRODUCTION TABLE OF CONTENTS
SUBJECT INTRODUCTION Scope. Task Coding.
CHAPTER/ SECTION/ SUBJECT
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STANDARD PRACTICES MANUAL AS907-1-1A INTRODUCTION 1. Scope. A. B. 2. This publication is written in agreement with the Air Transport Association of America Specification No. 2200. Changes to this publication will be made by issuance of publication temporary revisions and publication revisions. These changes may be supplemented by service bulletins.
Task Coding. Sample pages provided are examples only and are not to convey that it is the only method to project the following requirements. Refer to Figure 1 (Sheet 1 of 3), Page 2. A. JEMTOSS Section and Sub-section Numbering System. All procedures contained in the manual will have task and sub-task numbers applied. The numbers provide the following: (1) (2) (3) (4) B. Identification of the hardware (parts or parts) primary to the task. A unique identifier for a set of instructions (known as Task or Sub-task). Identification of alternate methods and configuration differences that may change the procedure applied to the task. Identification of airline changes to a task or sub-task.
Components of Task and Sub-task Number. The numbering system is an expansion of the ATA three element numbering system. The number has seven elements of which the first five elements are mandatory for each task and sub-task. The sixth and seventh elements are applied when necessary. The elements are specified as follows:
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ATA NUMBERING SYSTEM
72 - 30 - 01
ELEMENT ONE SYSTEM CHAPTER
ELEMENT TWO MODULE OR MAJOR ASSEMBLY ELEMENT THREE UNIT/SUBJECT OR DETAIL PIECE PART
F61180
ATA Numbering System Figure 1 (Sheet 1 of 3)
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ATA NUMBERING SYSTEM
72 - 30 - 01 - 050 - 801
ELEMENT ONE - THREE CHAPTER-SECTIONSUBJECT OF PAGE BLOCK ELEMENT FOUR MAINTENANCE FUNCTION ELEMENT FIVE UNIQUE IDENTIFIER
F61179
ATA Numbering System Figure 1 (Sheet 2 of 3)
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72-00-00 ENGINE ASSEMBLY LEVEL
72-00-00 DESCRIPTION AND OPERATION PAGE 1 DATE
72-30-01 INSPECTION PAGE 801 DATE
72-00-00 REMOVAL PAGE 301 DATE
72-30-01 REPAIR PAGE 901 DATE
72-00-00 INSPECTION PAGE 801 DATE
72-30-01 ASSEMBLY PAGE 1001 DATE
DETAIL PIECE PART LEVEL 72-30-01 REMOVAL PAGE 301 DATE
MODULE OR MAJOR ASSEMBLY LEVEL
72-30-01 DISASSEMBLY PAGE 501 DATE
72-30-01 CLEANING PAGE 601 DATE
F61181
ATA Numbering System Figure 1 (Sheet 3)
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STANDARD PRACTICES MANUAL AS907-1-1A C. Position Definitions. (1) Table 1, Page 5. Task Code Layout identifies the information that is used in general for the task codes in the Standard Practices Manual. Table 1. Task Code Layout Position 4 XXX MAINTENANCE FUNCTION Elements Nos. 1, 2 and 3 1 2 3 XX XX XX ATA NUMBER Position 5 XXX UNIQUE NUMBER FOR ALL TASKS AND SUBTASKS These elements are the existing ATA numbers. These elements of the numbering system may have a built-in hardware identification. The assignment of these numbers in conjunction with the third and fourth element numbers shall provide discrete task and sub-task identification. The fourth element numerically defines the maintenance function being performed. Table 2, Page 5. Maintenance Function Codes depicts the codes that shall be used to reflect those function breakouts in positions 1 and 2 of the element (e.g. 10, 20, 30) normally called for in an airline engine maintenance program. A third position of this element shall be reserved for use, at the manufacturers discretion, if further defining of the function is required. The third position will be zerofilled when further definition is not required. Should further definition be required, numeric 1 through 9 and alpha A through Z, excluding I and O, will be used. The fifth element is provided to create unique numbers for all tasks or sub-tasks which are similarly numbered through the first four elements. Tasks shall be numbered from 801 through 999. Sub-tasks shall be numbered 001 through 800.
Element No. 4
Element No. 5
Table 2. Task Code Layout Task 000 010 020 Description REMOVAL AND DISASSEMBLY Removal Remove Modular Sections Definition
Removal of the engine/component from a work stand, transport dolly, test stand, etc. or aircraft. This is the first echelon of disassembly which consists of sectionalization of the unit/engine into primary modular sections. Modular sections are identified by the third element of the ATA number when removed from the unit/engine.
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Table 2. Task Code Layout (Cont) Task 030 Description Definition Disassemble Modular This is the second echelon of disassembly which consists of Sections disassembly of the modular sections into subassemblies after removal from the unit/engine. Modular section designations appear in the second element of the ATA number for this echelon of disassembly. Disassemble This is the third echelon of engine disassembly which consists of Subassemblies disassembly of subassemblies to the piece part level. The subassemblies are identified by the third element of the ATA number. Remove Accessory/ This consists of removing individual accessory/power plant Power Plant components from either installed or uninstalled engines. Components CLEANING CLEANING Chemical Removal of surface deposits from a part by use of a chemical cleaning agent. After being dissolved, the deposit is washed or rinsed away after a soaking period. Also includes chemical power flushing. Abrasive Removal of surface deposits from a part by wet or dry particle impingement. Ultrasonic Removal of surface deposits and entrapped material by use of high frequency sound waves to produce cavitation at the surface of the part. Cleaning is performed in a liquid bath that transmits the sound energy and keeps the removed material in suspension. Mechanical Removal of surface deposits from a part by use of a brush, felt bob, sandpaper, or other hand or mechanical action. Unassigned UNASSIGNED Miscellaneous Removal of deposits from parts with compressed air, miscellaneous hand cleaning, and various combinations of cleaning procedures. Foam/Water Wash Removal or post emulsified fluorescent penetrant via an agitated water wash, automatic spray rinse, or an aqueous remover aerated to produce a foam. Testing of Solutions Test used to assist in identifying certain materials by electromechanically determining the presence or absence of known constituents. Unassigned UNASSIGNED INSPECTION INSPECTION Check A thorough visual examination of components, accessories, subsystems, and piece parts to detect structural failure, deterioration or damage: and to determine the need for corrective action. For example: exterior surfaces, electronic circuit cards, gears, control systems, linkages, accessories, components, tubing, wiring and connections, safety wiring, fasteners, clamps, etc., are inspected to verify proper condition and acceptability for continued service.
040
050
100 110
120 130
140 150 160
170
180
190 200 210
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Table 2. Task Code Layout (Cont) Task 220 Description Visual/Dimensional Definition A comparison of the dimensions and material conditions of parts, subassemblies, and assemblies with the specifications contained in technical manuals and/or blueprints, to detect deviations from established standard and limits and determine the acceptability for continued service, repair, or need to discard the item. A visual/ dimensional function code is also required to verify that proper corrective maintenance has been accomplished. Although some of these tasks may not require measurements, a complete spectrum of tasks/sub tasks requires a variety of measuring equipment to determine runout, concentricity, flatness, parallelism, hardness, thickness, clarity, dimensions, etc. Fluorescent penetrant inspection to detect surface cracks. Magnetic particle inspection to detect surface cracks in magnetic materials. Inspection for subsurface cracks, porosity, inclusions, or other non-homogeneous material structure by use of high frequency electromagnetic wave equipment. Parts are scanned and compared to similar parts or test specimens having known material defects. Inspection for subsurface cracks, porosity, inclusions, or other non-homogeneous material structure by use of x-ray techniques. Inspection for subsurface cracks, porosity, inclusions, or other non-homogeneous material structure by use of contact pulse echo ultrasonic techniques. Any special inspection to determine the integrity of a part for continued operation in service or qualitative analysis. UNASSIGNED REPAIR The joining of pieces by welding (fusion, resistance, spot, electron beam, plasma arc), brazing (furnace, torch, induction), or soldering.This category includes hard facing. Process of obtaining a desired shape or finish by grinding, turning, boring, reaming, broaching, milling, drilling, lapping, honing, sizing, polishing, buffing, cutting, forming, stamping, blanking, etc. Removing or applying a metallic coating on a surface by mechanical, chemical, or electrical means. Plating of chromium, cadmium, tin, etc. to build up the size of a part or provide surface protection. Includes masking or waxing prior to the process. The application of a protective coating to a part by feeding a powder into an ionized gas stream. Flame spraying uses a fuel oxygen flame to melt and propel metal onto parts to build up the size or provide surface protection. Repairing parts by hand (cutting, drilling, polishing, grinding, lapping, riveting, blending, routing, fitting, burring, planishing, sanding, sawing, recambering, drilling, tapping, heating, chilling) and including miscellaneous disassembly and assembly required.
230 240 250
Penetrant Magnetic Eddy Current
260 270
X-Ray Ultrasonic
280 290 300 310
Special Unassigned REPAIR Welding and Brazing
320
Machining
330
Stripping and Plating
340
Plasma and Flame Spraying
350
Miscellaneous Repairs
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Table 2. Task Code Layout (Cont) Task 355 Description Miscellaneous Component Repairs Definition Detailed instructions for the repair of the components identified as repairable within the HMM and contain unique procedures to accomplish the repair. Bonding and Molding/ Joining and curing of parts with an adhesive or fusible material Sealing (including silicone, fiberglass, glues). Heat Treating Controlled heating and cooling of a material to obtain the desired physical property (includes annealing, tempering, quenching, stress relieving, solution heat treat, etc.). Surface Treating Treating the surface of a part by painting, varnishing, aluminizing, Teflon coating, zinc chromate priming, tumble finishing, shot peening, etc. Baking and masking processes are included. Machine riveting and Joining of parts by riveting and flaring the rivet. Flaring INSTALLATION AND INSTALLATION AND ASSEMBLY ASSEMBLY Install Installation of the unit/engine onto a work stand, transport dolly, test stand, or aircraft. Install Modular The third echelon of assembly consisting of assembly of the Sections modular assemblies into a complete unit/engine assembly. The modular sections are identified by the third element of the ATA number. Assemble Modular The second echelon of assembly consisting of assembling Sections subassemblies into modular sections. The modular section is identified by the second element of the ATA number. Assemble The first echelon of assembly consisting of assembling piece parts Subassemblies into subassemblies. The subassemblies are identified by the third element of the ATA number. Installation or closing of access plates, closing of ports, Install/Close Items installation of components, tubing or any item which was removed Remove/Opened for or opened in order to provide access to perform the task. Access MATERIAL MATERIAL HANDLING HANDLING Shipping The movement of any part, subassembly, assembly, or component from the time it is packaged until it reaches its destination. Receiving The receipt activity for any incoming part, subassembly, assembly, or component. Packing Installing parts, subassemblies, assemblies, or components into shipping containers. Unpacking Removing parts, subassemblies, assemblies, or components from shipping containers. Storage Safekeeping of parts, subassemblies, assemblies, or components until required for use. Marshaling/ Marshaling is collection of parts, subassemblies, and accessories Positioning prior to release for assembly. Positioning is movement from one fixed state to another.
360 370
380
390 400 410 420
430
440
450
500 510 520 530 540 550 560
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Table 2. Task Code Layout (Cont) Task 570 580 590 600 Description Engine Ferry/Pod Maintenance Unassigned Unassigned SERVICING/ PRESERVING/ LUBRICATING Servicing Preserving Definition Necessary preparations before and after transporting an engine by aircraft ferry method. UNASSIGNED UNASSIGNED SERVICING/PRESERVING/LUBRICATING
610 620
630 640 650 660 670 680 690 700 710 720 730 740 750
Depreserving Lubricating Unassigned Unassigned Unassigned Unassigned Unassigned TESTING/CHECKING Oil Flow Air Flow Fuel Flow Water Flow Electrical/Return to Service
760 770 780 790 800
Engine Accessory/Bite Pressure Check Leak Check MISCELLANEOUS
Action required to sustain a unit or system in proper operating status including priming with applicable fluids prior to use. Preparation of a unit, part, assembly, etc., for safekeeping from decomposition or deterioration. Includes preparation for storage (applying a preservative layer, desiccants, etc.). Removing preservatives, desiccants, etc. from a unit, part, assembly, etc., prior to installation or operation. Applying oil, grease, dry film, or silicon lubricants on moving parts to reduce friction or cool the item. UNASSIGNED UNASSIGNED UNASSIGNED UNASSIGNED UNASSIGNED TESTING/CHECKING Measuring the flow of oil through components or compartments under specific conditions. Measuring the flow of air through components or compartments under specific conditions. Function checks and flow measurements through the part or system being tested. Function checks and flow measurements through the part or system being tested. Functional tests of the system or component as well as measurement of electrical or electronic parameters designed to determine whether the item can be returned to service. May include fault isolation procedures for components that require close correlation between test results and fault indications. Operation of an engine to establish systems function or operation under specific conditions to measure performance. Testing of an accessory to ensure proper operation or function. Testing to establish the ability of a normally pressurized component or system to operate properly. Determine the ability of a component or system to operate without leaking. MISCELLANEOUS
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Table 2. Task Code Layout (Cont) Task 810 Definition Operating an improperly functioning system or component to locate the cause; or performing a series of checks to isolate a failed part or component. Adjusting/Aligning/ Making a physical correction to ensure proper placement or Calibrating operation of a system or component. Rigging Hooking-up, arranging, or adjusting a component or accessory linkage for proper operation. Service Bulletin Performing the work specified in the service bulletin. Provides for Incorporation identification of modification tasks at the task level with sub-tasks recognizing any functional changes (chemical, visual/ dimensional, cleaning, machining, etc.) necessary to incorporate the service bulletin. Part Number Change/ Change of part number, application of part number by transfer, Reidentification engrave repair number, etc. Unassigned UNASSIGNED Description & DESCRIPTION AND OPERATION Electrical and mechanical Operation description of the unit or component. Includes leading particulars, descriptions, limitations, specifications, and theory of operation. Approved Vendor Includes processes that may be proprietary and controlled by a Processes particular manufacturer, or by non-proprietary and approved for application by conforming vendors. Airline Maintenance (CUSTOMER USE) Program Unassigned UNASSIGNED Special Equipment Identification of tasks to maintain special support equipment. Maintenance Standard Equipment Identification of tasks to maintain standard support equipment. Maintenance Tool Fabrication Includes fabricating any tool for which procedures to use are included in the manual. Special Tools, Equip Listing of all special tools, standard equipment, special equipment, and consumables required to perform maintenance on and Consumables the unit or component. Listing Illustrations, Tables, Unique number series for data retrieval of items that cannot be Front Matter, Etc. obtained by a task/sub-task number. Graphic, Illustration, Unique number series for general instructions. General Special Tools and Unique number series of tables in special tools and equipment. Equipment Materials and Unique number series. Compounds Description Fault Isolation
820 830 840
850 860 870
880
890 900 910 920 930 940
990 99G 99T 99M
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CHAPTER 70 STANDARD PRACTICES TABLE OF CONTENTS
SUBJECT GENERAL INFORMATION GENERAL INFORMATION STANDARD PRACTICES STANDARD PRACTICES CONVERSION FACTORS CONVERSION FACTORS (US AND METRIC) MACHINING DATA MACHINING DATA HAZARDOUS CHEMICALS HAZARDOUS CHEMICALS WATER TYPES WATER TYPES QUALITY OF GASES QUALITY OF GASES SOLUTION SHEETS SOLUTION SHEETS TECHNIQUES ASSEMBLY AND DISASSEMBLY TECHNIQUES INDUCTION HEAT INDUCTION HEATING FOR SHRINK FIT ASSEMBLY OF BEARINGS AND SEALS FASTENERS FASTENER RETENTION PROCEDURES SAFETY WIRE SAFETY WIRE PROCEDURE SAFETY CABLE SAFETY CABLE PROCEDURES
CHAPTER/ SECTION/ SUBJECT 70-00-00 70-00-01
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SUBJECT SAFETY CABLE SAFETY CABLE METHOD 1 (BERGEN TOOL) SAFETY CABLE SAFETY CABLE METHOD 2 (SNAPON TOOL) SAFETY CABLE SAFETY CABLE METHOD 3 (DANIELS (DMC) TOOL) RIVETED JOINTS RIVETED JOINTS ACCEPTABILITY LIMITS ACCEPTABILITY LIMITS FOR FORMED RIVETS ACCEPTABILITY LIMITS ACCEPTABILITY LIMITS FOR HISHEAR RIVETS HEAT TREATMENT HEAT-TREATMENT AND HANDLING OF 2024 ALUMINUM ALLOY RIVETS ACCEPTABILITY LIMITS ACCEPTABILITY LIMITS FOR BLIND RIVETS VISU-LOK VISU-LOK BLIND BOLT RIVET ASSEMBLIES HANDLING BEARINGS HANDLING OF BEARINGS TRI-WING FASTENERS TRI-WING FASTENERS MARKING PRACTICES MARKING PRACTICES TIME/CYCLE TIME/CYCLE MARKING OF PARTS TEMPORARY TEMPORARY MARKING
CHAPTER/ SECTION/ SUBJECT 70-11-03
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1 70-11-04 1 70-11-05 1 70-13-00 1 70-13-01 1 70-13-02 1 70-13-03 1 70-13-04 1 70-13-06 1 70-14-00 1 70-15-00 1 70-16-00 1 70-16-01 1 70-16-02 1
ALL
ALL
ALL ALL
ALL
ALL
ALL
ALL
ALL ALL ALL ALL ALL ALL
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SUBJECT ELECTROCHEMICAL ELECTROCHEMICAL ETCH MARKING VIBRO-PEEN VIBRO-PEEN MARKING METAL STAMP METAL STAMP MARKING LASER LASER MARKING GRIT BLAST GRIT BLAST MARKING DOT PEEN DOT PEEN MARKING FOR OPTICAL CHARACTER RECOGNITION SUITABILITY TEST SUITABILITY TEST OF TEMPORARY MARKING PRODUCTS CLEANING CLEANING ENGINE PARTS CHEMICAL CLEANING CHEMICAL CLEANING CLEANING METHOD NO. 1 CLEANING METHOD NO.1 SOLVENT DEGREASING CLEANING METHOD NO. 2 CLEANING METHOD DEGREASING CLEANING METHOD NO. CLEANING METHOD CLEANING CLEANING METHOD NO. NO. 2 VAPOR
PAGE
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1 70-16-04 1 70-16-05 1 70-16-06 1 70-16-07 1 70-16-08 1 70-16-80 1 70-20-00 1 70-21-00 1 70-21-01 1 70-21-02 1
ALL ALL ALL ALL ALL
ALL
ALL ALL ALL
ALL
ALL
3 NO. 3 STEAM 4
70-21-03 1 70-21-04 1 70-21-05 1 ALL ALL ALL
CLEANING METHOD NO.4 - DRY ABRASIVE BLAST CLEANING CLEANING METHOD NO. 5 CLEANING METHOD NO. 5 WET ABRASIVE BLAST CLEANING
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SUBJECT CLEANING METHOD NO. 6 CLEANING METHOD NO. 6 - HEAVYDUTY ALKALINE CLEANER (WITHOUT INHIBITED PHOSPHORIC ACID) CLEANING METHOD NO. 7 CLEANING METHOD NO. 7 - THREESTEP HEAVY-DUTY ALKALINE DESCALING (WITHOUT INHIBITED PHOSPHORIC ACID) CLEANING METHOD NO. 8 CLEANING METHOD NO. 8 CARBON REMOVAL FROM ALL MATERIALS CLEANING METHOD NO. 9 CLEANING METHOD NO. 9 LIGHT DUTY ALKALINE CLEANING OF TITANIUM ALLOYS CLEANING METHOD NO. 10 CLEANING METHOD NO. 10 - FOURSTEP ALKALINE CLEANING AND ACIDIC DESCALING (WITHOUT INHIBITED PHOSPHORIC ACID) CLEANING METHOD NO. 12 CLEANING METHOD NO. 12 HEAVYDUTY ACIDIC CLEANING FOR ALUMINUM CLEANING METHOD NO. 13 CLEANING METHOD NO. 13 MOLTEN SALT BATH AND ACIDIC DESCALING CLEANING METHOD NO. 14 CLEANING METHOD NO. 14 MANUALLY-ASSISTED DETERGENT CLEANING CLEANING METHOD NO. 15 CLEANING METHOD NO. 15 ULTRASONIC CLEANING CLEANING METHOD NO. 16
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1 70-21-07
ALL
1 70-21-08 1 70-21-09 1 70-21-10
ALL
ALL
ALL
1 70-21-12 1 70-21-13 1 70-21-14 1 70-21-15 1 70-21-16
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ALL
ALL
ALL
ALL
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SUBJECT CLEANING METHOD NO. 16 HEAVYDUTY ALKALINE CLEANER (WITH INHIBITED PHOSPHORIC ACID) CLEANING METHOD NO. 17 CLEANING METHOD NO. 17 THREESTEP HEAVY-DUTY ALKALINE DESCALING (WITH INHIBITED PHOSPHORIC ACID) CLEANING METHOD NO. 20 CLEANING METHOD NO. 20 FOURSTEP ALKALINE CLEANING AND ACIDIC DESCALING (WITH INHIBITED PHOSPHORIC ACID) CLEANING METHOD NO. 21 CLEANING METHOD NO. 21 CARBON REMOVAL BY COLD TANK TWO-PHASE REMOVER CLEANING METHOD NO. 22 CLEANING METHOD NO. 22 LIGHT DUTY AQUEOUS CLEANING CLEANING METHOD NO. 23 CLEANING METHOD NO. 23 HANDWIPE DEGREASING CLEANING METHOD NO. 24 CLEANING METHOD NO. 24 EXTERIOR ENGINE CLEANING CLEANING METHOD NO. 25 CLEANING METHOD NO. 25 REMOVAL OF CARBON WITH ALKALINE GEL CLEANING METHOD NO. 26 CLEANING METHOD NO. 26 ELECTRICAL WIRE HARNESS AND CONTACT CLEANING CLEANING PRECAUTIONS SPECIAL CLEANING PRECAUTIONS SPECIAL CLEANING NO. 1
PAGE 1
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70-21-17
1 70-21-20
ALL
1 70-21-21 1 70-21-22 1 70-21-23 1 70-21-24 1 70-21-25 1 70-21-26
ALL
ALL
ALL
ALL
ALL
ALL
1 70-22-00 1 70-22-01
ALL ALL
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SUBJECT SPECIAL CLEANING PROCEDURE NO. 1 - CLEANING OF BEARINGS USING SOLVENT (Method 1) OR WATER-BASED SOLUTION (Method 2) SPECIAL CLEANING NO. 2 SPECIAL CLEANING PROCEDURE NO. 2 - TITANIUM CLEANING SPECIAL CLEANING NO. 3 SPECIAL CLEANING PROCEDURE NO. 3 CLEANING EXTERNAL TUBES AND HOSES - Methods 1 and 2 SPECIAL CLEANING NO. 4 SPECIAL PROCEDURE NO. 4 CLEANING URETHANE-COATED ACOUSTIC PANELS SPECIAL CLEANING NO. 5 SPECIAL CLEANING PROCEDURE NO. 5 - CLEANING INTERNAL LUBE OIL TUBES SPECIAL CLEANING NO. 6 SPECIAL CLEANING PROCEDURE NO. 6 - BOLTHOLE CLEANING FOR EDDY CURRENT INSPECTION SPECIAL CLEANING NO. 9 SPECIAL CLEANING PROCEDURE NO. 9 FLUORESCENT PENETRANT REMOVAL BETWEEN SPECIAL REPETITIVE FLUORESCENT PENETRANT INSPECTIONS CLEANING METHOD CLEANING METHOD FOR CLEANING OF BOLTS, SCREWS, AND SHOULDERED STUDS STRIPPING PROCEDURES STRIPPING PROCEDURES STRIPPING METHOD NO. 1 STRIPPING METHOD NO. 1 STRIPPING EPOXY, POLYSULFIDE, AND POLYURETHANE PAINT SYSTEMS (HOT TANK METHOD)
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1 70-22-02 1 70-22-03 1 70-24-04 1 70-22-05 1 70-22-06 1 70-22-09
ALL
ALL
ALL
ALL
ALL
ALL
1 70-22-10 1 70-23-00 1 70-23-01
ALL
ALL ALL
ALL
Page TC-6 Dec 01/03
70-CONTENTS
SUBJECT STRIPPING METHOD NO. 2 STRIPPING METHOD NO. 2 STRIPPING SERMETEL W PAINT STRIPPING SILVER PLATE STRIPPING SILVER PLATE (ELECTROLYTIC METHOD) STRIPPING NICKEL AND SILVER PLATE STRIPPING NICKEL AND SILVER PLATE (CHEMICAL SOLUTIONS) STRIPPING CHROMIUM PLATE STRIPPING CHROMIUM PLATE STRIPPING SILVER THERMAL SPRAY STRIPPING SILVER THERMAL SPRAY FROM STATIONARY AIR AND OIL SEALS STRIPPING OF THERMAL SPRAY STRIPPING OF THERMAL SPRAY ALUMINUM OXIDE, NON-FERROUS, AND BOND COATINGS STRIPPING ALUMINUM BOND COATS STRIPPING OF PURE ALUMINUM AND NICKEL-ALUMINUM BOND COATINGS STRIPPING TUNGSTEN CARBIDE STRIPPING TUNGSTEN CARBIDE THERMAL SPRAYED COATING STRIPPING URETHANE COATING STRIPPING URETHANE COATING FROM UNPERFORATED METAL AND PLASTIC PARTS MOLTEN SALT METHOD MOLTEN SALT METHOD FOR STRIPPING SPRAYED TUNGSTEN OR CHROME CARBIDE STRIPPING THERMAL SPRAY STRIPPING THERMAL SPRAYED COATINGS STRIPPING NICKEL PLATE STRIPPING NICKEL PLATE
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EFFECTIVITY
1 70-23-03 1 70-23-04 1 70-23-05 1 70-23-06 1 70-23-07 1 70-23-08 1 70-23-09 1 70-23-10 1 70-23-11 1 70-23-12 1 70-23-13 1
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Page TC-7 Dec 01/03
70-CONTENTS
SUBJECT STRIPPING EPOXY RESIN STRIPPING EPOXY RESIN FROM ALUMINUM STRIPPING ANODIZED COATING STRIPPING ANODIZED COATING FROM ALUMINUM STRIPPING CHROMIUM CARBIDE STRIPPING CHROMIUM CARBIDE (WITH OR WITHOUT METCO 450 UNDERCOAT) THERMAL SPRAYED COATING STRIPPING ALUMINUM HONEYCOMB STRIPPING ALUMINUM HONEYCOMB BONDED WITH NARMCO METAL BOND 328 STRIPPING OF THERMAL SPRAY STRIPPING OF THERMAL SPRAYED ALUMINUM OXIDE/ NICKEL ALUMINIDE COATINGS - Inco-718, Ti-17 or Ti-6-4 STRIPPING OF THERMAL SPRAY STRIPPING OF THERMAL SPRAYED ALUMINUM OXIDE/ NICKEL ALUMINIDE COATINGS INCO-718, Ti-17, Ti-6-4, RENe 95, AND RENe 41 STRIPPING SILICONE RUBBER STRIPPING SILICONE RUBBER FROM TITANIUM AND ALUMINUM STRIPPING ELECTROLESS NICKEL STRIPPING ELECTROLESS NICKEL FROM MARAGE 250 STRIPPING OF THERMAL BARRIER STRIPPING OF THERMAL BARRIER TOP COATINGS AND NICKELCHROMIUM-ALUMINUM-YTTRIA BOND COATINGS HIGH PRESSURE WATER STRIPPING REMOVAL OF COATINGS BY HIGH PRESSURE WATER STRIPPING ULTRASONIC STRIPPING
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EFFECTIVITY
1 70-23-15 1 70-23-16
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1 70-23-17 1 70-23-18
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1 70-23-19
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1 70-23-20 1 70-23-21 1 70-23-22
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1 70-23-23 1 70-23-24
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Page TC-8 Dec 01/03
SUBJECT ULTRASONIC STRIPPING OF ROTATING PARTS NICKEL AND SILVER PLATE STRIPPING NICKEL AND SILVER PLATE STRIPPING THREE-LAYER SERMATEL STRIPPING OF THREE-LAYER SERMATEL 1638 COATING SOLUTION SHEETS SOLUTION SHEETS FOR CONSUMABLE MATERIALS ETCHING PROCEDURES ETCHING PROCEDURES FOR FLUORESCENT-PENETRANT INSPECTION SWAB ETCHING PROCEDURE SWAB ETCHING PROCEDURE DIP ETCHING PROCEDURE DIP ETCHING PROCEDURE ETCHING SOLUTIONS CONSUMABLE MATERIALS ETCHING SOLUTIONS INSPECTION METHODS INSPECTION METHODS DIMENSIONAL INSPECTION DIMENSIONAL INSPECTION USE LIMITS FOR INSTRUMENTS USE LIMITS FOR STANDARD MEASURING INSTRUMENTS ACCEPTABILITY LIMITS ACCEPTABILITY LIMITS FOR FLUORESCENT-PENETRANT INSPECTION TUBE FORMING LIMITS TUBE FORMING REQUIREMENTS FOR SECTION REPLACEMENT REPAIRS ACCEPTABILITY LIMITS
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EFFECTIVITY ALL
70-23-25 1 70-23-26 1 70-23-99 1 70-24-00 1 70-24-01 1 70-24-02 1 70-24-99 1 70-30-00 1 70-31-00 1 70-31-01 1 70-31-02 1 70-31-03 1 70-31-04 ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL
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Page TC-9 Dec 01/03
SUBJECT ACCEPTABILITY LIMITS FOR OPENFACE HONEYCOMB ACCEPTABILITY LIMITS ENGINE PART SURFACE INTEGRITY ACCEPTABILITY LIMITS FOR NONTRADITIONAL MACHINED SURFACES MACHINED TOLERANCES MACHINED FEATURES SHOP-RUN TOLERANCES SHEET METAL TOLERANCES SHEET METAL PART AND FABRICATED ASSEMBLIES SHOPRUN TOLERANCES INDIRECT INSPECTION INDIRECT INSPECTION METHODS MAGNETIC PARTICLE MAGNETIC-PARTICLE METHOD FLUORESCENT PENETRANT FLUORESCENT PENETRANT INSPECTION SPOT-FLUORESCENT PENETRANT SPOT-FLUORESCENT-PENETRANT INSPECTION RADIOGRAPHIC INSPECTION RADIOGRAPHIC INSPECTION ULTRASONIC INSPECTION ULTRASONIC INSPECTION EDDY CURRENT INSPECTION HIGH SPEED AND SLOW SPEED EDDY CURRENT INSPECTION EDDY CURRENT INSPECTION 2 MHz MANUAL EDDY CURRENT INSPECTION OF BORES IN TITANIUM ALLOY ROTATING ENGINE HARDWARE IMMERSION ULTRASONIC INSPECTION
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EFFECTIVITY ALL
70-31-05
1 70-31-06 1 70-31-07 1 70-32-00 1 70-32-01 1 70-32-02 1 70-32-03 1 70-32-05 1 70-32-06 1 70-32-07 1 70-32-08
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1 70-32-09
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Page TC-10 Dec 01/03
SUBJECT IMMERSION ULTRASONIC INSPECTION OF ENGINE RUN HARDWARE EDDY CURRENT INSPECTION 2 MHz EDDY CURRENT INSPECTION OF BORES IN ROTATING ENGINE HARDWARE USING SYSTEMS UNDER COMPUTER, NUMERIC, OR ROBOTIC CONTROL WHITE LIGHT INSPECTION WHITE LIGHT INSPECTION EDDY CURRENT INSPECTION EDDY CURRENT INSPECTION OF BORES IN INCONEL ROTATING ENGINE HARDWARE ENHANCED VISUAL INSPECTION ENHANCED VISUAL INSPECTION THERMOGRAPHIC INSPECTION THERMOGRAPHIC INSPECTION PROCEDURE ULTRASONIC THICKNESS INSPECTION ULTRASONIC THICKNESS INSPECTION OF ENGINE HARDWARE FOR THIN WALL MATERIAL TEST OF MAGNETIC-PARTICLE TEST OF MAGNETIC-PARTICLE INSPECTION PROCESS TEST OF FLUORESCENT-PENETRANT TEST OF FLUORESCENTPENETRANT TEST OF EMULSIFIER OR REMOVER TEST OF EMULSIFIER OR REMOVER SPECIAL INSPECTIONS SPECIAL INSPECTION PROCEDURES ANTIFRICTION BEARINGS
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70-32-10
1 70-32-11 1 70-32-12
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1 70-32-19 1 70-32-21 1 70-32-21
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1 70-32-80 1 70-32-81 1 70-32-82 1 70-33-00 1 70-33-01
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SUBJECT ANTIFRICTION BEARING INSPECTION HONEYCOMB STRUCTURES CAPILLARY INSPECTION OF OPEN FACE HONEYCOMB STRUCTURES FRETTING OR GALLING SPECIAL INSPECTION FOR SURFACE FRETTING OR GALLING INSPECTION OF SPLINES INSPECTION OF SPLINES HONEYCOMB SEALS INSPECTION OF HONEYCOMB SEALS INSPECTION OF SPLINES INSPECTION OF SPLINES HARDNESS MEASUREMENT HARDNESS MEASUREMENT GENERAL BRINELL HARDNESS TESTING BRINELL HARDNESS TESTING VICKERS HARDNESS TESTING VICKERS HARDNESS TESTING ROCKWELL HARDNESS TESTING ROCKWELL HARDNESS TESTING PORTABLE ROCKWELL HARDNESS TEST PORTABLE ROCKWELL HARDNESS TESTING STAND DESIGN REQUIREMENTS MULTIPLE PURPOSE AIRFLOW MEASUREMENT STAND DESIGN REQUIREMENTS AIRFLOW MEASUREMENT AIRFLOW MEASUREMENT WELDING AND BRAZING PRACTICES WELDING AND BRAZING PRACTICES
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EFFECTIVITY ALL
70-33-02 1 70-33-03 1 70-33-04 1 70-33-05 1 70-33-06 1 70-34-00 1 70-34-01 1 70-34-02 1 70-34-03 1 70-34-04 1 70-35-00 1 70-35-01 1 70-41-00 1 ALL
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SUBJECT TITANIUM WELDING TITANIUM WELDING PROCEDURE BRAZING OF JOINTS IN FORMED TUBING BRAZING OF JOINTS IN FORMED TUBING HIGH TEMPERATURE FURNACE BRAZE HIGH TEMPERATURE FURNACE BRAZE RESISTANCE WELDING RESISTANCE WELDING - SPOT, SEAM, AND PROJECTION ELECTRON BEAM WELDING ELECTRON BEAM WELDING PROCEDURE PLASMA ARC WELDING PLASMA ARC WELDING PROCEDURE AUTOMATIC WELDING AUTOMATIC WELDING FOR KNIFE EDGE SEAL REPAIR (Formerly Dabber Tig Welding) PREPARATION PROCEDURE PREPARATION PROCEDURE FOR FLUX-AIDED GAS TUNGSTEN ARC WELDING BLENDING AND REMOVAL OF HIGH METAL BLENDING AND REMOVAL OF HIGH METAL PROCEDURES POLISHING BOLT HOLE SURFACES POLISHING BOLT HOLE SURFACES REPAIR PRACTICES REPAIR PRACTICES FOR HOLE REWORK TOUCH-UP SILICONE-ALUMINUM PAINT TOUCH-UP SILICONE-ALUMINUM PAINT
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70-41-02 1 70-41-03 1 70-41-04 1 70-41-05 1 70-41-06 1 70-41-07 1 70-41-08 1 70-42-00 1 70-42-01 1 70-42-02 1 70-43-01 1 ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL
70-CONTENTS
SUBJECT PAINT ONE-COAT PROCESS SILICONE-ALUMINUM PAINT ONECOAT PROCESS PAINT TWO-COAT PROCESS SILICONE-ALUMINUM PAINT TWOCOAT PROCESS EPOXY PAINTING EPOXY PAINTING PROTECTIVE COATING INORGANIC ALUMINUM PROTECTIVE COATING CLEAR EPOXY COATING CLEAR EPOXY PAINTING CHEMICAL TOUCH-UP FOR ALUMINUM CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM CHEMICAL FILM COATING FOR ALUMINUM CHEMICAL FILM COATING FOR ALUMINUM REPLACEMENT OF DRY-FILM LUBRICANT REPLACEMENT OF DRY-FILM LUBRICANT COLLOIDIAL GRAPHITE COATING COLLOIDAL GRAPHITE COATING C02-028 COLLOIDIAL GRAPHITE COATING COLLOIDAL GRAPHITE COATING C02-030 BLACK OXIDE FINISH BLACK OXIDE FINISH ELASTOMER COATING ELASTOMER COATING, ABRASION RESISTANT URETHANE ELASTOMER TOUCH-UP URETHANE ELASTOMER TOUCH-UP
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EFFECTIVITY
1 70-43-03 1 70-43-04 1 70-43-05 1 70-43-06 1 70-43-07 1 70-43-08 1 70-43-09 1 70-43-10 1 70-43-11 1 70-43-12 1 70-43-13 1 70-43-14 1
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SUBJECT SOLID-FILM LUBRICANT ABRADABLE PLASTIC SEAL COMPOUND (RSP-3) SOLID-FILM LUBRICANT SOLID-FILM LUBRICANT - C02-049 EPOXY REPAIR EPOXY REPAIR OF MATING SURFACES AND INSERTS CHEMICAL TOUCH-UP OF ALUMINUM CHEMICAL TOUCH-UP OF ALUMINUM PROTECTIVE COATING (CHROMATE CONVERSION COATING) - C03-008 SOLID-FILM LUBRICANT SOLID-FILM LUBRICANT - C02-027 HONEYCOMB BONDMENT ADHESIVE HONEYCOMB BONDMENT ADHESIVE SURFACE PREPARATION SURFACE PREPARATION OF ALUMINUM FOR REPAIR BONDMENTS (GELLED PHOSPHORIC ACID ANODIZE METHOD) EPOXY POLYAMIDE COATING PAINT - EPOXY COATING FOR ALUMINUM AND FERROUS ALLOYS CHEMICAL TOUCH-UP CHEMICAL TOUCH-UP FOR BLACK OXIDE SURFACE COATINGS MOLYBDENUM DISULFIDE APPLICATION OF MOLYBDENUM DISULFIDE DISPERSED IN POLYIMIDE RESIN GRAPHITE LUBRICANT APPLICATION OF SOLID FILM GRAPHITE LUBRICANT DAG-143 SILICONE ABRADABLE COATING
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EFFECTIVITY
1 70-43-16 1 70-43-17 1 70-43-18
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1 70-43-19 1 70-43-20 1 70-43-21
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1 70-43-22 1 70-43-23 1 70-43-24 1 70-43-25 1 70-43-26
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SUBJECT APPLICATION OF SILICONE ABRADABLE COATING CHARGED WITH GLASS BEADS EPOXY POLYAMIDE COATING PAINT - EPOXY POLYAMIDE COATING THREAD LUBRICANT COATING APPLICATION OF PETROLATUM GRAPHITE THREAD LUBRICANT COATING - C02-079 MIXING INSTRUCTIONS MIXING INSTRUCTIONS FOR CONSUMABLE MATERIALS EQUIPMENT AND SETUP LOCALIZED HEAT TREATMENT EQUIPMENT AND SETUP HEAT TREAMENT PROCEDURES LOCALIZED HEAT TREATMENT PROCEDURES FURNACE HEAT TREATMENT FURNACE HEAT TREATMENT EQUIPMENT CALIBRATION HEAT TREAT EQUIPMENT CALIBRATION CHROME PLATING CHROME PLATING PROCEDURE ELECTROLESS NICKEL PLATING ELECTROLESS NICKEL PLATING SELECTIVE CONTACT PLATING SELECTIVE CONTACT PLATING SILVER PLATING SILVER PLATING MASKING AND CLEANING MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS SHOTPEENING
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70-43-27 1 70-43-28 1 70-43-99 1 70-44-01 1 70-44-02 1 70-44-03 1 70-44-04 1 70-45-01 1 70-45-02 1 70-45-03 1 70-45-04 1 70-46-01 ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL
1 70-47-01
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SUBJECT SHOTPEENING WET ABRASIVE BLAST WET ABRASIVE BLAST SURFACE FINISHING DRY ABRASIVE BLAST DRY ABRASIVE BLAST SURFACE FINISHING ROTARY FLAP PEENING ROTARY FLAP PEENING COLD-WORKING REPAIR COLD-WORKING REPAIR THREADED INSERTS THREADED INSERTS HELI-COIL INSERTS HELI-COIL INSERTS LOK-THREAD INSERTS LOK-THREAD INSERTS TAP-LOK INSERTS TAP-LOK INSERTS LOK-THREAD STUDS LOK-THREAD STUDS FLUID-FITTING INSERTS RING-LOCKED FLUID-FITTING (ROSAN) INSERTS THIN-WALL INSERTS THIN-WALL INSERTS REPAIR OF BLIND THREADED HOLES REPAIR OF BLIND THREADED HOLES IN ALUMINUM CASTINGS REPAIR OF THREADED THROUGHHOLES REPAIR OF THREADED THROUGHHOLES IN ALUMINUM CASTINGS KEY-LOCKED INSERTS INSTALLATION OF KEY-LOCKED INSERTS
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EFFECTIVITY ALL
1 70-47-03 1 70-47-04 1 70-47-05 1 70-48-00 1 70-48-01 1 70-48-02 1 70-48-03 1 70-48-05 1 70-48-07 1 70-48-08 1 70-48-09 1 70-48-10 1 70-48-11 1
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SUBJECT KEY-LOCKED STUDS INSTALLATION OF KEY-LOCKED STUDS SHANK NUT REPAIR SHANK NUT REPAIR ANCHOR NUTS AND WING BOLTS REMOVAL OF ANCHOR NUTS AND WING BOLTS EXPANSION PLUGS AND TAPERED PINS REPLACEMENT OF EXPANSION PLUGS AND TAPERED PINS (LEE PLUGS) ROSAN STUDS REPLACEMENT OF ROSAN STUDS KELOX INSERTS REPLACEMENT OF KELOX INSERTS KELOX STUDS REPLACEMENT OF KELOX STUDS ROSAN RING LOCKED INSERT ROSAN RING LOCKED INSERT REPLACEMENT INDENTATION STAKING INDENTATION STAKING THERMAL SPRAYING THERMAL SPRAYING PURE ALUMINUM (POWDER) THERMAL SPRAYING PURE ALUMINUM (POWDER) ALUMINUM OXIDE - ALUMINA (POWDER) THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER) CHROMIUM CARBIDE (POWDER) THERMAL SPRAYING CHROMIUM CARBIDE (POWDER) COPPER-NICKEL ALLOY (POWDER)
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EFFECTIVITY
1 70-48-13 1 70-48-14 1 70-48-15 1 70-48-16 1 70-48-17 1 70-48-18 1 70-48-19 1 70-48-20 1 70-49-00 1 70-49-01 1 70-49-02 1 70-49-03 1 70-49-04
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SUBJECT THERMAL SPRAYING COPPERNICKEL ALLOY (POWDER) COPPER-NICKEL-INDIUM (POWDER) THERMAL SPRAYING COPPERNICKEL-INDIUM (POWDER) MAGNESIUM ALLOY (WIRE) THERMAL SPRAYING MAGNESIUM ALLOY (WIRE) MOLYBDENUM (POWDER) THERMAL SPRAYING MOLYBDENUM (POWDER) MOLYBDENUM (WIRE) THERMAL SPRAYING MOLYBDENUM (WIRE) NICKEL-ALUMINIDE (POWDER) THERMAL SPRAYING NICKELALUMINIDE (POWDER) NICKEL-ALUMINUM (POWDER) THERMAL SPRAYING NICKELALUMINUM (POWDER) NICKEL-ALUMINUM (WIRE) THERMAL SPRAYING NICKELALUMINUM (WIRE) NICKEL-CHROMIUM (POWDER) THERMAL SPRAYING NICKELCHROMIUM (POWDER) NICKEL-CHROMIUM (WIRE) THERMAL SPRAYING NICKELCHROMIUM (WIRE) 75:25 NICKEL-GRAPHITE (POWDER) THERMAL SPRAYING 75:25 NICKELGRAPHITE (POWDER) 85:15 NICKEL-GRAPHITE (POWDER) THERMAL SPRAYING 85:15 NICKELGRAPHITE (POWDER) NICKEL-SILICON-BORON (POWDER) THERMAL SPRAYING NICKELSILICON-BORON (POWDER)
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EFFECTIVITY ALL
70-49-05 1 70-49-06 1 70-49-07 1 70-49-08 1 70-49-09 1 70-49-10 1 70-49-11 1 70-49-12 1 70-49-13 1 70-49-14 1 70-49-15 1 70-49-16 1 ALL
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SUBJECT COPPER-ZINC-SILVER ALLOY (WIRE) THERMAL SPRAYING COPPERZINC-SILVER ALLOY (WIRE) 50 PERCENT TUNGSTEN CARBIDE THERMAL SPRAYING 50 PERCENT TUNGSTEN CARBIDE SELFBONDING BLEND (POWDER) TUNGSTEN CARBIDE (POWDER) THERMAL SPRAYING TUNGSTEN CARBIDE (POWDER) CHROMIUM CARBIDE NO. 1 THERMAL SPRAYING CHROMIUM CARBIDE NO. 1 COMPOSITE (POWDER) NICKEL-CHROMIUM/ALUMINUM THERMAL SPRAYING NICKELCHROMIUM/ALUMINUM COMPOSITE (POWDER) ALUMINA/NICKEL-ALUMINUM THERMAL SPRAYING ALUMINA/ NICKEL-ALUMINUM COMPOSITE (POWDER) PURE ALUMINUM (WIRE) THERMAL SPRAYING PURE ALUMINUM (WIRE) 75 PERCENT TUNGSTEN CARBIDE THERMAL SPRAYING 75 PERCENT TUNGSTEN CARBIDE SELFBONDING BLEND (POWDER) ALUMINUM BRONZE ALLOY (POWDER) THERMAL SPRAYING ALUMINUM BRONZE ALLOY (POWDER) ALUMINUM BRONZE ALLOY (WIRE) THERMAL SPRAYING ALUMINUM BRONZE ALLOY (WIRE) COBALT-MOLYBDENUM-CHROMIUMSILICON THERMAL SPRAYING COBALTMOLYBDENUM-CHROMIUM-SILICON ALLOY (POWDER) - TRIBALLOY 400
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EFFECTIVITY
1 70-49-18 1 70-49-19 1 70-49-20 1 70-49-21 1 70-49-22 1 70-49-23 1 70-49-24 1 70-49-25 1 70-49-26 1 70-49-27 1
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SUBJECT TUNGSTEN CARBIDE (POWDER) THERMAL SPRAYING TUNGSTEN CARBIDE (POWDER) 75% CHROMIUM CARBIDE - 25% NICKEL CHROMIUM THERMAL SPRAYING 75 PERCENT CHROMIUM CARBIDE - 25 PERCENT NICKEL CHROMIUM (POWDER) COBALT-MOLYBDENUM-CHROMIUMSILICON THERMAL SPRAYING COBALTMOLYBDENUM-CHROMIUM-SILICON ALLOY (POWDER) - TRIBALLOY 800 NICKEL-ALUMINUM-MOLYBDENUM THERMAL SPRAYING NICKELALUMINUM-MOLYBDENUM (POWDER) INCONEL 718 (POWDER) THERMAL SPRAYING INCONEL 718 (POWDER) ALUMINUM OXIDE - ALUMINA THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER) SUPERFINE ALUMINUM SILICON POLYESTER THERMAL SPRAYING ALUMINUM SILICON POLYESTER (POWDER) THERMAL BARRIER COATING SYSTEM THERMAL BARRIER COATING SYSTEM - YTTRIUM OXIDE STABILIZED ZIRCONIUM OXIDE (8% YTTRIUM OXIDE) OVER NICKEL CHROMIUM ALUMINUM YTTRIUM BONDCOAT HIGH DENSITY INCONEL 718 HIGH DENSITY INCONEL 718 COATING APPLIED BY HVOF THERMAL SPRAY TUNGSTEN CARBIDE/17 COBALT WEAR COATING
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EFFECTIVITY
1 70-49-29 1 70-49-30 1 70-49-31 1 70-49-32 1 70-49-33 1 70-49-34 1 70-49-35
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SUBJECT TUNGSTEN CARBIDE/17% COBALT WEAR COATING APPLIED BY HIGH VELOCITY OXY-FUEL (HVOF) PROCESS NICKEL ALUMINUM (WIRE) ELECTRIC-ARC WIRE SPRAYING NICKEL ALUMINUM (WIRE) NICKEL-CHROME-ALUMINUM (WIRE) ELECTRIC-ARC WIRE SPRAYING NICKEL-CHROME-ALUMINUM (WIRE) PURE ALUMINUM (WIRE) ELECTRIC-ARC WIRE SPRAYING PURE ALUMINUM (WIRE) HIGH DENSITY HVOF T-800 HIGH DENSITY HVOF T-800 (TRIBALOY) COATING COPPER-ZINC-SILVER (WIRE) ELECTRIC-ARC WIRE SPRAYING COPPER-ZINC-SILVER (WIRE) ALLOY 718 (WIRE) ELECTRIC-ARC WIRE SPRAYING ALLOY 718 (WIRE) NICKEL-CHROMIUM-SILICON-IRON NICKEL-CHROMIUM-SILICON-IRON COATING APPLIED BY HIGH DENSITY HIGH VELOCITY OXY-FUEL (HVOF) ALUMINUM SILICON POLYESTER THERMAL SPRAYING ALUMINUM SILICON POLYESTER (POWDER) COLD PROCESS HIGH DENSITY HVOF T-400 HIGH DENSITY HVOF T-400 (TRIBALOY) COATING COPPER-NICKEL-INDIUM (WIRE) ELECTRIC-ARC WIRE SPRAYING COPPER-NICKEL-INDIUM (WIRE) HIGH DENSITY HVOF RENE 80
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EFFECTIVITY
1 70-49-38 1 70-49-39 1 70-49-40 1 70-49-43 1 70-49-44 1 70-49-45 1 70-49-46
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SUBJECT HIGH DENSITY HVOF RENe 80 COATING PURE MOLYBDENUM (WIRE) ELECTRIC-ARC WIRE SPRAYING PURE MOLYBDENUM (WIRE) PURE ALUMINUM BRONZE (WIRE) ELECTRIC-ARC WIRE SPRAYING ALUMINUM BRONZE (WIRE) TIGHTENING PRACTICES AND TORQUE VALUES TIGHTENING PRACTICES AND TORQUE VALUES WRENCH-ARC METHOD WRENCH-ARC METHOD FOR TIGHTENING BALL-NOSE FITTINGS WRENCH-ARC METHOD WRENCH-ARC METHOD FOR TIGHTENING FLARELESS FITTINGS ENGINE PARTS PRESERVATION OF ENGINE PARTS ANTIFRICTION BEARINGS PRESERVATION OF ANTIFRICTION BEARINGS TESTING AND QUALITY ANALYSIS TESTING AND QUALITY ANALYSIS METAL TO METAL BONDING TESTING AND QUALITY ANALYSIS FOR METAL-TO-METAL BONDING BOND STRENGTH TENSILE TESTING BOND STRENGTH TENSILE TESTING OF THERMAL SPRAY COATINGS BOND STRENGTH LAP-SHEAR TESTING BOND STRENGTH LAP-SHEAR TESTING OF THERMAL SPRAY COATINGS SCRATCH-HARDNESS TESTING
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70-49-51 1 70-49-52 1 70-51-00 1 70-51-01 1 70-51-02 1 70-60-00 1 70-60-01 1 70-70-00 1 70-70-01 1 70-71-01 ALL ALL ALL ALL ALL ALL ALL ALL ALL
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SUBJECT SCRATCH-HARDNESS TESTING OF THERMAL SPRAY COATINGS METALLOGRAPHIC EVALUATION METALLOGRAPHIC EVALUATION OF THERMAL SPRAY COATINGS ADHESIVE BOND STRENGTH ADHESIVE BOND STRENGTH TENSILE LAP SHEAR TESTING ADHESIVE BOND STRENGTH ADHESIVE BOND STRENGTH CLIMBING DRUM PEEL ADHESIVE BOND STRENGTH ADHESIVE BOND STRENGTH FLATWISE TENSILE TESTING CONSUMABLE MATERIALS CONSUMABLE MATERIALS SECTION ADHESIVES, PLASTICS, SEALANTS CONSUMABLE PRODUCTS ADHESIVES, PLASTICS, SEALANTS ANTI-SEIZE COMPOUNDS, LUBRICANTS, OILS CONSUMABLE PRODUCTS ANTISEIZE COMPOUNDS, LUBRICANTS, OILS FINISHES AND PROTECTIVE COATINGS CONSUMABLE PRODUCTS FINISHES AND PROTECTIVE COATINGS CLEANING COMPOUNDS AND SOLVENTS CONSUMABLE PRODUCTS CLEANING COMPOUNDS AND SOLVENTS INSPECTION AND MARKING COMPOUNDS CONSUMABLE PRODUCTS INSPECTION AND MARKING COMPOUNDS WELD, BRAZE
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70-71-04 1 70-71-05 1 70-71-06 1 70-71-07 1 70-80-00 1 70-80-01 1 70-80-02 1 70-80-03 1 70-80-04 1 70-80-05 1 70-80-06 ALL ALL ALL ALL ALL ALL ALL ALL ALL ALL
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SUBJECT CONSUMABLE PRODUCTS WELD, BRAZE THERMAL SPRAY CONSUMABLE PRODUCTS THERMAL SPRAY MISCELLANEOUS CONSUMABLE PRODUCTS MISCELLANEOUS INDEXED BY SUPPLIERS TRADE NAME CONSUMABLE PRODUCTS INDEXED BY SUPPLIERs TRADE NAME INDEXED BY SUPPLIER CONSUMABLE PRODUCTS INDEXED BY SUPPLIER
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70-80-07 1 70-80-10 1 70-80-20 1 70-80-30 1 ALL ALL ALL ALL
70-CONTENTS
70-CONTENTS
LIST OF EFFECTIVE PAGES CHAPTER/ SECTION CHAPTER/ SECTION
PAGE
DATE
TAB STANDARD PRACTICES Table of Contents TC-1 TC-2 TC-3 TC-4 TC-5 TC-6 TC-7 TC-8 TC-9 TC-10 TC-11 TC-12 TC-13 TC-14 TC-15 TC-16 TC-17 TC-18 TC-19 TC-20 TC-21 TC-22 TC-23 TC-24 TC-25 TC-26 LEP-1 LEP-2 LEP-3 LEP-4 LEP-5 LEP-6 LEP-7 LEP-8 LEP-9 LEP-10 LEP-11 LEP-12 LEP-13 LEP-14 LEP-15 LEP-16 LEP-17 LEP-18 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
PAGE LEP-19 LEP-20 LEP-21 LEP-22 LEP-23 LEP-24 LEP-25 LEP-26 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-00-00
70-00-01
70-00-02
70-00-03
List of Effective Pages
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 1 2 3 4 5 6 7 8 1 2 1 2 1 2 3 4 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03
70-00-04
70-00-05 70-00-06 70-00-99
Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec 01/03 01/03 01/03 01/03
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 98.1 98.2 98.3 98.4 98.5 98.6 98.7 98.8 98.9 98.10 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 CHAPTER/ SECTION PAGE 98.11 98.12 98.13 98.14 98.15 98.16 98.17 98.18 98.19 98.20 98.21 98.22 98.23 98.24 98.25 98.26 98.27 98.28 98.29 98.30 98.31 98.32 98.33 98.34 98.35 98.36 98.37 98.38 98.39 98.40 98.41 98.42 98.43 98.44 98.45 98.46 98.47 98.48 98.49 98.50 98.51 98.52 98.53 98.54 98.55 98.56 98.57 98.58 98.59 98.60 98.61 98.62 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 98.63 98.64 98.65 98.66 98.67 98.68 98.69 98.70 98.71 98.72 98.73 98.74 98.75 98.76 98.77 98.78 98.79 98.80 98.81 98.82 98.83 98.84 98.85 98.86 98.87 98.88 98.89 98.90 98.91 98.92 98.93 98.94 98.95 98.96 98.97 98.98 98.99 98.100 98.101 98.102 98.103 98.104 1 2 3 4 5 6 7 8 9 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 1 2 3 4 5 6 7 8 1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-10-01
70-11-00
70-11-01
70-11-02 70-11-03
Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-10-00
70-11-04
Dec 01/03 Dec 01/03 Dec 01/03

70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 1 2 1 2 3 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 70-14-00 70-15-00 CHAPTER/ SECTION PAGE 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 1 2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 1 2 1 2 3 4 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-13-06
70-11-05
70-13-00 70-13-01
Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-16-00
70-16-01
70-13-02 70-13-03 70-13-04
Dec 01/03 Dec 01/03 70-16-02 Dec 01/03 Dec 01/03 70-16-03 Dec 01/03 Dec 01/03 Dec 01/03
Dec 01/03 Dec 01/03 Dec Dec Dec Dec 01/03 01/03 01/03 01/03
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 5 6 1 2 1 2 1 2 3 4 1 2 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 1 2 3 4 5 6 1 2 3 4 1 2 1 2 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 70-21-04 70-16-06 Dec Dec Dec Dec 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 3 4 1 2 3 4 1 2 3 4 5 6 7 8 9 10 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 6 1 DATE Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-16-04 70-16-05
70-21-03
70-16-07 70-16-08
Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 70-21-08 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-21-05
70-21-06
70-21-07 70-16-80
70-20-00
70-21-09
70-21-00
70-21-10
70-21-01 70-21-02
Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 70-21-12
Dec 01/03
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION 70-21-13 PAGE 2 1 2 3 4 1 2 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 6 1 2 1 2 3 4 5 6 1 2 3 4 1 2 1 2 DATE Dec 01/03 Dec Dec Dec Dec 01/03 01/03 01/03 01/03 70-22-00 70-21-14 70-21-15 Dec 01/03 Dec 01/03 70-22-01 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 70-22-02 CHAPTER/ SECTION 70-21-26 PAGE 1 2 3 4 1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 1 2 3 4 5 6 1 2 1 2 3 4 1 2 3 4 1 2 3 4 DATE Dec Dec Dec Dec 01/03 01/03 01/03 01/03
Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-21-16
70-21-17
70-21-20
70-22-03
70-21-21 70-21-22
Dec 01/03 Dec 01/03 70-22-04 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 70-22-05
70-21-23
70-22-06
70-21-24 70-21-25
Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03
70-22-09
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION 70-22-10 PAGE 1 2 3 4 5 6 1 2 1 2 3 4 1 2 1 2 1 2 1 2 3 4 1 2 1 2 3 4 1 2 3 4 1 2 3 4 1 2 1 2 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 70-23-14 70-23-01 Dec Dec Dec Dec 01/03 01/03 01/03 01/03 70-23-15 70-23-16 70-23-17 70-23-18 CHAPTER/ SECTION 70-23-12 PAGE 1 2 3 4 1 2 1 2 1 2 1 2 1 2 1 2 3 4 1 2 1 2 1 2 3 4 1 2 1 2 3 4 1 2 3 4 1 2 DATE Dec Dec Dec Dec 01/03 01/03 01/03 01/03
70-23-13 70-23-00
Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec 01/03 01/03 01/03 01/03
70-23-02 70-23-03 70-23-04 70-23-05
Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec 01/03 01/03 01/03 01/03
70-23-19 70-23-20 70-23-21
Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec 01/03 01/03 01/03 01/03
70-23-06 70-23-07
70-23-08
70-23-22 70-23-23
Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-23-09
70-23-24
70-23-10 70-23-11
Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 70-23-25
Dec 01/03 Dec 01/03

70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 3 4 1 2 3 4 1 2 1 2 1 2 1 2 1 2 3 4 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 DATE Dec 01/03 Dec 01/03 Dec Dec Dec Dec 01/03 01/03 01/03 01/03 CHAPTER/ SECTION 70-31-01 PAGE 1 2 3 4 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 1 2 DATE Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-23-26
70-31-02
70-23-99 70-24-00 70-24-01 70-24-02 70-24-99
Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 70-31-04 70-31-03
70-30-00
70-31-05
70-31-00
70-31-06
Dec 01/03 Dec 01/03

70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1 2 3 4 1 2 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec 01/03 01/03 01/03 01/03
70-31-07
70-32-02
70-32-03 70-32-05
Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-32-00 70-32-01
Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-32-06
70-32-07
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 1 2 3 4 5 6 7 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 5 6 7 8 9 10 1 2 1 2 3 4 5 6 7 8 9 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-32-09
70-32-10
70-32-11 70-32-12
Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-32-08
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 1 2 3 4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 1 2 3 4 1 2 3 4 1 2 1 2 1 2 3 4 5 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-32-19
70-32-20
70-32-80
70-32-81
70-32-21
70-32-82 70-33-00 70-33-01
Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 6 7 8 9 10 1 2 3 4 5 6 1 2 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 7 8 9 10 11 12 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-33-02
70-34-02
70-33-03 70-33-04
Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 70-34-03
70-33-05
70-33-06
70-34-00
70-34-04
70-34-01
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION 70-35-00 PAGE 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 1 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 1 2 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-41-02 70-35-01
70-41-00
70-41-03
70-41-04
70-41-05
70-41-06 70-41-01 Dec 01/03
Dec 01/03 Dec 01/03

70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1 2 3 4 1 2 3 4 5 6 7 8 9 10 1 2 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION 70-42-02 PAGE 1 2 3 4 5 6 1 2 1 2 1 2 1 2 3 4 1 2 3 4 5 6 1 2 1 2 3 4 1 2 3 4 1 2 1 2 1 2 1 DATE Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03
70-41-07
70-43-01 70-43-02 70-43-03 70-43-04
Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
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STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION 70-43-13 PAGE 2 1 2 3 4 5 6 1 2 3 4 1 2 3 4 1 2 1 2 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 DATE Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 5 6 1 2 3 4 1 2 1 2 3 4 1 2 3 4 1 2 3 4 5 6 1 2 3 4 1 2 1 2 3 4 1 2 3 4 1 2 1 2 3 DATE Dec 01/03 Dec 01/03 Dec Dec Dec Dec 01/03 01/03 01/03 01/03
70-43-22
70-43-23 70-43-14 70-43-24
Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
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Dec 01/03 Dec 01/03 70-43-26 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
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STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 4 5 6 7 8 9 10 11 12 13 14 1 2 3 4 5 6 1 2 3 4 5 6 1 2 1 2 3 4 1 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-44-04
70-45-01
70-45-02 70-45-03
Dec 01/03 Dec 01/03 Dec Dec Dec Dec 01/03 01/03 01/03 01/03 70-47-01
70-45-04 70-46-01
Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 23 24 1 2 1 2 1 2 3 4 5 6 7 8 9 10 1 2 1 2 1 2 3 4 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 7 8 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 70-48-08 CHAPTER/ SECTION 70-48-07 PAGE 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-47-02 70-47-03 70-47-04
70-47-05 70-48-00 70-48-01
Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 70-48-09
70-48-02
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70-48-11
70-48-03
70-48-05
70-48-12
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 6 7 8 1 2 1 2 1 2 3 4 5 6 7 8 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 3 4 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-48-13 70-48-14 70-48-15
70-49-01
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Dec 01/03 Dec 01/03
70-49-08
Dec 01/03 Dec 01/03

70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 DATE Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION 70-49-19 PAGE 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 DATE Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-49-09
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Dec 01/03
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 70-49-46 70-49-35 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 70-49-47 CHAPTER/ SECTION PAGE 4 5 6 1 2 3 4 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 6 1 2 3 4 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-49-30
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70-49-39
Dec 01/03 Dec 01/03 Dec 01/03
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION 70-49-50 PAGE 1 2 3 4 5 6 1 2 3 4 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 1 2 3 4 1 2 3 4 5 6 7 8 9 10 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 70-71-03 70-70-01 CHAPTER/ SECTION 70-60-00 PAGE 1 2 3 4 1 2 1 2 3 4 5 6 7 8 1 2 3 4 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 1 2 3 4 1 2 3 4 5 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-60-01 70-70-00
70-49-51
70-49-52
70-51-00
70-71-01
70-71-02 70-51-01
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70-71-04
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 1 2 3 4 1 2 3 4 5 6 7 8 1 2 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 3 4 5 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-80-00
70-71-05
70-71-06
70-71-07
Dec 01/03 Dec 01/03
70-EFF
STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 1 2 3 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 70-80-05 70-80-02 Dec 01/03 Dec 01/03 Dec 01/03 CHAPTER/ SECTION PAGE 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 1 2 3 4 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-80-03
70-80-04
70-80-01
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STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 5 6 7 8 9 10 11 12 13 14 15 16 1 2 3 4 5 6 1 2 3 4 5 6 7 8 9 10 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 22 23 24 25 26 27 28 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03
70-80-20
70-80-06
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STANDARD PRACTICES MANUAL AS907-1-1A CHAPTER/ SECTION PAGE 45 46 47 48 49 50 51 52 53 54 55 56 57 58 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec Dec 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 01/03 CHAPTER/ SECTION PAGE 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 DATE Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03 Dec 01/03
70-80-30
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GENERAL INFORMATION - GENERAL INFORMATION TASK 70-00-00-800-001 1. How To Use Manual SUBTASK 70-00-00-99G-001 A. General. (1) The following disclosure notice is to inform you of your obligations as a recipient of technical information under U.S. export laws. THIS DOCUMENT CONTAINS INFORMATION THAT IS THE PROPERTY OF HONEYWELL. THIS DOCUMENT MAY NOT, IN WHOLE OR IN PART, BE DISCLOSED OR USED FOR MANUFACTURE OF THE PARTS DISCUSSED HEREIN WITHOUT THE PRIOR PERMISSION OF HONEYWELL. (2) The Standard Practices Manual consists of all of the process standard practices used for the maintenance operations on Honeywell AS907 engine. The SPM is used in conjunction with the applicable Honeywell manuals, and service bulletins to eliminate repetition of these process standard practices throughout these documents. The Standard Practices Manual provides one consolidated source of the detailed information required by the maintenance personnel. The Chapter No. of the required process of the Standard Practices Manual will be listed in the appropriate sections of the applicable manuals.
(3)
SUBTASK 70-00-00-100-051 B. Definitions and Format of Standard Practices Manual. (1) A standard practice is a single process that is required for the maintenance of numerous parts that are included in the engine. Each process has a defined area of application for accomplishing a specific task. It is identified by a 6-digit ATA number, for example, 70-21-06. Each process also has a 12-digit TASK number, for example, TASK 70-21-06-110-004, Cleaning Method No. 6 - Heavy-Duty Alkaline Cleaner (Without Inhibited Phosphoric Acid). The first six digits of the TASK number are always the same as the 6-digit ATA number for that process. A TASK number is always followed by the title of the TASK. A category of processes that can be performed in the same shop area are assigned with ATA numbers whose first 4 digits are identical. Each category is divided per the following: (a) (b) (c) (d)
EFFECTIVITY: ALL
(2)
70-XX-00: General 70-XX-01 through 70-XX-79: Process Standard Practices 70-XX-80 through 70-XX-98: Test Practices and Process Control 70-XX-99: Special Instructions
70-00-00
GENERAL INFORMATION Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (3) The General data for each category defines the particular characteristics of the category processes and nonspecific data to guide the maintenance personnel in utilizing the processes. The Test Practices and Process Control data provides the definition of the evaluation or verification of the quality of the process employed on samples of an identical or equivalent nature to the engine hardware. It also specifies the limits required for acceptability criteria. The Process Standard Practices data defines the general information relating to the process and the detailed instructions regarding the equipment, method, and quality assurance. The Solution Sheets define the technical information required for the baths relative to their composition, checking, regeneration, replacement, and temperature. These sheets are included in data . The Standard Practices Manual references a number of consumable products and compounds which are defined in the Consumable Products List in data 70-80-XX. Throughout the Standard Practices Manual, the terms "percent" and "percentage" and the symbol "%" shall mean percent by weight. Percent and percentage by volume shall be designated by the term "volume percent" or the symbol "V/V".
(4)
(5)
(6)
(7) (8)
SUBTASK 70-00-00-100-052 C. Safety. (1) Warnings for hazardous substances have been developed from dated Material Safety Data Sheets (MSDS), when available. Each warning is valid as of its specific preparation date. To ensure compliance with current precautionary information:
*
Read and follow specific instructions in MSDS for types of personal protective equipment (safety glasses, gloves, apron, etc.), for use of ventilators or respirators, for types of fire extinguishers, and for treating medical emergencies. Read and follow the hazardous material label posted on the container for the specific substance and the MSDS supplied by the manufacturer. Follow established shop practices and procedures when using, handling, and storing hazardous materials. Dispose of hazardous materials by complying with existing federal, state, or local regulations.
EFFECTIVITY: ALL
70-00-00
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: HONEYWELL ASSUMES NO RESPONSIBILITY FOR ANY HONEYWELL EQUIPMENT WHICH IS NOT MAINTANIED AND/OR REPAIRED IN ACCORDANCE WITH HONEYWELLS PUBLISHED INSTRUCTIONS. NEITHER DOES HONEYWELL ASSUME RESPONSIBILITY FOR SPECIAL TOOLS AND TEST EQUIPMENT FABRICATED BY COMPANIES OTHER THAN HONEYWELL. IMPROPERLY REPAIRED COMPONENTS MAY BE INFERIOR AND MAY AFFECT AIRWORTHINESS OR REDUCE THE USEFUL LIFE OF THE COMPONENTS. IMPROPERLY FABRICATED SPECIAL TOOLING OR TEST EQUIPMENT MAY RESULT IN DAMAGE TO THE PRODUCT COMPONENTS OR PROVIDE ERRONEOUS RESULTS. WHEN USED, EQUIPMENT OR PARTS THAT HAVE BEEN REPAIRED OR FABRICATED BY OTHER THAN HONEYWELLAUTHORIZED FACILITIES MAY INCREASE RISKS OF DEATH OR PERSONAL INJURY, COMPONENT FAILURES, AND SECONDARY DAMAGE AND MAY VOID ANY WARRANTIES UNDER-WRITTEN BY HONEYWELL.
WARNING:
(2)
Warranty/Liability.
EFFECTIVITY: ALL
70-00-00
EFFECTIVITY: ALL
70-00-00
STANDARD PRACTICES - STANDARD PRACTICES TASK 70-00-01-800-002 1. Standard Practices SUBTASK 70-00-01-99G-002 A. General. (1) This section covers processes frequently used in the maintenance and repair of jet engine parts. These practices are generally standard processes or procedures of Honeywell. The standard practices described in this section can be categorized into eight basic sub-groups: Chapter-Section
Subject Assembly and Disassembly Techniques Cleaning Inspection Methods Repair Methods Fits and Clearances Preservation Testing and Quality Analysis Shop Consumables SUBTASK 70-00-01-800-021 B. Tool Requirements. (1)
While standard hand tools, gages and materials can be used for many operations on engine parts, certain restrictions must be observed in specific instances. Among these are the following: (a) Use of low-melting-point forming tools (Kirksite or other lead-containing materials) can cause intergranular attack at elevated temperatures during heat treatment or engine operation. Use of intermediate-melting-point materials, such as aluminum, tin, zinc, cadmium, magnesium, bismuth, antimony and their alloys, such as brass can have the same effect. All three residues must be removed prior to subsequent heat treatments or installation of the parts in an engine. Avoiding their use is easier than assuring complete removal of any transferred low-melting-point metal. Fluorescent-penetrant contaminants can cause severe attack on nickel-base super alloys (Inconel W, Rene 41, etc.). All residues must be removed prior to subsequent heat treatments or installation of the parts in an engine.
(b)
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STANDARD PRACTICES MANUAL AS907-1-1A (c) Use of contaminated salts (Virgo, etc.) can also attack super alloys at elevated temperatures. All residues must be removed prior to subsequent heat treatments or installation of the parts in an engine. Halogens (fluorine, chlorine, bromine, iodine) and their compounds react with titanium and can result in stress-corrosion cracking at elevated temperatures. Materials containing halogens of this nature should not be used on titanium. Use special tools when called for in maintenance and repair instructions. These tools have been designed, manufactured and supplied to do a specific job better than generally available tools, to protect the part from possible damage, and to protect personnel from injury. Do not use cadmium-plated tools/fixtures for maintenance or repair of engines or parts. Cadmium will embrittle many metals, including titanium, if they are exposed to temperatures of 5008F (2608C) and above. Cadmium embrittled titanium can fail at room temperature under the influence of high stress and plastic deformation. Never use pressure-sensitive, gummed or adhesive tapes on engine parts except where absolutely necessary, such as when masking during repair. Tape and tape residues can cause surface attack at room temperature, and can cause severe, penetrating attack at elevated temperatures. When tape has been used in the repair process, be sure that all tape and adhesive residue have been completely cleaned from parts before subjecting them to such temperatures as those encountered in welding, baking, heat treating or normal engine operation.
(d)
(e)
(f)
(g)
SUBTASK 70-00-01-800-022 C. Safety Instructions. (1) The Standard Practices Manual contains processes where risks are involved to personnel and engine hardware. The purpose of this section is to provide the method by which these risks are identified in the text of the process standard practices. THE INFORMATION PROVIDED IN THIS DOCUMENT IS PRESENTED IN GOOD FAITH. IT DOES NOT REMOVE THE OBLIGATION OF THE PERSONNEL TO EXERCISE ALL PRECAUTIONS INCLUDING THOSE DICTATED BY GOOD, NORMAL PRACTICE.
WARNING:
(2)
In the Standard Practices specified for shop maintenance of an engine, certain operations can involve risks, to both personnel and engine hardware. It is urged that personnel act with care and caution, and with respect for all standards, laws and labor legislation required by the countries where these operations and processes are performed. Danger and damage may be minimized or avoided by adhering to careful preventive measures, strict adherence to the procedure provided in the standard practice instructions, using recommended tools and fixtures, and the wearing of appropriate protective clothing. The Standard Practices Manual complies with the specifications of ATA 100, Chapter 1-1-3, page 2, paragraph 1.G. as follows:
(3)
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STANDARD PRACTICES MANUAL AS907-1-1A (a) Each process where danger to personnel is involved, the text contains a WARNING to alert that harm may occur to personnel using the process. The following is an example. HYDROFLUORIC ACID SOLUTIONS ARE VERY DANGEROUS AND POISONOUS. PREVENT CONTACT WITH SKIN, EYES, AND CLOTHING. PREVENT INHALATION OF VAPORS. IF AN INCIDENT OCCURS, IMMEDIATELY WASH WITH AN ABUNDANT QUANTITY OF WATER AND OBTAIN IMMEDIATE MEDICAL ASSISTANCE. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING:
WARNING: (b)
Each process where material damage is involved, the text contains a CAUTION to alert personnel. The following is an example.
CAUTION: PERMANENT MARKING SHOULD NOT EXTEND ONTO ANY CURVE, CHAMFER, SHARP EDGE, OR FILLET ADJOINING THE SURFACE WHERE THE MARK IS PLACED. (4) (5) A WARNING or CAUTION is provided in the text of the processes of the Standard Practices Manual immediately before the paragraph where safety is involved. In each process standard practice at the beginning of the Equipment paragraph, the different compulsory protective equipment and safety installations in the shop area where the process is performed are described. A WARNING is provided in the text before the first time in which a solution or corrosive product is called out in the procedure. In each solution sheet: (a) (b) The Preparation paragraph is preceded by a WARNING when it requires handling of corrosive or toxic products. Where appropriate, the Regeneration paragraph is preceded by a WARNING to avoid a combustible or explosive mixture when servicing the solution.
(6) (7)
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CONVERSION FACTORS - CONVERSION FACTORS (US AND METRIC) TASK 70-00-02-800-003 1. Conversion Factors SUBTASK 70-00-02-99G-003 A. General. (1) The following table of conversion factors includes all the units used in the maintenance of an engine and for all the practices described in the Standard Practices Manual. After making the conversion calculation, the answer should be rounded-off to the nearest decimal unit to the accuracy required by the appropriate instructions. Conversion Factor = 25.4 millimeters (mm) = 0.3048 m (30.48006 cm) = 0.9144 meter (m) = 39.37 inches (1.0936 yards) = 0.3937 inch = 0.03937 inch = 645.16 square millimeters (mm2) [6.4516 square centimeters (cm2)] = 0.0929 square meter (m2) = 1.196 square yards (y2) (10.764 square feet) = 0.1550 square inch = 16.387 cubic centimeters (cc) = 0.028 cubic meter (m3) (28.316 liters) = 0.06102 cubic inch = 35.314 cubic feet (1.308 cu yd) = 29.57 cubic centimeters (cc) = 0.946 liter (946.353 cc) = 3.785 liters = 1.0567 quart (0.001 cubic meter) (0.264 US gallon)
3
Unit LENGTH 1 inch (in.) 1 foot (ft) 1 yard (yd) 1 meter (m) 1 centimeter (cm) 1 millimeter (mm) AREA 1 square inch (in.2) 1 square foot (ft2) 1 square meter (m2) 1 square centimeter (cm2) VOLUME 1 cubic inch (in.3) 1 cubic foot (ft )
3
1 cubic centimeter (cc) 1 cubic meter (m ) 1 fluid ounce (fl oz) 1 quart (qt) 1 US gallon (US gal) 1 liter (l)
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Unit WEIGHT 1 ounce (oz) 1 pound (lb) 1 gram (g) 1 kilogram (kg) PRESSURE 1 pound/square inch (psi) 1 kilopascal (kPa) CONCENTRATION 1 ounce (avoirdupois) per US gallon 1 fluid ounce/US gallon 1 pound/US gallon 1 g/l 1 ml/l TORQUE 1 pound-foot (lb ft) 1 pound-inch (lb in.) 1 Nm
Conversion Factor = 28.35 grams (g) = 0.4536 kilogram (kg) (453.5924 grams) = 0.035 ounce = 2.2046 pounds = 6.90 kilopascal (kPa) = 0.145 pound/square inch (psi) = 7.5 grams/liter (g/l) = 7.8 ml/liter = 0.1190 kg/l, or grams/cc (119.8 grams/liter) = 0.1335 oz/US gallon = 0.128 fl oz/US gallon = 12 pound-inch (lb in.) = 0.113 Newton meter (Nm) = 8.85 pound-inch (lb in.)
TEMPERATURE (Example: 258F = -48C) Note: Not for heating/cooling rates or temperature ranges. 8Fahrenheit (8F) 8Celsius (8C) 8Kelvin (8K) 8Kelvin (8K) 8Rankine (8R) 8Fahrenheit (8F / time) 8Celsius (8C / time) 8Fahrenheit (8F) 8Celsius (8C) SPECIFIC HEAT CAPACITY 1 Btu/lb 1 cal/g = 0.55 cal/g = 1.8 Btu/lb = 9/58C + 32 ( see Figure 1, Page 4) = 5/9 (8F - 32) [ see Figure 1, Page 4] = 8C + 273.18 (celsius absolute) = 5/9 (8F + 459.67) = 8F + 459.688 (Fahrenheit absolute) = 9/58C / time = 5/98F / time = 9/58C = 5/98F
HEATING/COOLING RATES (Example: 258F per minute = 148C per minute)
TEMPERATURE RANGE (Example: X8F 258F = Y8C 148C)
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Unit DISTANCE 1 mile (US Statute) 1 mile (Nautical) 1 kilometer (km) SURFACE FINISH 1 microinch (in.) METRIC RELATIONSHIPS 1 micrometer (also known as 1 micron) 1 millimeter (mm) 1 centimeter (cm) 1 decimeter (dm) 1 meter (Metric Standard of length) 1 liter 1 gram 1 bar 1 Pascal (Pa) 1 Newton (N) 1 kilogram/square millimeter (kg/mm2)
Conversion Factor = 1.609 kilometers (km) = 1.853 kilometers = 0.621 miles (US Statute) = 0.0254 micrometer (m) = 0.000001 meter (0.001 millimeter) = 0.001 meter = 0.01 meter = 0.1 meter
= 0.001 cubic meter = weight of 0.001 liter of water = 105 Pascal (Pa) = 1 N/m2 = 0.102 kilogram (kgf) = 9.81 Megapascal (MPa)
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Temperature Conversion Chart Figure 1
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MACHINING DATA - MACHINING DATA TASK 70-00-03-800-004 1. Machining Data SUBTASK 70-00-03-99G-004 A. Machinability. (1) Machinability is a relative term used to describe the amount of effort required to cut or remove material. Two major factors which affect the machinability of any material are its hardness and strength. Other factors are heat dissipation, work hardening, abrasiveness, and tool wear. Machinability directly affects the cost of production of machined parts. The degree of machinability of materials can only be accurately determined by testing. Using the same cutting conditions (depth of cut, feed, lubrication, etc.) and cutting tools with the same characteristics, cutting speeds are experimentally determined using a lathe. The principal metals currently used in the manufacture of jet engines are nickel, cobalt, titanium, iron, and aluminum base alloys. Presently vacuum-cast nickel base alloys are the most difficult to machine surpassing even wrought and cast cobalt base alloys. Machining technology has not been able to keep up with the decreasing machinability of new materials. As a result, studies are under way to find new cutting tool materials and methods. Nonconventional machining methods are also being explored. Based on studies of industry practices and machinability, machining recommendations were correlated to provide the nominal initial approach for each machining operation and material. Making any machining operation as effective and functional as possible requires more than average data recommendations on speeds and feeds. Variations from average machining data values must depend upon the total relationship among the machine tool equipment, the fixturing, the part configuration, the part tolerances, the surface integrity requirements, the cutting tool material and design, and the rigidity of setup. The machinability index (see Figure 1 (Sheet 1 of 2), Page 2) shows the degree of machinability of each material as a ratio of the cutting speed used for the material compared to the speed used for the reference material [AISI B1112 (Index 100)], expressed in percentage, to obtain the same cutting tool life.
(2)
(3)
(4)
(5)
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Machinability of Materials Figure 1 (Sheet 1 of 2)
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Machinability of Materials Figure 1 (Sheet 2)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-03-800-041 B. Machining Characteristics of Different Materials. (1) Cast materials are more difficult to machine than those which are wrought. Consequently, the degree of machinability may vary for the same material depending on the way it is formed. Stainless steels are the primary steels used in jet engines. It is important to distinguish between austenitic and martensitic stainless steels to determine the proper machining conditions. (a) Stainless austenitic steels have a tendency to work-harden causing the formation of hard layers in front of the cutting tool. These steels have poor thermal conductivity resulting in concentrated high temperatures at the tip of the cutting tool which is detrimental to tool life. Stainless austenitic steels also are known for their high coefficient of friction which results in a strong tendency to stick and seize causing a more rapid destruction of cutting tools. Stainless martensitic steels have a structure which is characterized by abrasive carbides (chromium carbide). The carbides are responsible for greater wear of the cutting tools.
(2)
(b)
(3)
Nickel-base alloys are characterized by a high elastic limit, a resistance to shear, and a tendency to work harden and seize under certain conditions. The conditions for machining nickel-base alloys are the same as those used for machining stainless austenitic steels. (a) (b) Powerful machines and solid cutting tools, capable of supporting the forces and dissipating heat rapidly, are required to machine nickel-base alloys. Machining of nickel-base alloys develops high pressures between the work and the cutting tool that create a layer of deformed metal on the surface of the work. The deformation leads to a hardening that makes further machining more difficult. When this occurs, a stress-relieve heat treatment may be recommended following the machining operation. Well sharpened tools which produce a positive cut rather than push metal, combined with sufficiently high feeds and cut depths are required to reduce work hardening of the metal.
(c)
(4)
Cobalt-base alloys are similar to nickel-base alloys in machining characteristics. They have properties of high elasticity and a tendency to work-harden and stick. (a) (b) Cobalt-base alloys require the use of high power equipment which is free of vibrations. Cutting tools must be solid and rigidly held reducing deflection of the tool through reduction of the cantilever and the use of strong tool holding systems.
(5)
Titanium-base alloys are more difficult to work than steels. However, these alloys may be machined with no difficulty in shops equipped to machine stainless steels.
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STANDARD PRACTICES MANUAL AS907-1-1A (a) Titanium-base alloys require the use of abundant cooling fluid and a limitation of machine speed to reduce high tool temperatures caused by poor thermal conductivity. The low modulus of elasticity of titanium-base alloys (close to one-half that of steels) gives rise to vibrations and chattering if the work is insufficiently held, if the cutting tools are not rigidly held, and/or if the machines are not powerful enough. During heat treatments in air, a superficial layer of very hard oxides or nitrides may form on some alloys. The removal of this very hard layer by machining, is a delicate operation. It is preferable to sand blast or chemically strip prior to machining.
(b)
(c)
(6)
Aluminum-base alloys are generally easily machined with cutting tools. Machining characteristics particular to aluminum are as follows: (a) Aluminum-base alloys have a low modulus of elasticity (close to one-third that of steel). Care must be taken in securing the work to prevent deflection. If necessary, supporting devices (steady rests) and reduced cutting forces may be employed, in accordance with the geometry. Some aluminum alloys have a noticeable abrasive effect on the cutting tool; this is a function of the hardness of the part, its structure, and most of all, its silicon content.
(b)
SUBTASK 70-00-03-800-042 C. Turning. (1) General. Turning is the machining operation whereby an external cylindrical or conical surface is generated through the direct action of a rotating workpiece and the longitudinal travel of a single point cutting tool. When this same action is applied to generate an internal surface, the operation is called boring. Facing is a special type of turning where the cutting tool moves perpendicular to the axis of rotation of the workpiece, generating a flat surface. (2) Equipment. Equipment for turning must have the capability to hold and rotate the workpiece while holding the tool stationary except for linear movement. Most turning is done on lathes. There are several types of lathes but the most common is the engine lathe, a heavy duty machine tool that utilizes typical lathe components: lathe bed, headstock assembly, tailstock assembly, carriage assembly (includes tool holding block or post), speed and feed change gearboxes, lead screw, feed rod, and cooling system. (3) Materials. (a) Cutting tools. See Figure 2, Page 7. 1 Two types of materials are used for cutting tools: high speed steels, designated by AISI specifications; and metal carbides designated by ISP specifications.
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STANDARD PRACTICES MANUAL AS907-1-1A 2 The use of high speed steels is limited by its hot hardness. The cobalt grade of HSS can be used for turning of work materials which have a hardness below HRC52. Metal carbides are used as the tool for turning most materials, but are required with materials having hardness of HRC52 or harder. Care must be exercised in the use of carbides since they have poor impact resistance. The ability to maintain sharp cutting edges on tools reduces workhardening, excessive cutting forces and potential distortion of the workpiece. A cutting tool is subject to wear on the side clearance face and side rake face. For given machining conditions, wear increases with time and reaches a level which requires replacement or grinding of the tool. The level of acceptable evenly distributed wear is 0.015 inch (0.4 mm) and of localized wear is 0.020 inch (0.5 mm) maximum. See Figure 4 (Sheet 1 of 7), Page 9. The tool materials and procedures for turning plasma spray coatings are basically the same as for turning solid materials, however, more critical limits are placed on the range of cutting speeds, depths cut, feed rates and the geometry of the cutting tool.
(b)
Cutting fluids. 1 Cutting fluids are used for cooling and lubricating the cutting tool and workpiece. There are 4 classes of cutting fluids: straight cutting oils, water soluble oils, semi-synthetic fluids, and synthetic fluids. The addition of a 10 percent chlorine containing extreme pressure additive produces cutting fluids of a higher lubricating value. NOTE: Studies have shown no evidence of adverse effects from the use of the chlorine containing additive, even on titanium. 3 Cutting fluids, especially those used with the machining of aluminum and copper alloys, must be inactive, i.e., must not cause any chemical reaction with the workpiece.
(4)
Procedure. Cutting tool life expectancy for parameters recommended in Figure 4 (Sheet 1 of 7), Page 9 is 60-90 minutes for high speed steel tools and 30-45 minutes for carbide tools, rated in continuous cut with soluble oil cutting fluid. Tool life will change if the machining parameters or cutting fluid is changed. Tool life is most critically effected by the surface rotational speed of the workpiece. Materials which are difficult to machine have more critical ranges of cutting speeds.
(5)
Quality Assurance. Check machined parts to be sure that edges are free of burrs and rolled metal.
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Tool Nomenclature Figure 2
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Tool Wear Figure 3
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Cutting Tool Test Data Figure 4 (Sheet 1 of 7)
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Cutting Tool Test Data Figure 4 (Sheet 7)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-03-800-043 D. Milling. (1) General. Milling is the machining operation whereby a surface is generated by incremental removal of metal from the work-piece by the rotation of a single tooth (fly) or multitooth (milling) cutter. Generally the workpiece is fed to the milling cutter but in special cases the cutter is moved past a stationary workpiece. (2) Types. There are 2 basic types of milling: peripheral and face. The types of milling are described as follows: (a) Peripheral milling generates a surface parallel to the cutter axis, by teeth on the periphery of the cutter. A further distinction in peripheral milling is that it can be either up milling (conventional) or down milling (climb). Up and down milling are defined as follows: 1 Up milling. The cutter rotates against the direction of feed of the workpiece. This type of milling has a minimal initial chip which increases as the tooth progresses into the cut. 2 Down milling. The cutter rotates in the same direction as the feed of the workpiece. Down milling has a maximum initial chip which decreases to almost zero thickness at the end. Down milling is generally preferred over up milling with proper setup except where depth of cut varies excessively or where very rough surfaces are encountered (castings or forgings). (b) Face milling generates a surface perpendicular to the milling cutter axis and is the result of the cutting action of teeth that occupy both the face and periphery of the cutter.
(3)
Equipment. (a) Milling machines are generally built for versatility (general purpose) or for productivity (manufacturing) or for special applications. Knee and column type mills fall into the general purpose classification. Bed and planer type mills fall into the manufacturing classification. Special milling machines are usually custom designed for specific applications. Bed type milling machines are rugged and have the capability of making heavy cuts. This type of mill has the table mounted directly on the bed and the table has only longitudinal movement, however, bed type mills may be made more flexible by adding a transverse motion to the table. For given setup, the spindle head is normally clamped in position, however, on other types of operations, vertical movement of the spindle occurs. The spindles can be both horizontal and vertical and a milling machine may have one, 2, 3, or even 4 spindles to permit milling of multiple surfaces in a single pass.
(b)
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STANDARD PRACTICES MANUAL AS907-1-1A (c) The most difficult type of milling is end milling. The end milling condition involves both up milling and down milling on the periphery of the cutter while simultaneously making a face cut. Because end milling combines the challenges of both face milling and periphery milling, end milling data is shown in Figure 5 (Sheet 1 of 3), Page 19.
(4)
Materials. (a) Cutting tools. 1 It should be noted that while high speed steel (HSS) tooling is indicated in Figure 5 (Sheet 1 of 3), Page 19, carbide tooling should be considered. If carbide tooling is to be used, attention should be given to the setup geometry of the tool because carbide is more affected by the angle of entry than HSS. The types of tool wear prevailing in milling are similar to those encountered in turning. In milling, however, tool wear resulting from flaking and cracking is more frequent due to the mechanical and thermal shocks exerted on the cutting edges and discontinuous cutting of the workpiece. The criterion ruling over tool wear is the relief angle wear. The permissible distributed amount of wear is 0.012 inch (0.3 mm) and maximum allowable localized wear is 0.020 inch (0.5 mm).
(b)
Cutting fluids. 1 Cutting fluids are used to cool and/or lubricate the cutting tool and workpiece. These fluids are classified as straight cutting oils, water soluble cutting oils, and semi-synthetic fluids. The type of work to be performed determines which cutting fluid to use. Cutting fluids, especially those used with the machining of copper and aluminum, must be inactive i.e., must not cause any chemical reaction with the workpiece.
(5)
Procedure. (a) Milling parameters. The parameters required to mill specific materials are listed in Figure 5 (Sheet 1 of 3), Page 19. The conditions shown are for rough milling using end mill tooling of high speed steel with expected tool life of 60-120 minutes using coolant. For finish milling operations, these values should be adjusted per the dimensional and surface requirements specific to each part. Figure 6, Page 22 and Figure 7, Page 23 show the nomenclature of face and end milling cutters. (b) Application of cutting fluid. 1 Milling operations require the use of 2 nozzles directing a copious supply of fluid to both the incoming and outgoing sides of the cutter. The fluid from one nozzle is pumped through the cutting zone by the cutter teeth while fluid from the other nozzle washes away the chips as they emerge from the cutter. Standard round nozzles are sufficient for
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STANDARD PRACTICES MANUAL AS907-1-1A narrow cutters. Wide cutters require using fan-shaped nozzles at least three-quarters the width of the milling cutter to provide good coverage. 2 For face milling, use of a ring-type distributor consisting of a tube with many small holes can be beneficial. This directs the fluid at all cutting edges and keeps the cutter completely bathed in fluid to provide even cooling. When a particular size face mill is used often, the type distributor can be supplemented with a special fan nozzle with a curved opening to match the cutter radius.
(6)
Quality Assurance. Check milled part to be sure that machined edges are free of burrs and rolled metal.
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End Milling Data. Figure 5 (Sheet 1 of 3)
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End Milling Data. Figure 5 (Sheet 2 of 3)
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End Milling Data. Figure 5 (Sheet 3)
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Face Milling Nomenclature Figure 6
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End Milling Nomenclature Figure 7
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-03-800-044 E. Grinding. (1) General. Grinding is the machining operation whereby a fine surface finish is generated by the cutting action of a very large number of small irregularly shaped abrasive particles bonded into a cutting wheel (belt grinding is not covered here). Small multipoint cutting edges cut simultaneously to produce very fine surfaces and close dimensional control while providing the capability to machine extremely hard materials. (a) Grinding practices used for jet engine alloys is unlike the grinding practices used for most other metals. The requirements and specifications controlling the permissible grinding conditions are very similar to those used for the preparation of laboratory fatigue and tensile specimens. Such necessary stringency results from the fact the conventional grinding practices can induce residual stresses that significantly lower the fatigue strength of highly stressed parts such as compressor and turbine blades. It is difficult to recommend a set of conditions that will accurately meet all grinding situations, however, the following general grinding information will help establish the background for application of the practices used in the grinding of jet engine materials. 1 Grit sizes. A grit as course as the finish and form holding requirements of the job permit should be used. 2 Grade selection. a b As the area of contact increases, the wheel hardness grade should decrease. Cylindrical grinding. One grade harder wheel than that required for surface grinding should be used. c Internal grinding. One grade softer wheel than that required for surface grinding should be used. 3 G-ratio. G-ratio is the relationship of metal removed to the volume of wheel worn away. A low G-ratio means difficult to grind material under one given set of conditions. 4 Stress conditions. Where the grinding G-ratio is more important than a low stress surface, the friability of the grit may be reduced and the wheel speeds increased.
(b)
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STANDARD PRACTICES MANUAL AS907-1-1A 5 Grit sharpness is of great importance to the grinding of hightemperature materials. Other than wheel dressing, a sharp grit is obtained by one of the following means: a b 6 (2) Equipment. There are 2 major categories of grinding machines: surface grinding machines and cylindrical grinding machines. These machines may be equipped with either vertical or horizontal spindles. The work table for either grinding machine may be either reciprocating or rotary. (3) Materials. Figure 8 (Sheet 1 of 4), Page 27 provides the essential facts to identify grinding wheel grade and speed, work speed, down feed, cross feed, and grinding coolant used to achieve minimum residual stress in parts. Figure 9, Page 31 shows the interpretation of grinding wheel markings. (4) Procedure. (a) Grinding. 1 2 The parameters for grinding specific alloys are shown in Figure 8 (Sheet 1 of 4), Page 27. Figure 10, Page 32 shows the effect of low stress, conventional, and abusive grinding conditions. A summary of high cycle fatigue response at room temperature for a number of alloys is shown in Figure 11, Page 33. All of these materials can be successfully ground and can retain high levels of surface integrity providing the proper procedures are employed and adequate controls are enforced. The results of a large number of controlled grinding tests indicate that abusive grinding practices for nickel-base alloys result when the following are used: a b c d High grinding wheel speeds (over 4000 sfm). Slow work speeds (under 15 sfm). Hard bonded grinding wheels (higher than letter J). Heavy down feeds [over 0.0005 inch (0.013 mm) per pass]. A friable grit that will fracture under grinding pressure to expose sharp new edges. A wheel just soft enough to break down under grinding pressure to expose new grains.
Wheel loading must be avoided to prevent stress buildup. Frequent wheel dressing is essential.
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STANDARD PRACTICES MANUAL AS907-1-1A e Improper grinding fluid (sulfo-chlorinated oil being desirable for nickel, cobalt, and iron-base alloys, and water-base coolant for titanium) or improper applications of the fluid during grinding. Improper or infrequent dressing of the grinding wheel. NOTE: Caution should be exercised when grinding chrome plate since it is possible to cause damage to the substrate. Damage is difficult to detect through the chrome plate. (b) Cutting fluid application. 1 A copious flow of cutting fluid at low pressure will generally provide good results for grinding operations. Where application of a large volume of fluid results in undue splashing, it is better to install splash guards on the machine than to reduce the coolant flow. The normal methods of applying fluids to grinding operations remove little heat until it has dissipated into the mass of the workpiece. Because of the high surface speeds involved, an entrained film of air usually encloses the grinding-wheel surface, and this prevents penetration of the fluid into the cutting zone. Special nozzles can be designed which will force the fluid through the air film and on to the wheel. These nozzles must be placed as close as possible to the workpiece to prevent complete loss of the fluid by the centrifugal force of the wheel.
(5)
Quality Assurance. Check machined part to be sure that edges are free of burrs or rolled metal.
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Surface Grinding Test Data Figure 8 (Sheet 1 of 4)
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Surface Grinding Test Data Figure 8 (Sheet 4)
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Interpretation of Grinding Wheel Markings Figure 9
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Grinding Conditions Figure 10
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Summary of High Cycle Fatigue Response to Surface Grinding Figure 11
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-03-800-045 F. Broaching. (1) General. Broaching is a machining process which generates a desired contour in the machined part by the push or pull cutting action of a tool with multiple, transverse cutting edges that incrementally remove metal. This process is capable of producing close tolerances in simple, plain surfaces and in more complicated forms as well. The broaching form discussed in this standard practice will be dovetail slots only. (2) Cutting Teeth. A dovetail contour can be broached in a workpiece by a single pass of the tool. The tool will normally have 3 basic sections of cutting teeth: (a) (b) (c) (3) Roughing teeth or slotters which remove approximately 0.003 inch (0.08 mm) of material per tooth (full edge contact). Intermediate teeth or rough formers which remove approximately 0.003 inch (0.08 mm) per tooth (partial edge contact). Finish teeth or finish formers which remove from 0.0015 to 0.000 inch (0.038 to 0.000 mm) per tooth (partial to full edge contact).
Equipment. Based on the direction of broach travel, there are 2 main types of broaching machines: (a) The horizontal broach is a general purpose machine suited for either high or low production. It is possible to design for extremely long stroke or obtain the equivalent long stroke by utilizing special vertical locking positions of the work carriage and the appropriate location of the broach ram. Peripheral and accessory equipment can be easily handled with the horizontal broach. The main disadvantages of the horizontal broach are the large floor space requirement and difficult cutting fluid management. Vertical broaching machines are more adaptable to high production because they are easily automated. Cutting fluid can be easily supplied to the entire broach section but good engineering is necessary to ensure that cutting area is well supplied. Vertical broaches occupy less floor space than the horizontals but require more headroom. Two basic types of broach cutters are used for generating the dovetail slots in disks: 1 2 Solid segments consist of multiple teeth grouped in families to generate a specific cross section. Insert segments consist of a number of individual teeth loaded into a tool holder. Each tool holder holds one family of teeth to generate a specific cross section.
(b)
(c)
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STANDARD PRACTICES MANUAL AS907-1-1A (4) Material. (a) Cutting tools. 1 2 Broaching test data in Figure 12 (Sheet 3), Page 38 identifies the types of tool materials required for broaching various metals. Laboratory test have demonstrated the importance of grinding broach tools under low stress conditions which involve slower wheel speeds (4000 sfm reduced from 6500 sfm), lower downfeeds [0.0005 inch (0.13 mm)] reduced from 0.001 inch (0.03 mm) per grinding pass, and wet grinding instead of dry. Figure 13, Page 39 shows the effect of grinding practices on tool life. Lowstress grinding conditions were responsible for an over 50 percent improvement in tool life. Conventional high speed steel tool wear standard cannot be uniformly applied to broaching tools. Since dovetail slot tolerance is seldom wide enough to accommodate a 0.015 inch (0.38 mm) wear land and the size and surface finish will fall below drawing tolerances after a 0.005-0.006 inch (0.13-0.15 mm) wear land is reached, the 0.015 inch (0.38 mm) wear land end point is acceptable for rough cutters but not for finish form cutters. See Figure 14, Page 40 for broack tool nomenclature.
(b) (5)
Cutting fluids. See Figure 12 (Sheet 3), Page 38.
Procedure. (a) Broaching. Broaching operations differ with the materials to be machined, the extremely close tolerances required, and the need for superior surface finishes. A laboratory test should precede the broaching of a new material in the shop. (b) Cutting fluid application. The cutting fluid listed in Figure 12 (Sheet 3), Page 38 is applied by flooding. Flooding application permits continuous flow of fluid to the cutting zone and is efficient in flushing away chips and in removing heat generated by the broach.
(6)
Quality Assurance. Check machined part to ensure that surface finish and dimensions agree with drawings.
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Broaching Test Data Figure 12 (Sheet 1 of 3)
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Broaching Test Data Figure 12 (Sheet 2 of 3)
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Broaching Test Data Figure 12 (Sheet 3)
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Effects of Broach Grinding Practices Figure 13
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Broach Tool Nomenclature Figure 14
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-03-800-046 G. Drilling. (1) General. (a) Drilling is a machining operation which generates round holes through the action of a tool, known as a twist drill, which normally has 2 cutting edges. Drilling common materials is accepted as simple in nature, however, the drilling of jet engine high temperature alloys has proven to be difficult because of work hardening materials. Drilling speeds are generally slower than those used for other operations because the cutting edge is in continuous contact with the metal when cutting, and the cutting edges are shielded from the flow and beneficial cooling action of the cutting fluid. Successful drilling of jet engine alloys depends largely upon the construction of the twist drill, the rigidity of the machine to the fixtured part, the depth of the hole, and the effectiveness of the cutting fluid.
(b)
(2)
Equipment. There are many variations of the basic drilling machine but generally they are equipped with a base, column, powered spindle, and work table. The spindle is built to accept taper shank drills or drill chuck and is capable of running at a variety of speeds through the change of gears or of a belt/pulley arrangement. Either manual or power feed moves the spindle and/or work table up and down to accommodate the size of the workpiece.
(3)
Materials. (a) Twist drills. The recommended twist drill material for use on particular alloys is shown in Figure 15 (Sheet 3), Page 45. Twist drill point geometry is shown in Figure 16, Page 46. (b) Cutting fluids. The preferred cutting fluids for conventional drilling operations are water base with emulsifiable oils and sulfurized or chlorinated mineral oils. These fluids provide lubrication and coolant to prevent chatter and friction and to protect tool and workpiece from overheating. The normal application method is flooding. Recommended cutting fluids are listed in Figure 15 (Sheet 3), Page 45.
(4)
Procedure. (a) Drilling test data (see Figure 15 (Sheet 3), Page 45) provides reliable parameters (speed, feed, cutting fluid, etc.) for drilling holes of approximately 0.25 inch (6.4 mm) diameter to a depth of 1 and 2 diameters. One cause of poor tool life in deep hole drilling (holes exceeding 3 or 4 diameters) was found to be that the deeper the drill penetrated, the tighter the hole became. This tightening action generated more heat and shortened the tool life.
(b)
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STANDARD PRACTICES MANUAL AS907-1-1A (c) One solution for drilling deep holes was found. Figure 17, Page 47 shows a technique used in the deep hole drilling of Inconel 718. As a consequence of the 5/16 inch (7.94 mm) diameter holes having to penetrate more than 6 diameters [2 inch (50.8 mm)] material, the special step drilling technique became necessary. With this method, a hole is drilled half-way through the material with the nominal size drill, and is continued to completion with a drill slightly smaller than the one used for drilling the first half hole. The bore is then reamed to equal size throughout its length. This 2-step drilling technique improved drill life from 2 holes per drill sharpening to 40 holes. Recommended guidelines to improve the success of the drilling operation are: 1 2 Ensure the drilling setup is rigid to prevent any vibration that could lead to work hardening. When possible, plan for a single operation. With the exception noted above, it may be difficult to start a second operation because of work hardened surfaces caused by the first operation.
(d)
(5)
Quality Assurance. Check machined part to ensure that drilled holes are properly positioned and are of the correct diameter.
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Drilling Test Data Figure 15 (Sheet 1 of 3)
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Drilling Test Data Figure 15 (Sheet 2 of 3)
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Drilling Test Data Figure 15 (Sheet 3)
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Twist Drill Point Nomenclature Figure 16
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Two Step Drilling Procedure Figure 17
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-03-800-047 H. Tapping. (1) General. Tapping is the machining operation whereby internal threads are cut into an already existing hole, using a multipoint thread tap. The hole may be made by drilling, boring, or casting and must be equal to or slightly smaller than the minor diameter of the thread. Taps, which are relatively fragile, are subjected to high torsional forces and the severe machining environment of entrapped chips. High temperature alloys that require small diameter tapping tend to magnify tapping difficulties. (2) Equipment. Radial drills, horizontal boring mills, turret drills, and other multi-purpose machines are used for tapping. Selection of the proper machine to be used for a particular tapping operation is based on the size, shape, and material of the part to be tapped; the number of related operations; the tolerances involved; the production rate; and the cost. Tapping recommendations must be based upon many factors. Individual setups may require experimentation to satisfy all variables. (3) Materials. (a) Taps. 1 Most tapping required on jet engine components produces threaded holes of 1/4 inch (6.35 mm) to 5/16 inch (7.94 mm). Due to these sizes and the alloys these taps are used on, the taps appear comparatively weak. For tapping under 5/16 inch (7.94 mm) a 2 fluted tap with larger chip space is best. For some applications, a 3 fluted tap holds size better. General purpose high speed steel taps such as M2 and M7 HSS have proven satisfactory for the majority of applications. The tapping of superalloys may justify the use of more highly alloyed high speed steel. However, it is often more economical to use cheaper taps and discard them after short runs than to use costly taps with longer lives. See Figure 18, Page 49 for tap nomenclature.
(b) (4)
Tapping fluids. See list in Figure 19 (Sheet 2), Page 51.
Procedure. Useful initial guidelines for tapping a variety of materials are shown in Figure 19 (Sheet 2), Page 51. Tapping fluids are applied by flooding.
(5)
Quality Assurance. Check tapped part to ensure threads are free of burrs and are of the correct geometry.
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Tap Nomenclature Figure 18
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Tap Test Data Figure 19 (Sheet 1 of 2)
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Tap Test Data Figure 19 (Sheet 2)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-03-800-048 I. Electrical Discharge Machining. (1) General. (a) Electrical discharge machining (EDM) is the machining operation which removes electrical conductive material utilizing high frequency electrical sparking to melt and/or vaporize the material in a controlled manner. This process is performed in a dielectric bath, normally transformer oil or paraffin oil, with specially shaped electrodes which discharge at high frequencies from a capacitor bank. EDM is a simple method for producing holes and depressions, of almost any shape, in electrically conductive materials too hard or too brittle to be machined by conventional machinery. EDM can normally achieve a machining accuracy of 0.002-0.004 inch (0.050.1 mm) and surface finishes in the range of 125-500 micro inches (3.2-12.5 microns). The thermal effects of EDM causes the machined surface to be altered from the base material. The thermal effects change not only the surface structure and material characteristics but also can create minute cracks which can progress into the base material. The depth of the alteration can vary from 0.001-0.005 inch (0.03-0.15 mm) depending upon whether the part is being rough or finish machined. The thickness and hardness of the altered layer increase with increased current. To minimize this formation lower current, higher frequencies, and a clean dielectric are required. For parts that are fatigue-stressed, the altered layer must be removed, either by chemical or mechanical means. Without this removal, electrical discharge machined parts lose 30-50 percent of their fatigue strength as compared with conventionally machined parts. Low alloy steels and martensitic stainless steels require passivation processing after EDM and after removal of the altered layer when removal is done by chemical means. EDM may be used only when specified in the Engine/ Shop Manual.
(b)
(c)
(d)
(e)
(f)
(g) (2)
Equipment. (a) The majority of electrical discharge machines are of the ram type which utilize a workhead moved by a hydraulic cylinder. Machines using quill-type workheads are also available but are used normally for smaller work. Both ram and quill machines have servo control for tool advance to maintain the constant spark gap. The servo input signal is the differential voltage between the selected reference voltage and the actual voltage across the gap. This voltage differential is amplified and the hydraulic control system advances the tool. A short circuit across the gap causes the servo to reverse the tool motion until control is restored.
(b)
(3)
Materials.
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STANDARD PRACTICES MANUAL AS907-1-1A (a) Electrodes. 1 Electrodes are selected in accordance with: workpiece finish, geometry, tolerance, material removal rate, wear ratio, quantity, and cost. Electrode materials are: brass, copper, copper graphite, copper tungsten, graphite, tungsten wire, and tungsten carbide.
2 (b)
Dielectric fluids. The main features of a dielectric fluid are: 1 It should retain its insulating properties until the striking of the spark occurs, i.e., when each pulse reaches the breakdown voltage; then, it should act as a good conductor. It should return to its initial insulating state when the electrical discharge is completed, i.e., between pulses, a voltage should not exist in the electrode-to-workpiece gap. It should act as a flushing agent to remove particles of material, resulting from the EDM process, out of the machining gap. It should act as a cooling agent for both the electrode and the workpiece. NOTE: Dielectric fluids most commonly used are transformer oil and paraffin oil.
3 4
(4)
Procedure. (a) (b) (c) Ensure that part is free of any scale or any other surface contamination prior to machining. Ensure that part is connected to the positive side of the DC potential and that the electrode is attached to the negative side. After the machining operation, clean the part of all dielectric oil.
(5)
Quality Assurance. (a) (b) (c) (d) For parts on which altered layer must be removed, check for freedom of EDM machining marks after completing mechanical or chemical rework. Check for abnormal overheating indications. Check that part shows no cracks, pits, etc. Allowable limits for altered layer, cracks, pits, etc., must be specified in the Engine/Shop Manual.
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-03-800-049 J. Electro-Chemical Machining. (1) General. (a) Electro-chemical machining (ECM) is the machining process which removes metal by controlled anodic dissolution through the passage of direct current in a flowing electrolyte, with the workpiece being the anode and the electrode is the cathode. ECM can be used to machine extremely hard materials especially the super alloys. ECM can be used for many different operations such as face milling, drilling holes of any shape, trepanning, contour surface forming, deburring, and polishing. Because of the high costs involved in tooling and set up, the ECM process is best suited for production work. The electrolyte is pumped under pressure, 100-300 psi (690-2070 kPa) and flows at a rate of 50-200 ft/sec (15-61 m/sec) between the workpiece and the electrode. This cutting gap can vary from 0.001-0.030 inch (0.03-0.76 mm). The current density determines the feed rate which can vary from 0.010-0.25 inch (0.25-6.35 mm) per minute. The higher the feed rate the better the surface finish. During operation, the electrolyte, usually a saline solution, is maintained at a temperature of between 75-1508F (24-668C). The entire electrolytic cell is enclosed in a flow chamber or box sealed to permit the tool to be fed into the workpiece and prevent leakage of the electrolyte. Suspended solids are removed and the electrolyte is circulated for reuse. There is no tool wear. Safety precautions must be maintained in the use of ECM equipment and materials. Ventilation of mists, vapors, and dusts should be provided. Wearing of protective gloves and face shields may be required for handling chemicals. Sound operating procedures must be worked out to minimize the likelihood of short circuits which might cause explosions. ECM can be used on all electrically conductive materials with machining tolerances ranging from 0.003 inch (0.08 mm) to 0.010 inch (0.25 mm) depending upon the complexity of the part. ECM generated surface finishes are generally lower than 200 micro inches (5 microns) for titanium alloys and lower than 100 microinches (2.5 microns) for the other materials. ECM does not create compressive stresses in machined surfaces like those generated by mechanical machining. This results in machined surfaces which have fatigue strengths 20 to 30 percent less than mechanically machined parts. Surface conditioning by shotpeening or other methods may be required to raise the fatigue strength.
(b)
(c)
(d)
(e)
(f)
(g)
(2)
Equipment. ECM equipment must have servomechanisms to advance the tool; an electrolyte system which can pump, filter, and maintain the electrolyte at the proper temperature; and a control system that maintains current density and cutting gap. In addition the machine must be rigid enough to resist the high pressure of the pumped electrolyte which tends to force the tool and workpiece apart.
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STANDARD PRACTICES MANUAL AS907-1-1A (3) Materials. (a) Electrodes. The electrodes or tools are of critical importance to successful ECM operations. These tools are normally empirically designed, although basically the tool is required to have the needed stiffness, machinability, electrical and thermal conductivity, and chemical resistance to the electrolyte. Most ECM tools are made of copper, brass, stainless steel, or titanium. (b) Electrolytes. Electrolytes have 3 functions: they carry the current across the cutting gap, carry away the dissolved material, and act as a coolant for both the tool and the workpiece. Electrolytes are selected for particular processes and materials. The most common electrolyte used with titanium and superalloys is NaCl in a variety of concentrations. Other electrolytes are KCl and NaNO. (4) Procedure. (a) (b) (5) Prior to machining, parts must be degreased and freed of any scale or of any other surface contamination. At completion of ECM machining, parts must be rinsed in water and cleaned to remove electrolyte and any contaminants resulting from machining.
Quality Assurance. Parts must be inspected to ensure that pitting and inter-granular attack (IGA) does not exceed Engine/Shop Manual limits.
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HAZARDOUS CHEMICALS - HAZARDOUS CHEMICALS TASK 70-00-04-800-005 1. Hazardous Chemicals SUBTASK 70-00-04-99G-005 A. General. Several chemical elements and compounds used in the industrial processes described in this manual are hazardous. Appropriate warnings are included in the specific procedures; however, the warnings have been purposely kept brief to avoid delaying the reader with superfluous instructions. The information in this section is provided in more detail to familiarize shop personnel with the characteristic hazards of the chemicals involved. This listing is representative of the chemicals used in various processes, but is not intended to be exhaustive. Many commercial processing compounds contain one or more of the chemicals listed. The composition of tradenamed products can usually be found on the container or its label, or in the manufacturers literature. Because of the fact that some compound may properly be designated by more than one name, other chemical and common names are included in parentheses following the name listed. Form and color data, when included, show room-temperature characteristics of the chemical. All chemicals should be handled with care and used with adequate ventilation. -AACETIC ACID. (Colorless liquid) Moderate-to-high toxicity. Acrid fumes, irritating to mucous membranes, eyes and skin. Contact with skin can cause ulcers and dermatitis upon prolonged exposure. Emits toxic fumes when heated. Moderate fire and explosion hazard when exposed to heat or flame. Highly explosive in contact with chromic acid, nitric acid and sodium peroxide. Wash from skin or eyes with cool water. ACETIC ANHYDRIDE. (Colorless liquid) Moderate-to-high toxicity. Irritant and corrosive on contact with tissues, particularly eyes and upper respiratory tract. Moderate fire and explosion hazard when exposed to heat or flame. Emits highly toxic fumes when heated. Reacts vigorously with oxidizing materials, and violently on contact with water or steam. Wash from skin or eyes with cool water, after blotting excess from surface with clean cloth or paper towel. ACETONE. (Dimethyl ketone) (Colorless liquid) Moderate toxicity when swallowed, inhaled or absorbed by the skin. May act as a narcotic or anesthetic in moderately high concentrations of vapor in air. Extremely high fire and explosion hazard. ACETYLENE. (Colorless gas) Narcotic and anesthetic in proportions of 40 percent or more with oxygen. Causes asphyxiation in very high concentrations. Moderate fire and explosion hazard, particularly at high pressures. Forms explosive compounds with copper and silver. ACIDS. Many inorganic acids, such as sulfuric, hydrochloric, nitric and some organic acids, react with water to evolve considerable quantities of heat. If water is poured into concentrated acids, steam is generated explosively, thereby spattering the hot concentrated acid onto personnel and equipment in the vicinity. The
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HAZARDOUS CHEMICALS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (1) operator should pour the acid into the water while stirring vigorously, so as to avoid the hazard. ACROLEIN. (Acrylic aldehyde) (Heavy vapor, product of heating glycerine or acrylic compounds to decomposition) Extremely irritating to eyes and mucous membrane. Highly toxic when inhaled or ingested, but its extremely acrid odor serves as its own warning agent. ACRYLIC PLASTICS. Emit fumes of acrolein when heated to decomposition. ALCOHOL, DENATURED. (Colorless liquid) Toxicity depends upon the specific denaturant used, and the alcohol in question. (Refer to specific alcohol.) Dangerous fire hazard. ALKALIES. A term generally applied to the hydroxides and carbonates of the alkali metals (lithium, potassium, sodium, calcium) and of ammonia. Common cause of occupational dermatitis. Alkaline solutions cause softening and solution of skin proteins, and result in the skin becoming white, soggy, wrinkled and macerated. The stronger caustics may produce chemical burns, which are often deep and slow in healing. Breathing of dusts or sprays causes ulceration of intranasal mucous membrane. Toxicity is variable, depending on type and strength of solution. Ammonium alkalies are systemically poisonous. Wash from skin or eyes with cool water. ALUMINUM (powder or dust). Suspected as cause of an acute lung fibrosis. Moderate hazard of explosion and/or fire when exposed to heat or flame. Irritating to eyes. ALUMINUM OXIDE (dust, "grinding dust"). Possible cause of lung damage, especially in combination with silica and oxides of iron. AMMONIA (gas). Slightly acid, very irritating gas which dissolves readily in water to form ammonium hydroxide, which is commonly called ammonia. The gas is used as a nitriding atmosphere. AMMONIUM HYDROXIDE (Aqua ammonia) Moderately alkaline solution of ammonia in water. Fumes are irritating to eyes and mucous membrane. Solution is toxic when swallowed. ANILINE DYES (Liquid) Used in layout fluids and marking compounds, these dyes have varying degrees of toxicity, depending upon the specific dye involved. Skin contact may cause dermatitis. Highly toxic fumes are emitted when dyes are heated to decomposition. These dyes can be absorbed through the skin. Use protective clothing when handling. ANTIMONY (Lustrous blue-white metal) Used as a hardening agent in alloys with softer metals, this element, its compounds, and its vapors when heated or released by solution in acid are extremely toxic. Moderate fire and explosion hazard in the form of dust. ASBESTOS PARTICLES Cause fibrosis, lesions and thickening of lung tissue upon prolonged inhalation of minute quantities of fiber or dust suspended in air. -B"BAKELITE" (Phenol-formaldehyde plastic, Trade Names: "Formica", "Textolite", "Micarta", etc.) Emits toxic fumes when heated to decomposition. BATTERY ELECTROLYTE (liquid): (Refer to sulfuric acid or sodium hydroxide, whichever is present.)
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STANDARD PRACTICES MANUAL AS907-1-1A BENZENE (Coal tar naphtha) Fumes or vapors are irritating to mucous membranes and skin. Toxic when absorbed, inhaled or swallowed. Has narcotic effect on central nervous system, and anesthetic action can result in coma and death. Continued moderate exposure can damage the blood-forming tissues. Fire hazard when exposed to heat or flame. BERYLLIUM (metal, appearance similar to magnesium) Dusts and vapors of the metal and its compounds are highly toxic when inhaled or ingested; moderately toxic upon skin contact. Artificial isotopes (Be7 and Be10) are radioactively hazardous. Will burn spontaneously in air. BISULFITES (White crystalline salts) Emits toxic fumes of sulfur dioxide when heated to decomposition. BORAX (Sodium tetraborate) Moderately toxic when inhaled or swallowed. BORON HYDRIDES (Polyboranes) Highly toxic on skin contact, inhalation or ingestion. Causes severe irritation to central nervous system. BRASS May emit zinc oxide fumes when melted. The fumes are mildly toxic when inhaled. BROMINE (brown liquid) One of the halogen family of elements; hence highly corrosive and irritating to tissues. Liquid is toxic upon skin contact and when swallowed. Vapor is toxic when inhaled. Wash from skin with mild soap and lukewarm water. -CCADMIUM (white metal) Emits toxic fumes of cadmium vapor when heated. Compounds of cadmium are highly toxic when inhaled or swallowed, causing deterioration of liver and kidneys, and severe irritation of the respiratory tract. CARBON MONOXIDE (Colorless, odorless gas; product of incomplete combustion) Causes asphyxiation in moderate, or prolonged slight concentrations by inhibiting oxygen absorption by the blood. CARBON TETRACHLORIDE (Colorless liquid) Vapor can be narcotic, causing unconsciousness followed by damage to liver, kidneys and lungs upon exposure to high concentrations. Repeated or prolonged skin contact removes skin oils and fat, causing severe dermatitis. Emits highly toxic phosgene gas when heated to decomposition. Review local EPA restrictions on its use. CHLORINE (Pungent yellow-green gas) One of the halogen family of elements; hence highly corrosive and irritating to tissues. Irritating to lungs upon inhalation, causing pulmonary edema and possible death. Irritating to eyes and mucous membrane. CHROMIUM COMPOUNDS (Dusts; solutions) Highly toxic when swallowed. Dusts and sprays cause corrosive lesions and ulcers to skin and mucous membranes. CLEANING SOLVENTS (Kerosene, Stoddard Solvent, Varsol, mineral spirits, and other petroleum distillates) Moderately toxic upon ingestion or continued contact with the skin. Inhalation of spray or droplets can cause lung inflammation leading to pneumonia. These solvents are flammable. -DO-DICHLOROBENZENE (Refer to Orthodichlorobenzene.)
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STANDARD PRACTICES MANUAL AS907-1-1A DIETHYLENETRIAMINE High concentrations of fumes are irritating to the eyes and mucous membranes. Contact with the skin causes acute dermatitis and permanent tissue damage. Wash immediately with warm water and soap. -EEPOXY RESIN CATALYSTS May contain diethylenetriamines, which are extremely toxic on skin contact, inhalation of fumes or ingestion. Skin contact can result in severe dermatitis and permanent tissue damage. Wash immediately with warm water and soap. ETHYL ALCOHOL (Ethanol, Grain alcohol) Mildly toxic upon continuous exposure to vapors. Irritant to mucous membrane. Ingestion of high-percentage alcoholic solutions can be extremely toxic. Dangerous fire hazard, especially as vapor. ETHYL-METHYL-KETONE (Refer to methyl-ethyl-ketone. -FFIBER-GLASS (Glass fiber, glass wool) Non-toxic local irritant. Minute fibers can penetrate the skin and cause temporary irritation, itching and dermatitis. FLUORINE (Pale yellow gas) Fluorine is an extremely active gaseous element, uniting directly with nearly all other elements except oxygen. Hydrofluoric acid, used as an etchant for metals and glass, releases fumes of hydrogen fluoride which attacks tooth and bone tissue, and causes ulceration of mucous membrane. Fumes condense on surrounding areas causing severe burns, but does result in immediate burns on skin. Rinsing of hands important after each use. -HHALOGENS A chemical grouping of elements which includes fluorine, chlorine, bromine and iodine in descending order of chemical activity. Beneficial or even essential to life in trace quantities, all halogens are toxic and corrosive in larger quantities. HYDROCHLORIC ACID (Muriatic acid. Colorless-to-light-yellow-green liquid) Concentrated hydrochloric acid emits fumes of hydrogen chloride at room temperature; these fumes become visible when the breath is blown across an open container of the liquid. The acid is extremely active, chemically, and is highly toxic upon skin contact, inhalation of fumes, or ingestion. Skin burns result from contact with the liquid and acute irritation of mucous membranes results from breathing the fumes. Rinse from skin with cool, clear water. -IIODINE (Grey-black crystals) The least active of the halogens, iodine solutions in water or alcohol cause skin burns on contact. Iodine vaporizes at 3648F (184.358C) to a violet vapor which is extremely irritating to eyes and mucous membranes. Wash from skin with a mixture of equal parts of cool 10-percent sodium or ammonium thiosulfate solution and ethyl alcohol. ISOPROPYL ALCOHOL Moderately toxic when swallowed or inhaled as vapor. Can cause eye damage (cornea burns) on contact. Moderate fire and explosion hazard, especially as vapor. -KKEROSENE (Coal oil) (Refer to Cleaning Solvents.) -L-
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STANDARD PRACTICES MANUAL AS907-1-1A LEAD Inhalation of lead fumes or ingestion of lead compounds is highly toxic. Lead compounds can be absorbed through the skin, or ingested with food or tobacco when present on fingers. Deterioration of the liver and kidneys results from ingestion. LEAD TETRAETHIDE (Tetraethyl lead. Colorless liquid. Gasoline anti-knock compound.) Highly toxic when absorbed through the skin, inhaled or ingested. Disturbances of the central nervous system, deterioration of liver, kidneys, male gonads and blood vessels are typical consequences. -MMAGNESIUM (White, lustrous metal) Fire and explosion hazard, particularly in the presence of water or steam. Ignites readily in the form of dust, flakes or machining chips. Fumes of burning magnesium can be mildly to moderately toxic if inhaled. MANGANESE (Brittle, grey-white metal) Dust and fumes of manganese and its compounds can be moderately toxic upon inhalation or ingestion. Damage to the central nervous system, resulting in permanent disability, is a typical consequence. MERCURY (Quicksilver) Highly toxic in the form of soluble compounds, which affect the central nervous system, and cause deterioration of liver, kidneys, spleen and bone. Psychic disorders, confusion and loss of memory may occur. METHYL ALCOHOL (Methanol; wood alcohol. Colorless liquid.) Moderately toxic when vapors are inhaled or liquid is absorbed through the skin; highly toxic when swallowed. Causes blindness, convulsions, coma and death. Dangerous fire and explosion hazard, especially as vapor. METHYL-ETHYL-KETONE (Ethyl-methyl-ketone; 2 butanone) Moderately toxic upon skin contact, inhalation or ingestion. Prolonged or repeated contact with the skin can result in dissolving of skin oils and fat, thus causing dermatitis. Fire and explosion hazard, especially as vapor. METHYLENE CHLORIDE (Methylene Bichloride) Colorless, volatile liquid penetrating ether-like odor. Poisonous vapors emitted when contact with flame. -NNITRIC ACID Extremely toxic upon skin contact, inhalation or ingestion. Reacts with the skin to precipitate proteins and form a yellow stain which disappears only when the skin wears away to expose a new layer. Concentrated nitric acid emits fumes of nitric oxide, which react with moisture in the lungs to re-form nitric acid. Fire and explosion hazard when mixed with many reducing agents. Can form explosive compounds with many organic substances. NITRIC OXIDE (Colorless gas) and NITRIC DIOXIDE (reddish brown gas). Nitric oxide is formed when nitric acid reacts with organic material, when organic nitrocompounds are burned, and when nitric acid is used to etch metal. Nitric oxide is soluble in water, and reacts with water and with oxygen in the air to form nitric dioxide, nitric and nitrous acids. Inhalation of nitric oxide and dioxide causes pulmonary edema by reacting with moisture in the lungs to form nitric acid. Fatal edema can develop within 6 to 24 hours of exposure. -OORTHODICHLOROBENZENE (Aromatic, colorless liquid. Component of some organic cleaning compounds.) Moderately toxic upon skin contact, ingestion and inhalation of vapor. Somewhat narcotic. May cause kidney and liver damage.
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STANDARD PRACTICES MANUAL AS907-1-1A OXALIC ACID Highly toxic upon skin contact, inhalation of dust, or ingestion of crystals or solution. Removes calcium from blood, causes obstruction and ultimate failure of kidneys, and corrosion of tissues of the mouth, esophagus and stomach. -PPERCHLOROETHYLENE (Clear liquid, aromatic odor. Degreasing agent). Moderately toxic upon skin contact or inhalation of vapor; highly toxic if swallowed. Anesthetic vapor can cause nausea and mental confusion. Skin contact can cause dermatitis. PHOSGENE (Carbonyl chloride) (Decomposition-product of carbon tetrachloride, polyvinyl chloride, and other organic chlorides.) There is no immediate warning that dangerous concentrations are being breathed. Delayed effect (2 - 24 hours) is edema of the lungs, often fatal, resulting from further decomposition of phosgene into hydrochloric acid and carbon monoxide in contact with moisture in the lungs. PHOSPHORUS (Pure phosphorus occurs in three allotropic forms: yellow, red and black. The yellow, waxy form is toxic and burns spontaneously in air.) Phosphorus is an essential ingredient of living tissue; however, many of its compounds are moderately to highly toxic, causing stomach hemorrhage, and liver and kidney damage. -SSILICON CARBIDE ("Carborundum" abrasive grit, grinding dust) Prolonged exposure of lungs to grinding dust, even in minute quantities, can cause fibrosis of the lungs. SODIUM CYANIDE (White crystalline solid; used as a heat treating and stripping salt) Extremely toxic upon skin contact, inhalation or ingestion of vapors, dust or solutions. Mixing of cyanides with acids results in the emission of hydrogen cyanide, which is used for the execution of criminals in gas chambers because of the extreme rapidity of its fatal action. SODIUM DICHROMATE (orange crystalline solid) (Refer to Chromium Compounds.) SODIUM HYDROXIDE (lye) Extremely corrosive and destructive to all body tissues, both solid and in solution. Causes deep chemical burns and scarring. Prolonged contact with dilute solutions will ulcerate and destroy tissues. Mists, vapors and dusts of this product cause small burns, and contact with the eyes rapidly causes severe damage. (Refer to Alkalies.) Reacts with water or steam to produce heat. SULFUR DIOXIDE (gas) Moderately to highly toxic. Extremely irritating to mucous membrane and eyes. It affects the upper respiratory tract, and may cause pulmonary edema by uniting with moisture in the lungs to form sulfurous acid. Reacts with water or steam to produce toxic and corrosive fumes. SULFURIC ACID (Colorless to light straw colored liquid; syrupy consistency in high concentration) Highly toxic in moderate-to-strong concentration, causing destruction of all kinds of tissue. It dehydrates other substances by absorbing water actively, thereby diluting itself. A strong oxidizer, it can ignite combustibles on contact. It produces heat by reaction with water or steam. -TTOLUENE (Toluol, methyl benzene) Moderately toxic upon ingestion, inhalation, or absorption through the skin. Fire and explosion hazard when exposed to heat or flame. Reacts with HNO and HSO4 to form an explosive.
EFFECTIVITY: ALL
70-00-04
STANDARD PRACTICES MANUAL AS907-1-1A TRICHLOROETHANE 1-1-1 (EPA exempt solvent) Slightly toxic, emits chlorides when heated. TRICHLOROETHYLENE (Colorless liquid; degreasing agent) slight-to-moderate toxicity upon skin contact, inhalation or ingestion. Nausea and moderate anesthetic effect are typical consequences of moderate exposure. Emits fumes of chlorides when heated to decomposition. -VVINYL PLASTICS (Polyvinyl acetate, polyvinyl chloride - PVC) Emits toxic fumes when heated to decomposition. PVC decomposes to phosgene. -XXYLENE (Xylol, dimethyl benzene. Colorless liquid.) Slightly toxic upon inhalation, ingestion or absorption by the skin. Fire and explosion hazard when exposed to heat or flame. -ZZINC Freshly formed zinc oxide, when inhaled, can cause "brass founders shakes", so called because the oxide is formed as brass is melted for casting. Noncumulative, the condition is relieved by exposing the victim to fresh air.
EFFECTIVITY: ALL
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EFFECTIVITY: ALL
70-00-04
WATER TYPES - WATER TYPES TASK 70-00-05-800-006 1. Water Types SUBTASK 70-00-05-99G-006 A. General. This chapter defines all types of water used in the shop or in quality testing. The types are grouped under 3 headings as follows. Note that the water type designations are intended to aid in obtaining satisfactory results when applying standard methods and will enable procurement of facilities to supply the different water types. (1) (2) (3) Water (tap water). Deionized water. Distilled water.
SUBTASK 70-00-05-800-061 B. Water. (1) The term water is used to refer to currently available drinking water having an average resistance between 4000 and 5000 L.cm. Since the resistivity of tap water supplied by local water networks (filtered and treated surface water or government approved spring water) is usually in the above range, the actual resistivity values are of little importance. This water is approved for use in degreasing, stripping, and rinsing solutions (a minimum resistivity of 10000 L.cm is recommended in the general case). The water must be clean and free from insoluble matter in suspension and from dissolved salts that could contaminate the baths. This water is designated in the Standard Practices Manual by the term water.
(2)
(3)
SUBTASK 70-00-05-800-062 C. Deionized Water. Deionized water is characterized by its resistivity and is divided in the Standard Practices Manual into 3 types: (1) Deionized water with a minimum resistivity of 50000 ohmcm to be used for preparing and topping baths prone to contamination by mineral and organic impurities. These baths include: (a) Electrolytic and chemical treatment baths, and copper, nickel, silver, cadmium, zinc, and other plating baths, except for chromium plating.
EFFECTIVITY: ALL
70-00-05
WATER TYPES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (b) (c) (d) Sulfuric and chromic anodizing treatments with sealing baths. Deionized water with a minimum resistivity of 50000 ohmcm to be used for rinsing titanium and titanium alloys. Deionized water with a minimum resistivity of 10000 ohmcm to be used for preparing and topping the following. 1 2 Chromium baths. Chemical conversion baths (chromium, phosphorus, etc.).
SUBTASK 70-00-05-800-063 D. Distilled Water. (1) Distilled water is to be used for volumetric analysis and for bath quality testing. Demineralized water with hydrogen ions added (Permutit Water) with a minimum resistivity of 500000 ohmcm may be used as a substitute for distilled water. In the Standard Practices Manual, this water is designated by the term distilled water.
(2)
EFFECTIVITY: ALL
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WATER TYPES Page 2 Dec 01/03
QUALITY OF GASES - QUALITY OF GASES TASK 70-00-06-800-007 1. Quality Of Gases SUBTASK 70-00-06-99G-007 A. General. This chapter defines the quality of gases utilized for standard practices and other process document applications. The three required qualities of gas are the following: (1) (2) (3) Commercial quality gases. Pure gases. Very pure gases.
SUBTASK 70-00-06-800-071 B. Commercial Quality Gases. (1) Under the term "Commercial quality gases" are grouped the gases that meet the following specifications: (a) (b) (c) (2) Gas content, between 99.0 percent and 99.8 percent. Oxygen content, less than or equal to 20 ppm. Water content, less than or equal to 20 ppm.
These gases are designated only by their name, e.g. Argon.
SUBTASK 70-00-06-800-072 C. Pure Gases. (1) Under the term "Pure gases" are grouped the gases that meet the following specifications: (a) (b) (c) (2) Gas content, between 99.990 percent and 99.998 percent. Oxygen content, less than or equal to 10 ppm. Water content, less than or equal to 10 ppm.
These gases are designated by their name preceded by the term "pure" e.g. Pure Argon.
EFFECTIVITY: ALL
70-00-06
QUALITY OF GASES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-06-800-073 D. Very Pure Gases. (1) Under the term "very pure gases" are grouped the gases that meet the following specifications: (a) (b) (c) (2) Gas content, between 99.995 percent and 99.998 percent. Oxygen content, less than or equal to 5 ppm. Water content, less than or equal to 5 ppm.
These gases are designated by their name preceded by the term "very pure", e.g. Very Pure Argon.
EFFECTIVITY: ALL
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QUALITY OF GASES Page 2 Dec 01/03
SOLUTION SHEETS - SOLUTION SHEETS TASK 70-00-99-800-303 1. Solution Sheets SUBTASK 70-00-99-99G-303 A. General. (1) (2) This chapter specifies each bath recommended in the cleaning and surface preparation treatment processes by solution sheets numbered SXXXX. A Solution Sheet is a document that specifies composition, preparation, checking, and regeneration of a solution. NOTE: Two solutions which contain the same products but of different concentrations are treated as different solutions and are assigned separate solution numbers. (3) A large number of the solutions and their constituents are dangerous for human skin and clothing. It is necessary for personnel to be well protected from any direct contact by wearing aprons, gloves, and protective goggles or face shields when working with these types of solutions. For this type of situation, the preparation instructions will be preceded by a WARNING note, as per the following example. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAN CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH AN ABUNDANT QUANTITY OF WATER. AVOID BREATHING OF VAPORS. OPERATOR SHOULD WEAR A FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING:
WARNING: (4)
The preparation and regeneration must be performed according to the order detailed in the procedures for preparing and regenerating the solution. (a) (b) Never pour water into concentrated acid. Pour the acid, alkali, or oxidizing agent very slowly into the water, small quantities at a time, without producing any splashing and with stirring after each addition.
(5) (6)
The preparation, checking, and regeneration of a solution must be accomplished with the guidance and responsibility of an experienced chemist. In cases where the supplier of the chemicals used in the preparation, checking, and regeneration of the following solutions is recommending a newer, up-dated analytical control procedure, that new procedure may be substituted for the control procedures recommended in this 70-00-99 section, but the data showing correlation of results must be provided comparing the two methods of analysis.
EFFECTIVITY: ALL
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SOLUTION SHEETS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-800-235 B. Water for Electrolytic and Chemical Treatment Baths. (1) Most of the baths, unless otherwise specified, are of the aqueous solution type. The water type is specified in Chapter 70-00-05.
SUBTASK 70-00-99-800-236 C. Composition of Baths. (1) The chemical compositions of the baths are expressed in ounces per US gallon; grams per liter for solid products; fluid ounces per US gallon; and milliliters per liter for liquid products.
SUBTASK 70-00-99-800-237 D. Special Recommendations. (1) Monitoring of Baths. (a) The personnel utilizing the baths must be familiar with the characteristics and the performance of the baths. It is recommended that a record sheet for each bath be maintained which documents the following data. 1 2 The typical composition, the limits of use, and the working conditions. The date and results of analyses accomplished: a b 3 After preparation. During operation.
The date and activity accomplished, such as additions, purifications, and regenerations, after special analyses or tests indicate corrective action is required.
(2)
Verification of the Equipment. (a) (b) Periodically verify the general state of tanks, of tank heating systems, of bath stirring facilities, and of vapor and fumes removal devices. Periodically verify the accuracy of measurement and control apparatus, such as voltmeters, ammeters, thermometers, densimeters, rheostats, pH-meters, and other apparatus that is utilized to monitor and control the baths.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-800-238 E. Table of Solutions. Table 1. Solutions NO. 0001 NAME 50:50 Nitric Acid Stripping Solution CHAPTER 70-23-06 70-23-07 70-23-12 70-23-24 70-23-25 70-23-08 70-23-18 70-23-09
0002 0003
Stripping Solution for Pure Aluminum Thermal Spray Stripping Solution for Tungsten Carbide Thermal Sprayed Coating Stripping Solution for Bond and Finish Coatings Stripping Solution for Nickel or Silver Plate Stripping Solution for Chemical Stripping of Chromium Plate Stripping Solution for Electrolytic Stripping of Chromium Plate Stripping Solution for Urethane Coatings Stripping Solution for Tungsten or Chrome Carbide Thermal Spray Stripping Solution for nickel plate Stripping Solution for Epoxy Resin Stripping Solution for Anodized Coating Stripping Solution (acid bath) for Chromium Carbide Thermal Spray and NickelAluminum Bond Coat Stripping Solution for Oxidizing Alkaline Cleaners Stripping Solution for Aluminum Honeycomb bonded with Narmco Metalbond 328
0004 0005 0006
70-23-07 70-23-04 70-23-05
0007
70-23-05
0008 0009
70-23-10 70-23-11
0010 0011 0012 0013
70-23-13 70-23-14 70-23-15 70-23-16
0014 0015
70-23-16 70-23-17
EFFECTIVITY: ALL
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Table 1. Solutions (Cont) NO. 0016 NAME Stripping Solution for Aluminanickel Aluminum Composite and Duplex Coatings Stripping Solution (Cyanide) for Aluminum Oxide/Nickel Aluminide Coatings Alkaline Permanganate Solution CHAPTER 70-23-18
0017
70-23-19
1001
70-21-07 70-21-10 70-21-17 70-21-20 70-22-02 70-22-05 70-21-12 70-22-02 70-21-09 70-22-02 70-21-07 70-21-10 70-21-17 70-21-20 70-22-02 70-22-05 70-21-06 70-21-07 70-21-10 70-21-16 70-21-17 70-21-20 70-21-06 70-21-07 70-21-10 70-21-16 70-21-17 70-21-20 70-22-01 70-22-02 70-21-06 70-21-16 70-21-17 70-21-20 70-21-10 70-21-20
1002 1003
Acid Stripping Solution for Titanium Alkaline Degreasing/Rust Removing Solution for Titanium Alkaline Permanganate Solution
1004
1005
Alkaline Degreasing/Rust Removing Solution
1006
1007 1008
Oxide Conditioning Solution for Titanium Phosphoric Acid Solution with Inhibitor - C04-119
1009
Acid Stripping Solution for Stainless Steel and Heatresistant Alloys
EFFECTIVITY: ALL
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Table 1. Solutions (Cont) NO. 1010 NAME Alkaline Degreasing/Rust Removing Solution for Titanium Acid stripping Solution for Stainless Steel and Heatresistant Alloys Alkaline Permanganate Solution CHAPTER 70-21-09 70-22-02 70-21-10 70-21-20 70-21-07 70-21-10 70-21-17 70-21-20 70-22-02 70-22-05 70-21-13 70-22-02 70-21-07 70-21-10 70-21-17 70-21-20 70-22-02 70-22-05 70-21-07 70-21-10 70-21-17 70-21-20 70-22-02 70-22-05 70-21-16 70-21-17 70-21-20 70-21-06 70-21-07 70-21-10 70-21-16 70-21-17 70-21-20 70-21-07 70-21-10 70-21-17 70-21-20 70-22-02 70-22-05 70-22-02 70-21-16 70-21-17 70-21-20
1011
1012
1013 1014
Acid Stripping Solution Alkaline Permanganate Solution
1015
Alkaline Permanganate Solution
1016
Phosphoric Acid Solution with Inhibitor - C04-120 Heavy Duty Alkaline Cleaner
1017
1018
Alkaline Permanganate Solution
1019 1020
Titanium Scale Conditioner Phosphoric Acid Solution with Inhibitor - C04-190
EFFECTIVITY: ALL
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Table 1. Solutions (Cont) NO. 1021 NAME Acid Stripping Solution for Stainless Steel and Heatresistant Alloys Phosphoric Acid Solution with Inhibitor - C04-121 Acid stripping Solution for Stainless Steel and Heatresistant Alloys Alkaline Degreasing/Rust Removing Solution CHAPTER 70-21-10 70-21-20 70-21-16 70-21-17 70-21-20 70-21-10 70-21-20 70-21-06 70-21-07 70-21-10 70-21-16 70-21-17 70-21-20 70-21-03 70-22-03 70-46-01 70-21-06 70-21-07 70-21-10 70-21-16 70-21-17 70-21-20 70-21-06 70-21-07 70-21-10 70-21-16 70-21-17 70-21-20 70-21-13 70-22-02 70-21-09 70-22-02 70-21-09 70-22-02 70-21-08 70-21-08 70-21-08
1022
1023
1024
1025
Alkaline Cleaning Solutions
1026
1027
1029 1030 1031
Acid Stripping Solution Alkaline Degreasing Solution Alkaline Degreasing/Rust Removing Solution for Titanium Carbon Remover and Paint Stripper Carbon Remover and Paint Stripper Carbon Remover and Paint Stripper
1034 1035 1036
EFFECTIVITY: ALL
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Table 1. Solutions (Cont) NO. 1037 1038 1039 1040 1041 1046 1047 1048 1050 1053 1054 1103 NAME Carbon Remover and Paint Stripper Heavy Duty Alkaline Cleaner C04-048 Solvent Solution Solvent Solution Magnetic-particle Suspension Solution Solution for Ultrasonic Cleaning Compound Cleaner Solution for Ultrasonic Cleaning Wet Abrasive Blasting Wet Abrasive Blasting Wet Abrasive Blasting Wet Abrasive Blasting Acid Stripping Solution for Stainless Steel and Heatresistant Alloys Phosphoric Acid Solution with Inhibitor - C04-143 Developer Developer Developer Developer Remover Remover Remover Silicone Rubber Remover Silicone Rubber Remover Silicone Rubber Remover Non-cyanide Alkaline Stripping Solution ASC 2-N Acid Stripping Solution 50/50 Nitric/Phosphoric acid Stripping Solution CHAPTER 70-21-08 70-21-07 70-21-01 70-21-02 70-21-01 70-32-01 70-21-15 70-21-15 70-21-05 70-21-05 70-21-05 70-21-05 70-21-10 70-21-20 70-21-16 70-21-17 70-21-20 70-32-02 70-32-02 70-32-02 70-32-02 70-32-02 70-32-02 70-32-02 70-23-20 70-23-20 70-23-20 70-23-21 70-23-21
1104
1123 1124 1125 1126 1127 1128 1129 1130 1131 1132 1133 1134 1135
EFFECTIVITY: ALL
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Table 1. Solutions (Cont) NO. 1136 1137 1138 1139 1140 1141 1142 1143 1144 1145 1146 1147 1148 1149 1150 NAME AIO Acid Stripping Solution Acid Stripping Solution of NiCrAlY Plasma Coatings Acidic Stripper for Plasma and D-gun Deposited Coatings Alkaline Degreasing/Rust Removing Solution Alkaline Degreasing/Rust Removing Solution Light Duty Alkaline Cleaner Light Duty Alkaline Cleaner Light Duty Alkaline Cleaner Light Duty Alkaline Cleaner Light Duty Alkaline Cleaner Versene Cleaning of Codep Coated HPTR Blades Degreasol 99R Cold Solvent Hot Tank Water Based Jettacin Cleaner Ammonium Versene Cleaning Solution Alkaline Degreasing/Rust Removing Solution (HDL-202) 70-23-22 70-23-09 70-21-09 70-22-02 70-21-09 70-22-02 70-21-22 70-21-22 70-46-01 70-21-22 70-46-01 70-21-22 70-21-22 70-46-01 70-22-07 70-21-01 70-22-09 70-21-22 70-22-08 70-21-06 70-21-07 70-21-10 70-21-16 70-21-17 70-21-20 70-22-01 70-23-02 70-21-09 70-21-10 70-22-02 70-21-10 70-21-20 DELETED CHAPTER
1151
Alkaline Degreasing/Rust Removing Solution for Titanium (HDL-202) Acid Stripping Solution for Stainless Steel and Heatresistant Alloys Light-duty Aqueous Degreaser (DG-Kleen Immersion)
1152
1153
EFFECTIVITY: ALL
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Table 1. Solutions (Cont) NO. 1154 1155 1156 1157 1158 1159 NAME Light-duty Alkaline Cleaner (DG-Kleen Spray) Carbon Remover and Paint Stripper (Kemstrip-596) Corrosion Inhibitor Solution for Steel (Corrotek) Acid Descaler Cleaner - C04189 Light Duty Alkaline Cleaner (Soluwax) Acid Stripping Solution for Stainless Steel and Heatresistant Alloys Non-phenolic, Alkaline, Diphase, Hot Tank Paint, and Carbon Remover Alkaline Degreasing/Rust Removing Solution (HTP-1150) CHAPTER 70-21-22 70-21-08 70-23-01 70-60-00 70-21-10 70-21-20 70-21-22 70-21-10 70-21-20 70-21-08 70-23-01 70-21-06 70-21-07 70-21-10 70-21-16 70-21-17 70-21-20 70-21-06 70-21-07 70-21-10 70-21-16 70-21-17 70-21-20 70-21-07 70-21-10 70-21-17 70-21-20 70-22-02 70-21-07 70-21-10 70-21-17 70-21-20 70-22-02 70-21-10 70-21-20 70-21-16 70-21-17 70-21-20
1160
1161
1162
Alkaline Degreasing/Rust Removing Solution (HTP1150L)
1163
Alkaline Permanganate Solution (HTP-1190)
1164
Alkaline Permanganate Solution (HTP-1190L)
1165
Acid Stripping Solution for Stainless Steels and Heat Resistant Alloys (AC-111) Phosphoric Acid Solution with Inhibitor - C04-217
1166
EFFECTIVITY: ALL
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Table 1. Solutions (Cont) NO. 1167 1168 NAME Light Duty Alkaline Cleaner (ED-306LF) Alkaline Degreasing/Rust Removing Solution for Titanium (Eldorado HTP-1150/ HTP1150L) Solution for Inspection of Open Face Honeycomb Light Duty Alkaline Cleaner Super Bee 300LF Non-Phenolic, Non-Chromate, and Non-Chlorinated Solvent or Acid, Diphase, Hot Tank Paint Carbon Remover Abradable Plastic Seal Compound (RSP-3) Chromated Conversion Coating Chromate Conversion Coating Alkaline Degreasing/Rust Removing Solution for Titanium Parts - C04-233 Alkaline Degreasing/Rust Removing Solution for NonTitanium Parts - C04-233 CHAPTER 70-21-22 70-21-09 70-22-02
1169 1170 1171
70-32-02 70-21-22 70-21-24 70-23-01
1172 1173 1174 1175
70-43-15 70-43-08 70-43-08 70-21-09 70-22-02 70-21-06 70-21-07 70-21-10 70-21-16 70-21-17 70-21-20 70-21-07 70-21-10 70-21-17 70-21-20 70-22-02 70-21-16 70-21-17 70-21-20 70-21-10 70-21-20 70-21-22 70-21-22
1176
1177
Alkaline Permanganate Solution - C04-234
1178
Phosphoric Acid Solution with Inhibitor - C04-235 Acid Stripping Solution for Stainless Steel and HeatResistant Alloys - C04-236 Light-Duty Alkaline Cleaner C04-208 Light-Duty Alkaline Cleaner C04-193
1179
1180 1181
EFFECTIVITY: ALL
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Table 1. Solutions (Cont) NO. 1182 1183 NAME Light-Duty Alkaline Cleaner C04-237 Acid Stripping Solution for Stainless Steel and HeatResistant Alloys - C04-239 (for Cee-Bee J3 product only) Acid Stripping Solution for Stainless Steel and HeatResistant Alloys - C04-240 (for Ardrox 1873A product only) Phosphoric Acid Solution with Inhibitor - C04-122 Plating Remover Solution C04-244 Paint and Carbon Remover C04-245 Plating Remover for Nickel or Silver Plate - C04-246 Alkaline Rust Remover - C04247 Acid Stripping Solution Acid Stripping Solution Acid Stripping Solution CHAPTER 70-21-22 70-21-10 70-21-20
1184
70-21-10 70-21-20
1185
70-21-16 70-21-17 70-21-20 70-23-21 70-21-08 70-23-01 70-23-04 70-22-03 70-22-05 70-21-13 70-22-02 70-21-13 70-22-02 70-21-13 70-22-02
1186 1187 1188 1189 1190 1191 1192
TASK 70-00-99-800-001 2. Solution S0001 SUBTASK 70-00-99-99G-001 A. Composition (1) The following commercial products are recommended for the removal of silver and copper-nickel-indium thermal spray coating. This process is satisfactory for use on A286, Inco 718, and titanium parts.
EFFECTIVITY: ALL
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Description Nitric acid, 428Baume
Consumable No. C04-072
Concentration (Initial Mix) 50% v/v
NOTE: The nominal acid content of 428Baume nitric acid is 68% by weight. If a different concentration is used, the volume must be adjusted to obtain the same weight of acid per unit volume. For example, 408Baume 55% v/v or 388Baume 61% v/v.
SUBTASK 70-00-99-809-051 B. Preparation WARNING: NITRIC ACID IS TOXIC. DO NOT LET THIS MATERIAL TOUCH YOU. USE PERSONAL PROTECTION EQUIPMENT. USE VAPOR/FUME CONTROL OR A RESPIRATOR. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. DO NOT POUR WATER INTO CONCENTRATED ACID. THE HEAT OF THE REACTION WILL CAUSE BOILING AND SPATTERING.
WARNING: WARNING: (1) (2) (3)
Add the required volume of water to the tank. Add the nitric acid C04-072 slowly and carefully while stirring the solution to mix. Allow the solution to cool to the operating temperature.
SUBTASK 70-00-99-809-052 C. Regeneration (1) Replace the solution when it losses its effectiveness. NOTE: When used for stripping silver, the solution will have dissolved a significant quantity of metal by the time it is exhausted. The silver should be reclaimed before discarding the solution.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-800-002 3. Solution S0002 SUBTASK 70-00-99-99G-002 A. Composition. Table 2. Alkaline Stripping/Cleaning Solutions Consumable Product Turco 4781-7 or Turco 4781-7L Ardrox 185 or Ardrox 185L Turco 4181 or Turco 4181L Ferlon MagChem HDL-2888 Cee-Bee J84A or Cee-Bee J84AL MagChem HDL-202 Eldorado HPT-1150 Eldorado HPT-1150L Applied 5-840 No. C04-053 C04-052 C04-009 C04-050 C04-187 C04-049 C04-182 C04-212 C04-213 C04-235 Concentration (Initial Mix) 20 oz/US gal. (150 g/l) 45% V/V 20 oz/US gal. (150 g/l) 25% V/V 20 oz/US gal. (150 g/l) 35% V/V 20 oz/US gal. (150 g/l) 20 oz/US gal. (150 g/l) 20 oz/US gal. (150 g/l) 16% V/V 18% V/V 20 oz/US gal. (150 g/l) 20% V/V 20 oz/US gal. (150 g/l) Operating Temp 8F (8C) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82)
SUBTASK 70-00-99-809-372 B. Preparation. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4)
Fill the tank to one-half of its working level with water. Add the alkaline cleaner product slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir the solution again to mix.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-373 C. Check. (1) Description Cleaner, Heavy-duty Alkaline (Powder) Cleaner, Heavy-duty Alkaline (Liquid) (2) Determine the concentration of alkaline cleaner product: Limits 16-20 oz/US gal. (120-150 g/l) 75-100% of initial mix Recommended Interval Weekly Weekly
Follow the manufacturers control procedures to maintain the solution.
SUBTASK 70-00-99-809-374 D. Regeneration. (1) (2) (3) (4) Every day, remove surface contamination from the tank. Maintain the solution within the check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank with water up to working level on a daily basis. Replace the solution if it loses its effectiveness.
TASK 70-00-99-800-003 4. Solution S0003 SUBTASK 70-00-99-99G-003 A. Commercial Products. (1) The following commercial products are recommended for the removal of tungsten carbide thermal spray coating from parts. Concentration and Operating Temperature (See instructions)
Product Identification Enstrip A (powder) Enstrip T-L Concentrate (powder) Caustic soda (Sodium hydroxide)
Manufacturer C04-082 C04-083 C04-084
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-053 B. Instructions: (1) Measure out enough water to fill tank to 2/3 of its operating volume. THESE STRIPPING COMPOUNDS ARE STRONG ALKALIS. WEAR PROTECTIVE CLOTHING AND FACE SHIELD OR GOGGLES WHILE MIXING. IF CHEMICALS OR SOLUTION CONTACTS THE SKIN OR EYES, FLUSH AT ONCE WITH CLEAR WATER.
WARNING:
(2) (3)
While stirring vigorously, add 20 ounces (1-1/4 pounds) of Enstrip A powder per gallon of water. Slowly add one pound of Enstrip T-L Concentrate per gallon of water while stirring, then add 12 ounces (3/4 pound) of caustic soda per gallon of water while continuing to stir. Add measured quantities of water to the tank to bring it up to full operating volume. Adjust concentration by adding to each additional gallon of water 1-1/4 pounds of Enstrip A, one pound of Enstrip T-L Concentrate, and 12 ounces (3/4 pound) of caustic soda. Stir during all additions. Heat solution to operating temperature of 1508-1608F (668-718C).
(4)
(5)
TASK 70-00-99-800-004 5. Solution S0004 SUBTASK 70-00-99-99G-004 A. Commercial Products. (1) The following commercial products are recommended for stripping a variety of thermal spray coatings and bond coats, as designated in the stripping procedures. Concentration and Operating Temperature Full strength 708-1108F (218438C)
Product Identification Enstrip L-90
Manufacturer C04-008
(2)
Stripping Solution - The stripping solution will be fresh pre-mixed liquid Enstrip L90.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: STRIPPING SOLUTION IS TOXIC AND REACTS VIGOROUSLY. WEAR PROTECTIVE CLOTHING, GLOVES AND FACE PROTECTION WHILE HANDLING AND USING. WASH IMMEDIATELY WITH CLEAR WATER IF SOLUTION CONTACTS THE SKIN OR EYES.
CAUTION: DUE TO THE LIMITED SHELF LIFE OF THE SOLUTION, THE AGE AT TIME OF USE SHALL NOT EXCEED 6 MONTHS FROM DATE OF MANUFACTURE. A MANUFACTURERS LOT OF SOLUTION IS DEFINED AS THAT AMOUNT OF SOLUTION COMPLETELY BLENDED ONE TIME. (3) Solution Control: Analyze the solution as follows, for level of activator prior to use. Trained personnel are required.
SUBTASK 70-00-99-809-054 B. Instructions: (1) Reagents used for analysis: (a) 0.1N Silver Nitrate (AgNO3): Weight 16.9888 grams of Analytical Reagent grade AgNO3 on an analytical balance. Dissolve in distilled water and dilute to one liter in a volumetric flask. 0.1N Sodium Thiocyanate (NaSCn): Dissolve 8.1 grams of Analytical Reagent grade NaSCn in distilled water and dilute to one liter in a volumetric flask. Standardize against the 0.1N AgNO3 each time. 2 Percent Ferric Ammonium Sulfate Solution: Dissolve 2 grams of Ferric Ammonium Sulfate in 100 ml of 1N HNO3. Nitric Acid (HNO3): 1.0 Normal.
(b)
(c) (d)
SUBTASK 70-00-99-809-055 C. Procedure. (1) Place 50 Ml of distilled water into a 300 ml Erlenmeyer flask and pipette in 25 ml of stripping solution C04-008 at room temperature. NEVER ADD WATER TO ACIDS. ADD ACIDS TO WATER WHILE STIRRING VIGOROUSLY. LOCALIZED HEAT OF SOLUTION CAN CAUSE BOILING AND SPATTERING. WEAR CLOSE-FITTING GOGGLES OR A FACE MASK, RUBBER OR NEOPRENE GLOVES, AND PROTECTIVE CLOTHING.
WARNING:
(2) (3)
Pipette 20.0 ml of 0.1N AgNO3 into flask. Add 5 ml Nitrobenzene to the flask. NITROBENZENE IS EXTREMELY FLAMMABLE AND TOXIC.
WARNING: (4) (5)
Add 5 ml of the 2 percent Ferric Ammonium Sulfate solution. Titrate with the 0.1N NaSCn to a permanent light pink end point. Record the ml of NaSCn required to reach this end point.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (6) Calculate the activator content as follows: NOTE: If the activator content of solution is not within 0.88 to 1.10 grams/liter reject the solution. (a) 2-[(ml NaSCn X N NaSCn) X 1.42] = Grams/Liter activator. NOTE: Procedures for the disposal of toxic wastes should be followed when discarding exhausted stripping solution. TASK 70-00-99-800-005 6. Solution S0005 SUBTASK 70-00-99-99G-005 A. Composition. No. C04-085 C04-086 C04-084 Concentration (Initial Mix) 8 oz/gal. (60 g/l) 20 oz/gal. (150 g/l) See NOTE. To maintain solution alkalinity.
Consumable Product Metex Strip Aid Sodium cyanide Sodium hydroxide
NOTE: Solutions used to remove nickel only can have an initial concentration of sodium cyanide C04-086 equal to 14 oz. per gal. (105 g/l). Solutions used to remove silver or both nickel and silver must use an initial concentration of sodium cyanide C04-086 equal to 20 oz/gal. (150 g/l).
SUBTASK 70-00-99-809-388 B. Preparation. (1) Fill a tank to 60-70 percent of its operating level with tap water. Measure the quantity required. The water temperature can be increased to 1408F (608C) to make the chemical dissolve faster. SODIUM HYDROXIDE, O-S-598, IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION AND VAPOR CONTROL ARE REQUIRED. AVOID ALL CONTACT. SOLUTION CONTAINS SODIUM CYANIDE AND IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION AND VAPOR CONTROL ARE REQUIRED. AVOID ALL CONTACT.
WARNING:
WARNING:
(2) (3)
Add Metex Strip Aid C04-085 and sodium cyanide C04-086 at the concentration specified. Be sure to dissolve each one completely before you add the next. When solution has cooled, add water to bring volume to the operating level and mix thoroughly.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (4) Add sodium hydroxide C04-084 to adjust the alkalinity of the solution to 12-12.5 pH.
SUBTASK 70-00-99-809-389 C. Check. CAUTION: THE FREE SODIUM CYANIDE CONCENTRATION MUST BE MAINTAINED ABOVE 5 OZ/GAL. (37.5 G/L) TO PREVENT POSSIBLE DAMAGE TO THE PARTS. IF THE FREE CYANIDE CONCENTRATION FALLS BELOW 5 OZ/GAL. (37.5 G/L), THE SURFACE OF THE NICKEL COULD BECOME PASSIVE, AND CREATE GALVANIC ACTION AND THE PART COULD BE PITTED OR ETCHED. (1) Do a check of the solution in accordance with the manufacturers instructions. Table 3. Checks Free Cyanide pH Limits 16-24 oz/gal. (90-120 g/l) See NOTE. 12-12.5 Recommended Interval Each week, when in use. Each day, when in use.
NOTE: Solutions used to remove nickel only must have a sodium cyanide concentration C04-086 of 12-16 oz/gal. (90-120 g/l). Solutions used to remove silver or nickel and silver must have a sodium cyanide concentration C04-086 of 16-24 oz/gal. (120-180 g/l).
(2)
Use the manufacturers control procedures to keep the solution within the check limits.
SUBTASK 70-00-99-809-390 D. Regeneration. (1) (2) Each day, remove the surface contamination from the tank. Add the applicable materials to keep the solution within the check limits as follows: (a) (b) (c) (3) Add sodium hydroxide C04-084 to keep the correct pH level. Add Metex Strip Aid C04-085 and sodium cyanide C04-086 in the same ratio as the original make-up. Replace the bath when the quantity of Metex Strip Aid C04-085 added equals the quantity in the original make-up.
Replace the solution if it becomes too weak to work correctly or it becomes contaminated.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-800-006 7. Solution S0006 SUBTASK 70-00-99-99G-006 A. Commercial Products. WARNING: THIS IS A STRONG ACID. WEAR FACE SHIELD AND PROTECTIVE CLOTHING. IF SOLUTION CONTACTS SKIN OR EYES, FLUSH IMMEDIATELY WITH CLEAR WATER AND OBTAIN MEDICAL AID.
(1)
The following commercial products are recommended for stripping chromium plate as directed by the overhaul manual. This material is used for chemical stripping. To electrolytically strip, refer to TASK 70-00-99-800-007, Solution S0007. Concentration and Operating Temperature Undiluted at room temperature
Product Identification Hydrochloric Acid (31 - 36%) (20-22 Baume) Inhibitor SUBTASK 70-00-99-809-058 B. Instructions: (1) (2)
0.2-0.5% of the acid volume
C04-010
Add inhibitor C04-010 into Hydrochloric Acid with slow stirring until the color of the inhibitor is uniformly mixed throughout the acid. When make-up acid is added, inhibitor must be added to maintain the specific percentage of inhibitor in the tank.
TASK 70-00-99-800-007 8. Solution S0007 SUBTASK 70-00-99-99G-007 A. Composition. No. C04-086 C04-123 Concentration (Initial Mix) 7 oz/gal. (52 grams/liter) 8 oz/gal. (60 grams/liter)
Consumable Product Sodium hydroxide Sodium carbonate
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-391 B. Preparation. (1) Fill tank to 60-70 percent of operating level with tap water. THESE MATERIALS ARE STRONGLY ALKALINE. AVOID CONTACT WITH EYES AND SKIN. WEAR FACE SHIELD AND PROTECTIVE CLOTHING. IF ELECTROLYTES CONTACT EYES OR SKIN, FLUSH IMMEDIATELY WITH CLEAR WATER AND SEEK MEDICAL AID.
WARNING:
(2) (3) (4)
Slowly add the required quantity of sodium hydroxide C04-086 while stirring, then add the required quantity of sodium carbonate C04-123 while continuing to stir. Fill the tank to the operating level and mix thoroughly. Increase the temperature of the solution to the operating temperature of 1208-1408F (508-608C).
SUBTASK 70-00-99-809-394 C. Check. (1) Checks Sodium hydroxide Determine the concentration of the solution as follows: Limits 6-8 oz/gal. (45-60 grams/liter) Recommended Interval Weekly
(2)
Determination of sodium hydroxide. (a) (b) (c) Use a pipette to transfer a 5 ml sample of the working solution into a 250 ml Erlenmeyer flask. Add 25 ml of deionized water and 5 ml of sulfo orange indicator. Titrate with 1.0 Normal HC1 to an orange/yellow end point. Oz/gal. of sodium hydroxide = ml x 1.067.
(3)
Determination of sodium carbonate. (a) (b) (c) (d) Use a pipette to transfer a 10 ml sample of the working solution into a 250 ml Erlenmeyer flask. Add 100 ml of hot deionized water and 35 ml of 10% barium nitrate solution. Let the precipitate go to the bottom of the flask. Filter the solution and wash the precipitate twice with hot deionized water. Transfer the filter paper with the precipitate to a beaker, add 100 ml of deionized water and methyl orange indicator.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (e) Titrate with 1.0 Normal HC1 to an orange/pink end point. Oz/gal. of Sodium carbonate = ml x 0.707. SUBTASK 70-00-99-809-414 D. Regeneration. (1) (2) Every day, remove the surface contamination from the tank. Add the applicable materials to keep the solution within the check limits as follows: (a) (b) Keep the sodium hydroxide concentration at a minimum of 6 ounces per gallon (45 grams per liter). The stripping rate will decrease with carbonate build-up. Replace the bath when the carbonate level increases to 12-13 ounces per gallon (90-97 grams per liter).
(3)
Replace the solution if it becomes too weak to work correctly or if it becomes contaminated.
TASK 70-00-99-800-008 9. Solution S0008 SUBTASK 70-00-99-809-060 A. Commercial Products. CAUTION: WEAR RUBBER GLOVES WHEN MIXING OR HANDLING STRIPPING SOLUTIONS. (1) The following commercial products are recommended for stripping urethane coatings from non-perforated aluminum (A) and fiber-glass (B) surfaces. Concentration 60-70 parts by volume Manufacturer Dow Chemical Co. Refer to the List of Suppliers in Step 1.D. of 70-80-00. GAF Corporation Refer to the List of Suppliers in Step 1.D. of 70-80-00.
Product Identification -APerchloroethylene
-add1-methyl-2-pyrrolidinone 30-40 parts by volume
-BSolution A above -addFiller, Phenolic Microballoons Type BJO-0930

EFFECTIVITY: ALL
Quantity sufficient to form thin paste
C10-093
70-00-99
TASK 70-00-99-800-009 10. Solution S0009 SUBTASK 70-00-99-809-061 A. Commercial Products. Concentration and Operating Temperature Full strength, dry 8508-9008F (4548-4828C) Full strength, dry 9508F258F (5108C148C)
Product Identification Kolene DGS Virgo Molten Salts
Manufacturer C04-191 C04-070
SUBTASK 70-00-99-809-062 B. Instructions. WARNING: WEAR PROTECTIVE CLOTHING, GLOVES, AND FACE SHIELD OR GOGGLES WHILE HANDLING OR USING STRIPPING SALTS. IF SALT CONTACTS THE SKIN, FLUSH IMMEDIATELY WITH CLEAR WATER, AND TREAT AS AN ALKALINE BURN.
CAUTION: PROTECT CONTENTS OF TANK FROM INTRODUCTION OF WATER AT ANY TIME. BOTH TEMPERATURE OF MOLTEN SALT AND HEAT OF REACTION CAN CAUSE EXPLOSIVE VAPORIZATION OF WATER AND SPATTERING OF CONTENTS. (1) When filling tank for the first time, use a tank designed for molten salt/molten metal use. (Equipment supplied by Kolene Corporation, or equivalent, is recommended.) Be sure that inside of tank is clean and dry before filling. Fill tank with dry salt flakes, and turn on heater to begin melting. Add dry salt to maintain desired working level as salt melts, or as drag-out losses require.
(2)
TASK 70-00-99-800-010 11. Solution S0010 SUBTASK 70-00-99-99G-010 A. Commercial Products. (1) The following commercial products are recommended for the chemical stripping of nickel plate from engine parts. This is an effective method to strip and clean metal and other deposits from Titanium Compressor Blades.
EFFECTIVITY: ALL
70-00-99
Product Identification Enstrip Q516 Sodium Cyanide SUBTASK 70-00-99-809-063 B. Instructions: (1)
Concentration Refer to instructions Refer to instructions
Manufacturer Enthone, Inc. C04-092 C04-086
Mix Enstrip Q516 at 8% per gallon, using distilled or deionized water. ALL CYANIDES ARE EXTREMELY POISONOUS, AND REACT WITH ACIDS TO FORM DEADLY HYDROGEN CYANIDE GAS. WEAR FACE SHIELD, RUBBER GLOVES AND APRON, AND USE ONLY IN AN AREA VENTILATED BY A POWER-DRIVEN EXHAUST FAN. WASH HANDS, FACE, AND OTHER EXPOSED SKIN AREAS THOROUGHLY AFTER REMOVAL OF PROTECTIVE CLOTHING AND BEFORE EATING OR SMOKING.
WARNING:
(2)
Add Sodium Cyanide to bring the free cyanide content up to 11% per gallon.
CAUTION: MOST LOCAL SEWAGE DISPOSAL REGULATIONS PROHIBIT THE DISCHARGE OF TOXIC WASTES INTO NATURAL WATERWAYS. MAKE SURE THAT USED STRIPPING SOLUTION IS THOROUGHLY OXIDIZED AND NEUTRALIZED, OR OTHERWISE RENDERED HARMLESS, BEFORE DISPOSAL. (3) Operating temperature is 1208F (498C) max. (Percentages by volume, room temperature.)
TASK 70-00-99-800-011 12. Solution S0011 SUBTASK 70-00-99-809-064 A. Commercial Products. (1) The following commercial products are recommended for stripping epoxy resin from aluminum components. Concentration and Operating Temperature Full strength Ambient Temperature
Product Identification Cee-Bee A-202
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-800-012 13. Solution S0012 SUBTASK 70-00-99-99G-012 A. Commercial Products. (1) The following commercial products are recommended for stripping anodized protective coating from aluminum. Concentration and Operating Temp. Refer to instructions Refer to instructions
Product Identification Phosphoric acid Chromic acid SUBTASK 70-00-99-809-065 B. Instructions:
Manufacturer Local purchase Local purchase
WARNING:
ACIDS EMIT TOXIC FUMES, MIX AND USE IN A WELL-VENTILATED AREA, AND WEAR ACID-RESISTANT CLOTHING, GLOVES AND FACE PROTECTION. IF ACID CONTACTS THE SKIN OR EYES, WASH IMMEDIATELY IN CLEAR WATER.
CAUTION: DO NOT POUR WATER INTO ACID; HEAT OR REACTION WILL CAUSE BOILING AND SPATTERING. (1) (2) Mix a solution of 35cc of phosphoric acid and 20 g of chromic acid in one liter of tap water. Pour the acid into the water, stirring vigorously during the addition. Solution temperature is to be 758-1808F (248-828C).
TASK 70-00-99-800-013 14. Solution S0013 SUBTASK 70-00-99-99G-013 A. Commercial Products. (1) The following commercial products are recommended for stripping of chromium carbide thermal spray and nickel-aluminum bond coat:
EFFECTIVITY: ALL
70-00-99
Table 4. Product Identification Nitric Acid (69-71% by weight HNO3) Phosphoric Acid (85% by weight H3PO4) SUBTASK 70-00-99-809-066 B. Instructions: THIS IS A STRONG ACID. USE IN A WELL VENTILATED AREA AND TAKE ALL NECESSARY PRECAUTIONS TO AVOID SKIN OR EYE CONTACT. IF CONTACT OCCURS, WASH IMMEDIATELY WITH CLEAR WATER AND OBTAIN MEDICAL AID. Concentration and Operating Temp. 50% by Volume Nitric Acid 1708F 108F (778C 58C) 50% by Vol. Phosphoric Acid 1708F 108F (778C 58C) Manufacturer Local purchase Local purchase
WARNING:
(1) (2)
Mix equal volumes of nitric acid and phosphoric acid. Maintain nitric acid between 39 and 50% by volume of total acid concentration. Personnel trained in analytical chemistry are required to perform the quality assurance checking.
TASK 70-00-99-800-014 15. Solution S0014 SUBTASK 70-00-99-809-212 A. Commercial Products. (1) The following commercial products are recommended as oxidizing alkaline cleaners. Mix in accordance with the following directions: Concentration and Operating Temperature* 2-1/2 1/2 pounds/gal. (300 grams/liter) 1608-1808F (718828C) 2-1/2 1/2 pounds/gal. (300 grams/liter) 1608-1808F (718828C)
Product Identification Turco 4338-C
Cee-Bee J88
C04-055
Ardrox 188
160 grams/liter 1608-1808F (718-828C)
C04-058
EFFECTIVITY: ALL
70-00-99
Product Identification
Concentration and Operating Temperature*
Manufacturer
NOTE: *Solvent is tap water, and mixing temperature is room temperature, unless otherwise specified.
TASK 70-00-99-800-015 16. Solution S0015 SUBTASK 70-00-99-809-067 A. Commercial Products. WARNING: STRIPPER SHOULD ONLY BE USED IN A WELL VENTILATED AREA. WEAR PROTECTIVE CLOTHING, GLOVES, RESPIRATOR AND FACE SHIELD WHEN USING STRIPPING SOLUTION. IF EITHER HOT OR COLD SOLUTION CONTACTS THE SKIN, FLUSH IMMEDIATELY WITH CLEAR WATER.
CAUTION: WHEN NOT IN USE, REDUCE SOLUTION TEMPERATURE TO BELOW 2008F (938C) AND KEEP COVERED. CAUTION: DISPOSE OF IN ACCORDANCE WITH LOCAL REGULATIONS. NOTE: Melting point of DMSO is 65.48F (18.558C). DMSO is very hygroscopic and must be protected from atmosphere moisture. (1) The following commercial product is recommended for stripping open face aluminum honeycomb seal material which has been bonded with Metalbond 328 to aluminum: Concentration and Operating Temp. Undiluted at 2108-2308F (9981108C)
Product Identification Dimethyl Sulfoxide (DMSO)
TASK 70-00-99-800-016 17. Solution S0016 SUBTASK 70-00-99-99G-016 A. Commercial Products. (1) The following commercial products are recommended for stripping of aluminum oxide and nickel aluminide coatings from engine parts.
EFFECTIVITY: ALL
70-00-99
Product Identification Nitric Acid 69-71% (42 Baume)
Concentration and Operating Temp. Concentrated at 1708-1808F (778-828C)
Manufacturer Local purchase
SUBTASK 70-00-99-809-068 B. Instructions: WARNING: USE IN A WELL VENTILATED AREA. NITRIC ACID AND ITS FUMES ARE VERY TOXIC. DO NOT INHALE FUMES. WEAR ACID RESISTANT CLOTHING, GLOVES, AND FACE SHIELD. IF NITRIC ACID CONTACTS THE SKIN OR EYES, WASH IMMEDIATELY IN CLEAR WATER.
(1) (2) (3)
Use as purchased in concentrated form. Add to tank slowly and bring to operating level. Heat tank to proper temperature.
TASK 70-00-99-800-017 18. Solution S0017 SUBTASK 70-00-99-99G-017 A. Commercial Products. (1) The following solution is recommended for the chemical stripping of thermal sprayed aluminum oxide/nickel aluminide coatings from engine parts. Concentration 12 oz/gal -add4 oz/gal -add2 oz/gal Manufacturer Local Purchase Local Purchase Local Purchase
Product Identification Sodium Cyanide Meta Nitrobenzene Sulfonic Acid Sodium Hydroxide SUBTASK 70-00-99-809-069 B. Instructions: (1) (2)
Operating Temperature: 1408-1608F (608-718C) Instructions: Fill tank 3/4 full of tap water.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: THIS IS AN ALKALINE SODIUM CYANIDE SOLUTION CONTAINING AN ORGANIC OXIDIZING AGENT. THIS SOLUTION IS VERY POISONOUS AND WILL REACT WITH ACIDS TO FORM DEADLY HYDROGEN CYANIDE GAS. WEAR FACE SHIELD, RUBBER GLOVES AND APRON. USE ONLY IN WELL VENTILATED AREA. WASH HANDS, FACE AND ANY EXPOSED SKIN AREAS AFTER REMOVAL OF PROTECTIVE CLOTHING.
CAUTION: DO NOT ALLOW STRIPPING SOLUTION TO COME IN CONTACT WITH PAPER, WOOD, CLOTH OR OTHER ORGANIC MATERIAL. USE NEOPRENE RUBBER OR STEEL FOR TANKS, BASKETS OR HANDLING EQUIPMENT. (3) (4) (5) (6) (7) Add chemicals in the quantity and the order listed above. Dissolve each one completely before adding the next. Fill tank to operating level with water. Bring to operating temperature. Control. Add tap water to maintain tank volume level. Add sodium hydroxide to maintain alkalinity at pH 12.
CAUTION: MOST LOCAL SEWAGE DISPOSAL REGULATIONS PROHIBIT THE DISCHARGE OF TOXIC WASTES INTO NATURAL WATERWAYS. MAKE SURE THAT USED STRIPPING SOLUTION IS THOROUGHLY OXIDIZED AND NEUTRALIZED, OR OTHERWISE RENDERED HARMLESS BEFORE DISPOSAL. (8) When solution does not strip in the required time, dump, clean and recharge tank with new material.
TASK 70-00-99-801-001 19. Solution S1001 SUBTASK 70-00-99-99G-021 A. Composition. No. C04-058Compound C04-058Compound Concentration US (metric) 21 oz/US gal (160 g/l) As received
Consumable Product Ardrox 188 Ardrox 188RFU
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-070 B. Preparation. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
WARNING:
NOTE: Tank should have automatic level (water make-up) device or solution will decompose rapidly. (1) (2) Alternative procedure available. If using Ardrox 188RFU, fill the tank to the working level. Alternative procedure. If using Ardrox 188, do these steps: (a) (b) (c) (d) Fill the tank half-full with water. Add the Ardrox 188 slowly and carefully while stirring to mix. Fill the tank with water to working level. Stir again to mix thoroughly.
SUBTASK 70-00-99-809-071 C. Check. (1) Checks Sodium hydroxide Potassium permanganate (2) (3) Determine the concentration of Ardrox 188 or Ardrox 188RFU: Limits 80-120 g/l 30-60 g/l Recommended Interval Biweekly Monthly
Follow the manufacturers control procedures to maintain the solution. Regeneration. (a) (b) (c) Add the correct products/chemicals to keep the solution in the check limits per the manufacturers instructions. Losses due to evaporation must be replaced by filling the tank with water to working level. Remove oxide slurries from bottom of tank.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-002 20. Solution S1002 SUBTASK 70-00-99-99G-022 A. Composition. No. C04-072 C04-011 Concentration (Initial Mix) 51-58 fl oz/US gal (400-445 ml/l) 3.0-3.8 fl oz/US gal (20-25 ml/l)
Consumable Product Nitric Acid Hydrofluoric acid
SUBTASK 70-00-99-809-072 B. Preparation. NOTE: The use of an alternative solution in place of S1002 is highly recommended. WARNING: HYDROFLUORIC ACID SOLUTION C04-011 IS UNUSUALLY DANGEROUS AND POISONOUS. CONTACT WITH THE SOLUTION OR VAPOR WILL RESULT IN SERIOUS INJURY OR DEATH. PREVENT CONTACT WITH SKIN, EYES, AND CLOTHING. PREVENT INHALATION OF VAPORS. IF INCIDENT OCCURS, WASH IMMEDIATELY WITH LARGE AMOUNTS OF CLEAR WATER AND OBTAIN MEDICAL ASSISTANCE IMMEDIATELY. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4)
Fill the tank half-full with water. Add the nitric acid slowly and carefully while stirring the solution to mix. Add the hydrofluoric acid slowly and carefully while stirring the solution to mix. Fill tank with water to working level, stirring the solution again to mix.
SUBTASK 70-00-99-809-073 C. Check. (1) Checks Nitric Acid Hydrofluoric Acid Determination of the Nitric Acid Quantity: Limits 300-450 ml/l 15-25 ml/l Recommended Interval Biweekly Biweekly
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (a) Reagents. 1 2 3 4 Titrated solution of 1 N caustic soda. Phenolphthalein solution. Distilled water. Reference solution of nitric acid. Put 250 ml of water into a 500 ml calibrated vial. Add 200 ml of nitric acid (d = 1.41). Make up to 500 ml with distilled water and shake to mix. a Determination of concentration of reference solution: Put exactly 5 ml of the solution into a 250 ml beaker. Add 75 ml of distilled water and titrate with n1 ml of 1 N caustic soda in presence of phenolphthalein. Concentration of the solution T1 in g/l HNO3 = n1 x 12.6.
Titrated solution of ferrous sulfate. Dissolve 160 g of FeSO47H2O in 900 ml of sulfuric acid (at 250 ml/l). a Determination of concentration of solution: Titrate 2 ml of the reference nitric acid (of concentration T1) with n2 ml of ferrous sulfate solution T2: T2 = T1 / (n2 - 0.2) NOTE: The concentration of the solution of ferrous sulfate will be determined at least once a week.
(b)
Equipment. Nalgene (polypropylene) pipette of 2 ml. NOTE: The calibration of this pipette will be verified, and corrected if necessary, before use.
(c)
Procedure. 1 2 3 4 5 6 Pour 100 ml of pure H2SO4 into a 400 ml beaker. Place the beaker in a bath of ice-water. Remove 2 ml from the bath with the help of the Nalgene pipette and a safety bulb. Let the sample run out slowly while keeping the end of the pipette under the surface of the H2SO4. While the sample is running out, stir the acid mixture by constantly moving the end of the pipette along the wall of the beaker. Once the sample has run out, do not withdraw the end of the pipette from the acid mixture.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A 7 Titrate with the ferrous sulfate solution until the initial yellow coloring changes to brown. Use the pipette to stir the mixture whose temperature must not exceed 1408F (608C) during the titration. Rinse the pipette, sucking the mixture with the help of the bulb and allowing it to run out into the beaker afterward. Complete the titration, if necessary, adding the ferrous sulfate solution drop by drop until the change to brown occurs. Let A ml be the total volume of ferrous sulfate of concentration T2 used.
8 9 10 (d)
Quantitative formula. HNO3 ml/l = (A-0.2) x T2 x 1.05
(2)
Determination of the Hydrofluoric Acid Quantity. (a) Reagents. 1 2 3 (b) Titrated solution of 1 N caustic soda. Bromothymol blue: 0.1 g/100 ml solution in ethanol. Distilled water.
Equipment. 1 2 pH-meter. Nalgene (polypropylene) pipette of 5 ml. NOTE: The calibration of this pipette must be verified, and corrected if necessary, before use.
(c)
Procedure. 1 2 Transfer 5 ml from the solution (Nalgene pipette) into a polyethylene beaker containing 100 ml of distilled water. Mix well and titrate with the 1 N caustic soda in the presence of bromothymol blue. Continue titrating until the blue changes to greenish blue, then using a pH-meter, until a pH of 7.6 is obtained. Let B ml be the total volume of 1 N caustic soda used.
3 (d)
Quantitative formula. HF ml/l = [(0.2 x B) - ((A-0.2) x T2) / 63)] x 22.68
SUBTASK 70-00-99-809-074 D. Regeneration. (1) Every day remove surface scum from tank.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) Maintain solution within check limits by the addition of appropriate products. (a) Addition of nitric acid. If V is tank volume in liters, then volume of nitric acid (d = 1.41) to be added is V (400 - [(A-0.2) x T2 x 1.05]) milliliters. (b) Addition of hydrofluoric acid. If V is tank volume in liters, then volume of hydrofluoric acid (d = 1.26) to be added is HF ml/l = [(0.2 x B) - (((A-0.2) x T2) / 63)] x 22.68 (3) (4) Losses through evaporation will be made up by filling the tank to working level with water. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-003 21. Solution S1003 SUBTASK 70-00-99-99G-023 A. Composition. No. C04-009 C04-009 Concentration (Initial Mix) 12 oz/US gal (90 g/l) 20% by volume
Consumable Product Turco 4181 Turco 4181L SUBTASK 70-00-99-809-075 B. Preparation. WARNING:
ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
WARNING: (1)
Alternative procedure available. If using Turco 4181L, do these steps: (a) (b) (c) Fill the tank with water to 70% of the working level. Add the Turco 4181L slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (d) (2) Stir the solution again to mix.
Alternative procedure. If using Turco 4181, do these steps: (a) (b) (c) (d) Fill the tank with water to two-thirds of the working level. Add the Turco 4181 slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-076 C. Check. (1) Checks Turco 4181 Turco 4181L (2) Determine the concentration of the Turco 4181 or Turco 4181L. Limits 60-90 g/l 12-20% by volume Recommended Interval Monthly Monthly
SUBTASK 70-00-99-809-077 D. Regeneration. (1) (2) (3) Every day remove surface scum from tank. Maintain solution within check limits by the addition of appropriate products per the manufacturers requirements. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-004 22. Solution S1004 SUBTASK 70-00-99-99G-024 A. Composition. No. C04-084 C04-118 Concentration (Initial Mix) 25 oz/US gal (187 g/l) 10 oz/US gal (75 g/l)
Consumable Product Caustic soda Potassium permanganate
EFFECTIVITY: ALL
70-00-99
WARNING: (1) (2) (3) (4) (5) (6)
Fill the tank half-full with water. Add the caustic soda product slowly and carefully while stirring the solution to mix. Heat the solution to 130-1508F (55-658C). Add the potassium permanganate while stirring solution to mix. Fill tank to working level with water. Stir solution again to mix.
SUBTASK 70-00-99-809-079 C. Check. (1) Checks Caustic soda Potassium permanganate (a) Reagents. 1 2 (b) 1 N solution of sulfuric acid. Distilled water. Determination of the Caustic Soda Quantity. Limits 150-225 g/l 60-90 g/l Recommended Interval Monthly Monthly
Equipment. 1 Potentiometer.
(c)
Procedure. 1 2 3 Transfer exactly 5 ml from the solution into a 100 ml beaker. Add 50 ml of distilled water. Titrate with potentiometer using 1 N sulfuric acid solution up to pH = 7 (i.e., A ml), then to pH = 3.5 (i.e., B ml).
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (d) Quantitative formula: NaOH g/l = (A - B) x 8 (2) Determining the Permanganate Quantity. (a) Reagents. 1 2 3 4 (b) Concentrated sulfuric acid. Titrated solution of 0.1 N ammonium ferrous sulfate. Titrated solution of 0.1 N permanganate. Distilled water.
Procedure. 1 2 3 4 5 Transfer exactly 1 ml of the solution into a 200 ml beaker. Add 50 ml of distilled water. Add 2 ml of concentrated sulfuric acid. Reduce with an excess of 0.1 N ammonium ferrous sulfate (i.e., n1 ml). Back titrate with n2 ml of 0.1 N permanganate.
(c)
Quantitative formula: KMnO4 g/l = (n2 - n1) x 3.16
SUBTASK 70-00-99-809-080 D. Regeneration. (1) (2) Every day check losses through evaporation. Losses through evaporation will be made up by filling the tank to working level with water. Maintain solution within check limits by the addition of appropriate products. (a) Addition of caustic soda. If V is tank volume in liters, then quantity of caustic soda to be added is V [225 - ((A - B) x 80)] grams (b) Addition of potassium permanganate. If V is tank volume in liters, the quantity of potassium permanganate to be added is V [90 - ((n2 - n1) x 3.16)] grams (3) Replace the solution if it loses its effectiveness.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-005 23. Solution S1005 SUBTASK 70-00-99-99G-025 A. Composition. No. C04-053 C04-053 Concentration (Initial Mix) 40 oz/US gal (300 g/l) 90% V/V
Consumable Product Turco 4781-7 Turco 4781-7L SUBTASK 70-00-99-809-081 B. Preparation. WARNING:
ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES. DO NOT DUMP LARGE QUANTITIES OF ALKALINE MATERIAL INTO THE WATER AT ONE TIME.
WARNING: WARNING: (1)
Alternative procedure available. If using Turco 4781-7L, do these steps: (a) (b) (c) Add the required amount of Turco 4781-7L product to the process tank. Fill the tank to the working level with water. Stir the solution to mix.
(2)
Alternative procedure. If using Turco 4781-7, do these steps: (a) (b) (c) (d) Fill the tank with water to two-thirds (67%) of working level. Add the Turco 4781-7 product slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-082 C. Check. (1) Determine the concentration of Turco 4781-7:
EFFECTIVITY: ALL
70-00-99
Checks Turco 4781-7 Turco 4781-7L (2)
Limits 200-300 g/l 60-90% V/V
Recommended Interval Monthly Monthly
SUBTASK 70-00-99-809-083 D. Regeneration. (1) (2) (3) (4) Every day remove surface scum from the tank. Maintain the solution within the check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank with water up to the working level on a daily basis. Replace the solution if it loses its effectiveness.
WARNING: (1)
Alternative procedure available. If using Turco 4181L, do these steps:
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (a) (b) (c) (d) (2) Fill the tank with water to one-fifth (20%) of the working level. Add the Turco 4181L product slowly and carefully while stirring the solution to mix. Fill the tank to the working level. Stir the solution again to mix.
Alternative procedure. If using Turco 4181, do these steps: (a) (b) (c) (d) Fill the tank with water to two-thirds (67%) of the working level. Add the Turco 4181 product slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-085 C. Check. (1) Checks Turco 4181 Turco 4181L (2) Determination of the Turco 4181 or Turco 4181L quantity: Limits 200-300 g/l 50-70% by volume Recommended Interval Monthly Monthly
SUBTASK 70-00-99-809-086 D. Regeneration. (1) (2) (3) (4) Every day remove surface scum from tank. Maintain solution within check limits by the addition of appropriate products per the manufacturers requirements. Losses through evaporation will be made up by filling the tank to working level with water. Replace the solution if it loses its effectiveness.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-007 25. Solution S1007 SUBTASK 70-00-99-99G-027 A. Composition. No. C04-080 C04-080 Concentration (Initial Mix) 120 oz/US gal (900 g/l) As received
WARNING: (1) (2)
Alternative procedure available. If using Turco 4316L, fill the tank to the working level. Alternative procedure. If using Turco 4316, do these steps: (a) (b) (c) (d) (e) Fill the tank one-third full with water. Add the Turco 4316 product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix. Automatic water leveling device must be installed to replace losses through evaporation.
SUBTASK 70-00-99-809-088 C. Check. (1) Determination of the Turco 4316 or Turco 4316L quantity:
EFFECTIVITY: ALL
70-00-99
Checks Turco 4316 Turco 4316L Chloride concentration (2)
Limits 800-1000 g/l 800-1000 g/l 1500 ppm
Recommended Interval Weekly Weekly Monthly
SUBTASK 70-00-99-809-089 D. Regeneration. (1) (2) Every day remove surface scum from tank. Maintain solution within check limits by the addition of appropriate products. (a) Addition of Turco 4316. If V is tank volume in liters, the quantity of Turco 4316 to be added is V (900 A x 21.75) grams. (3) Losses through evaporation will be made up by filling the tank to working level with water when the bath temperature has cooled below 2128F (1008C) if water leveling device is not operational. To prevent formation of excess carbonate (surface glazing, high temperature), remove 2 to 5 percent of the tank volume each week and make up to the working level with new bath solution.
(4)
TASK 70-00-99-801-008 26. Solution S1008 SUBTASK 70-00-99-99G-028 A. Composition. No. C04-119 Concentration (Initial Mix) 50% V/V
Consumable Product Turco 4409
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-090 B. Preparation. WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4)
Fill the tank 40% of its working level with water. Add the inhibited phosphoric acid C04-119 slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-091 C. Check. (1) Checks Turco 4409 (2) Determine the concentration of the inhibited phosphoric acid C04-119: Limits 45-50% V/V Recommended Interval Monthly
SUBTASK 70-00-99-809-092 D. Regeneration. (1) (2) (3) (4) Every day remove surface contamination from the tank. Maintain solution within the check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank to working level with water. Replace the solution if it loses its effectiveness.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-009 27. Solution S1009 SUBTASK 70-00-99-99G-029 A. Composition. No. C04-104 Concentration (Initial Mix) 16 oz/US gal (120 g/l)
Consumable Product Turco 4931 SUBTASK 70-00-99-809-093 B. Preparation. WARNING:
ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID BREATHING VAPORS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4)
Fill the tank two-thirds full with water. Add the Turco 4931 product slowly and carefully while stirring the solution to dissolve product. Fill up tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-094 C. Check. (1) Checks Turco 4931 Stock loss test per ARP 1755 on AMS 5504 panel (a) Determination of the Turco 4931 Quantity: Limits 80-120 g/l 0.05 mils (1.25 mm) total Recommended Interval Biweekly Weekly
Without pH-meter. 1 Reagents. a Titrated solution of 1 N caustic soda.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A b c 2 Solution of methyl orange. Distilled water (or demineralized).
Procedure. a b c d Take a sample of Turco 4931 from the solution and let it cool down to ambient temperature. Dilute exactly 10 ml of this sample in a 200 ml Erlenmeyer flask. Add 100 ml of distilled water (or demineralized) and 4-6 drops of methyl orange. Titrate with A ml of 1 N caustic soda and until initial red color turns to yellow.
Quantitative formula: Turco 4931 g/l = A x 12.6
(b)
With pH-meter. 1 Reagents. a b 2 Titrated solution of 1 N caustic soda. Distilled (or demineralized) water.
Equipment. a pH-meter equipped with a pair of electrodes (measurement and reference).
Procedure. a b c d Transfer exactly 50 ml of the cooled solution into a 200 ml beaker. Immerse the electrodes in the solution and add distilled water if necessary. Stir solution by magnetic device. Titrate with 1 N caustic soda until a pH of 3.5 is obtained. Let A be number of ml of caustic soda used.
Quantitative formula: Turco 4931 g/l = A x 2.4
SUBTASK 70-00-99-809-095 D. Regeneration. (1) (2) Remove surface contamination from tank daily. Maintain solution within check limits by the addition of appropriate products.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (a) Addition of Turco 4931. 1 Without pH-meter. If V is tank volume in liters, then quantity of Turco 4931 to be added is V [120 - (A x 12.6)] grams. 2 With pH-meter. If V is tank volume in liters, then quantity of Turco 4931 to be added is V [120 - (A x 2.4)] grams. (3) (4) Losses due to evaporation will be made up by filling the tank to working level with water. Replace the solution if it loses its effectiveness, or if stock loss test exceeds limits specified in Subtask 70-00-99-809-094, Check.
TASK 70-00-99-801-010 28. Solution S1010 SUBTASK 70-00-99-99G-030 A. Composition. No. C04-033 Concentration(Initial Mix) 16 oz/US gal(120 g/l)
Consumable Product Turco Vitroklene SUBTASK 70-00-99-809-096 B. Preparation. WARNING:
ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4)
Fill the tank two-thirds full with water. Add the Turco Vitroklene product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-097 C. Check. (1) Checks Turco Vitroklene (2) Do a check of the solution in accordance with the manufacturers instructions. Limits 60-120 g/l Recommended Interval Monthly
Follow manufacturers control procedures to maintain the solution within the check limits.
SUBTASK 70-00-99-809-098 D. Regeneration. (1) (2) (3) (4) Each day remove surface scum from tank. Add applicable materials to keep the solution within the check limits. Each day, fill the tank with water to the working level. Replace the solution if it loses its effectiveness or is contaminated.
TASK 70-00-99-801-011 29. Solution S1011 SUBTASK 70-00-99-99G-031 A. General. (1) Not used.
TASK 70-00-99-801-012 30. Solution S1012 SUBTASK 70-00-99-99G-032 A. Composition. No. C04-054 C04-054 Concentration (Initial Mix) 40 oz/US gal(300 g/l) Parts 1 and 2, 20% by volume (each)
Consumable Product Turco 4338-C Turco 4338-L
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-102 B. Preparation. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1)
Alternative procedure available. If using Turco 4338-L, do these steps: (a) (b) (c) (d) Fill the tank with water to two-fifths (40%) of the working level. Add equal amounts of Turco 4338-L Part 1 and Part 2. Fill the tank with water to working level. Stir the solution again to mix.
(2)
Alternative procedure. If using Turco 4338-C, do these steps: (a) (b) (c) (d) Fill the tank with water to two-thirds (67%) of the working level. Add the Turco 4338-C product slowly and carefully while stirring the solution to mix. Fill the tank with water to working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-103 C. Check. (1) Checks Turco 4338-C Turco 4338-L Potassium Permanganate (2) Determine the Turco 4338-C or Turco 4338-L quantity: Limits 240-360 g/l Parts 1 and 2, 15-25% by volume (each) 60-90 g/l Recommended Interval Monthly Monthly Monthly
SUBTASK 70-00-99-809-104 D. Regeneration. (1) Maintain solution within check limits by the addition of appropriate products.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) (3) Losses through evaporation will be made up by filling the tank to working level with water. Remove oxide slurries that have collected on the tank bottom.
TASK 70-00-99-801-013 31. Solution S1013 SUBTASK 70-00-99-99G-033 A. Composition. No. C04-073 C04-072 Concentration (Initial Mix) 9 fl oz/US gal (70 ml/l) 61-63 fl oz/US gal (480-490 ml/l)
Consumable Product Turco 4104 Nitric acid
SUBTASK 70-00-99-809-105 B. Preparation. WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4) (5)
Fill the tank one-third full with water. Add the nitric acid slowly and carefully while stirring the solution to mix. Add the Turco 4104 slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-106 C. Check. (1) Do a check of the solution in accordance with the manufacurers instructions.
EFFECTIVITY: ALL
70-00-99
Checks Nitric acid Turco 4104 (2)
Limits 450-490 ml/l 50-70 ml/l
Follow manufacturers control procedures to maintain the solution within check limits.
TASK 70-00-99-801-014 32. Solution S1014 SUBTASK 70-00-99-99G-034 A. Composition. No. C04-055 C04-055 Concentration (Initial Mix) 28 oz/US gal (210 g/l) As received
Consumable Product Cee-Bee J88 or J88A Cee-Bee J88L SUBTASK 70-00-99-809-108 B. Preparation. WARNING:
WARNING: (1)
Alternative procedure available. If using Cee-Bee J88L, fill the tank to the working level.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) Alternative procedure. If using Cee-Bee J88 or J88A, do these steps: (a) (b) (c) (d) Fill the tank two-thirds full with water. Add the Cee-Bee J88 or J88A product slowly and carefully while stirring the solution to mix. Fill the tank with water to working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-109 C. Check. (1) Checks Cee-Bee J88 or J88A Cee-Bee J88L Potassium Permanganate (2) Determine the concentration of Cee-Bee J88, Cee-Bee J88A, or Cee-Bee J88L: Limits 180-240 g/l 180-240 g/l 55-75 g/l Recommended Interval Biweekly Biweekly Monthly
Follow the manufacturers control procedures to maintain the solution
SUBTASK 70-00-99-809-110 D. Regeneration. (1) (2) (3) Add the correct products to keep the solution in the check limits. Make up for losses through evaporation by filling the tank to working level with water. Remove oxide slurries that have collected on the tank bottom.
TASK 70-00-99-801-015 33. Solution S1015 SUBTASK 70-00-99-99G-035 A. General. (1) Not used.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-016 34. Solution S1016 SUBTASK 70-00-99-99G-036 A. Composition. No. C04-120 Concentration (Initial Mix) 60% V/V
Consumable Product Phos-It SUBTASK 70-00-99-809-114 B. Preparation. WARNING:
ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4)
Fill the tank to 30% of its working level with water. Add the inhibited phosphoric acid C04-120 slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-115 C. Checks. (1) Checks Phos-It (2) Determine the concentration of the inhibited phosphoric acid C04-120: Limits 55-60% V/V Recommended Interval Monthly
SUBTASK 70-00-99-809-116 D. Regeneration. (1) Every day, remove surface contamination from the tank.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) (3) (4) Maintain the solution within the check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank with water to the working level on a daily basis. Replace solution when it loses its effectiveness.
TASK 70-00-99-801-017 35. Solution S1017 SUBTASK 70-00-99-99G-037 A. Composition. No. C04-187 Concentration (Initial Mix) 40 oz/US gal (300 g/l)
Consumable Product MagChem HDP 2888 SUBTASK 70-00-99-809-117 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill the tank two-thirds full with water. Add the heavy duty alkaline cleaner C04-187 slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-118 C. Check. (1) Checks MagChem HDP 2888 Do a check of the solution in accordance with the manufacturers instructions. Limits 200-300 g/l Recommended Interval Monthly
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) Follow the manufacturers control procedures to maintain the solution.
SUBTASK 70-00-99-809-119 D. Regeneration. (1) (2) (3) (4) Each day, remove the surface scum from the tank. Add applicable materials to keep the solution within the check limits. Each day, fill the tank with water to the working level. Replace the solution if it loses its effectiveness or is contaminated.
Consumable Product MagChem HDP 2524 SUBTASK 70-00-99-809-120 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill the tank two-thirds full with water. Add the alkaline permanganate cleaner C04-188 slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-121 C. Check. (1) Do a check of the solution in accordance with the manufacturers instructions.
EFFECTIVITY: ALL
70-00-99
Checks MagChem HDP 2524 Potassium permanganate (2)
Limits 200-280 g/l 50-70 g/l
SUBTASK 70-00-99-809-122 D. Regeneration. (1) (2) (3) (4) Maintain the solution within the check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank to the working level with water. Remove oxide slurries that have collected on the tank bottom. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-019 37. Solution S1019 SUBTASK 70-00-99-99G-039 A. Composition. No. C04-081 Concentration (Initial Mix) 5.85 lb/U.S. gal (700 g/l)
Consumable Product Ardrox 1630
SUBTASK 70-00-99-809-123 B. Preparation. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING OF VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
WARNING: (1) (2)
Fill the tank one-third full with water. Add the Ardrox 1630 product slowly and carefully while stirring the solution to mix.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (3) (4) (5) Fill tank with water to working level. Stir solution again to mix. Automatic water leveling device must be installed to replace losses through evaporation.
SUBTASK 70-00-99-809-124 C. Check. (1) Checks Ardrox 1630 (a) Determination of Ardrox 1630: Limits 660-700 g/l Equipment and Reagents required. 1 2 3 4 5 6 (b) 100 ml graduated flask. 250 ml Erlenmeyer flask. 50 ml burette. 10 ml pipette. 1.0N hydrochloric acid. Phenolphthalein indicator solution (0.5 g in 100 ml ethanol/water 50% v/v). Recommended Interval Weekly
Procedure. 1 Make up volume of solution to working level by adding water, thoroughly agitate bath, and remove sample at nominal operating temperature. Exercise caution as solution is strongly alkaline and does contain chromate. Using a pipette, take 10 ml bath solution at working temperature, place in 100 ml graduated flask and fill with distilled water to the 100 ml mark. Transfer 10 ml of this solution to an Erlenmeyer flask, add 5 drops of phenolphthalein indicator solution and titrate with 1.0N hydrochloric acid to end point (color change from purple to clear). Two titrations should not differ by more than 0.1 ml. Using average of two titrations, ml HCl solution x 40 = Alkalinity in g NaOH/l. Alkalinity x 1.015 = g/l Ardrox 1630.
2 3
4 5 (2)
Regeneration.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (a) (b) Add Ardrox 1630 as required to restore bath solution to working strength. If performance is unsatisfactory, the descaling agent is exhausted. Discard old bath solution and prepare fresh solution.
Consumable Product MagChem AP-954 SUBTASK 70-00-99-809-125 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill the tank to 40% of its working level with water. Add the inhibited phosphoric acid C04-190 slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir solution again to mix.
SUBTASK 70-00-99-809-126 C. Check. (1) Checks MagChem AP-954 (2) Determine the concentration of the inhibited phosphoric acid C04-190: Limits 45-50% V/V Recommended Interval Monthly
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-127 D. Regeneration. (1) (2) (3) (4) Every day remove surface scum from the tank. Maintain solution within the check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank with water to the working level on a daily basis. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-021 39. Solution S1021 SUBTASK 70-00-99-99G-041 A. Composition. No. C04-066 C04-072 Concentration (Initial Mix) 25 fl oz/US gal (200 ml/l) 1.28 fl oz/US gal (10 ml/l)
Consumable Product Ardrox 1873 Nitric acid
SUBTASK 70-00-99-809-128 B. Preparation. WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4) (5)
Fill the tank half-full with water. Add the Ardrox 1873 slowly and carefully while stirring to mix. Fill the tank with water to approximate working level. Add Nitric acid to adjust pH of solution to 3.0-3.2. During use the bath pH will tend to rise but should not be allowed to exceed 3.5. Stir again to mix thoroughly.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-129 C. Check. (1) Checks Ardrox 1873 pH Stock loss test per ARP 1775 on AMS 5504 panel (a) Reagents. 1 2 (b) Titrated 1 N potassium hydroxide solution. Distilled water. Determination of the Ardrox 1873 Quantity: Limits 160-200 ml/l 3.0-3.2 0.05 mils (1.25 mm) total Recommended Interval Monthly Weekly Weekly
Equipment. 1 pH-meter.
(c)
Procedure. 1 2 3 4 Take a sample of solution and leave to cool to 688F (208C). The sample pH must be 3.0-3.2. Transfer exactly 50 ml cooled solution into a 100 ml beaker. Immerse electrodes of pH meter in solution and titrate with 1 N potash solution until pH indicated by the pH-meter equals 11. Perform 2 titrations, which should agree within 0.1 ml.
(d)
Quantitative formula: 1 An Ardrox 1873 solution of 20 percent by volume quantitated as described above calls for approximately 18 ml 1 N potassium hydroxide. Accordingly, 1 ml 1 N KOH corresponds to a concentration of 11 ml Ardrox 1873 per liter of solution.
SUBTASK 70-00-99-809-130 D. Regeneration. (1) Before adding the Ardrox 1873, evaporate the water sufficiently for the solution bath to admit the addition. During this procedure the method used to control the water level must be set to closed position.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (2) To adjust the concentration of the solution, for each ml short of the required 18 ml add 2.9 US gal (11 liters) Ardrox 1873 into the tank containing 265 US gal (1000 liters) solution; this renewal is to be repeated whenever a loss of 1 ml from the initial amount 18 ml is observed. With the requisite amount of Ardrox 1873 added, the level of the bath must be readjusted by restoring the water leveling device. Stir thoroughly to make the solution homogeneous and restore the pH to 3.0-3.2 by adding concentrated nitric acid. If, after renewal, the bath is not effective, drain it off and make up a new one. The solution must be discarded and a new solution must be made up if stock loss test exceeds limits specified in Subtask 70-00-99-809-129, Check.
(3) (4) (5) (6)
Consumable Product Ardrox 1218 SUBTASK 70-00-99-809-131 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill the tank to 40% of its working level with water. Add the inhibited phosphoric acid C04-121 slowly and carefully while stirring to mix. Fill tank with water to working level. Stir solution again to mix.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-132 C. Check. (1) Checks Ardrox 1218 (2) Determine the concentration of the inhibited phosphoric acid C04-121: Limits 45-50% V/V Recommended Interval Monthly
SUBTASK 70-00-99-809-133 D. Regeneration. (1) (2) (3) (4) Every day, remove surface contamination from the tank. Maintain solution with check limits by addition of appropriate products. Losses through evaporation will be made up by filling the tank with water up to working level on a daily basis. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-023 41. Solution S1023 SUBTASK 70-00-99-99G-043 A. Composition. No. C04-067 Concentration (Initial Mix) 25 fl oz/US gal (200 ml/l)
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-134 B. Preparation. WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING:
CAUTION: NOT SUITABLE FOR IMMERSION OF INCOLOY 903. (1) (2) (3) (4) Fill the tank half-full with water. Add the Ardrox 1871 slowly and carefully while stirring to mix. Fill the tank with water to working level. Stir again to mix thoroughly.
SUBTASK 70-00-99-809-135 C. Check. (1) Checks Ardrox 1871 Stock loss test per ARP 1755 on AMS 5504 panel (2) Determination of the Ardrox 1871 Quantity: Limits 160-200 ml/l 0.05 mils (1.25 mm) total Recommended Interval Monthly Weekly
SUBTASK 70-00-99-809-136 D. Regeneration. (1) Before adding the Ardrox 1871, evaporate the water sufficiently for the solution bath to admit the addition. During this procedure the ball valve controlling the water level must be set to closed position. Add the correct products to keep the solution in the check limits. With the requisite amount of Ardrox 1871 added, the level of the bath must be readjusted by putting back the ball valve into normal operation. Stir thoroughly to make the solution homogeneous before reuse. If, after renewal, the bath is not effective, drain it off and make up a new one.
(2) (3) (4) (5)
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (6) The solution must be discarded and a new solution must be made up if stock loss test exceeds limits specified in Subtask 70-00-99-809-135, Check.
Consumable Product Ardrox 185 Ardrox 185L SUBTASK 70-00-99-809-137 B. Preparation. WARNING:
WARNING: (1)
Alternative procedure available. If using Ardrox 185L, do these steps. (a) (b) (c) (d) Fill the tank with water to two-fifths (40%) of the working level. Add the Ardrox 185L slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir again to mix thoroughly.
(2)
Alternative procedure. If using Ardrox 185, do these steps. (a) (b) (c) (d) Fill the tank with water to two-thirds (67%) of the working level. Add the Ardrox 185 slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir again to mix thoroughly.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-138 C. Check. (1) Checks Ardrox 185 Ardrox 185L (2) Determination of the Ardrox 185 or Ardrox 185L quantity: Limits 200-300 g/l 34-50% by volume Recommended Interval Monthly Monthly
SUBTASK 70-00-99-809-139 D. Regeneration. (1) (2) (3) (4) Every day remove surface scum from tank. Maintain solution within check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank with water up to working level. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-025 43. Solution S1025 SUBTASK 70-00-99-809-159 A. Composition. No. C04-043 C04-045 C04-044 C04-152 C04-163 C04-163 C04-184 C04-208 C04-221 C04-045 Concentration (Initial Mix) 1.3 fl oz/US gal (10 ml/l) 1.3 fl oz/US gal (10 ml/l) 1.3 fl oz/US gal (10 ml/l) 1.3 fl oz/US gal (10 ml/1) 1.3 fl oz/US gal (10 ml/1) 1.3 fl oz/US gal (10 ml/1) 1.3 fl oz/US gal (10 ml/l) 1.3 fl oz/US gal (10 ml/l) 1.3 fl oz/US gal (10 ml/l) 1.3 fl oz/US gal (10 ml/l)
Consumable Product Turco 5729-A DUBOIS C 1102 Cee-Bee Intex 8201 Turco 5729-R Ardrox 6333 Ardrox 6333A MagChem DG-Kleen Turco 5948 DPM Super Bee 300LF Citrikleen HD
NOTE: The concentration of the product is given approximately and can vary slightly.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-140 B. Preparation. (1) Preparation for Portable Equipment Solutions. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (a) (b) (c) (d) (2)
Fill the tank three-quarters full with water. Add one of the products listed in Subtask 70-00-99-809-159, Composition. Add the product slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir solution again to mix.
Preparation for Fixed Equipment Solutions. (a) Use the liquid products full strength and adjust the metering orifice/valve on the equipment to obtain the concentration specified in Subtask 70-00-99-809159, Composition.
SUBTASK 70-00-99-809-141 C. Check. (1) Not applicable.
SUBTASK 70-00-99-809-142 D. Regeneration. (1) Not applicable.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-026 44. Solution S1026 SUBTASK 70-00-99-99G-046 A. Composition. No. C04-049 C04-049 Concentration (Initial Mix) 40 oz/US gal (300 g/l) 37% V/V
Consumable Product Cee-Bee J84A Cee-Bee J84AL SUBTASK 70-00-99-809-143 B. Preparation. WARNING:
WARNING: (1)
Alternative procedure available. If using Cee-Bee J84AL, do these steps: (a) (b) (c) (d) Fill the tank with water to one-half (50%) of the working level. Add the Cee-Bee J84AL slowly. Fill the tank with water to the working level. Stir the solution again to mix.
(2)
Alternative procedure. If using Cee-Bee J88A, do these steps: (a) (b) (c) (d) Fill the tank with water to two-thirds (67%) of the working level. Add the Cee-Bee J84A product slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-144 C. Check. (1) Find the concentration of Cee-Bee J84A or Cee-Bee J88AL:
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Checks Cee-Bee J84A Cee-Bee J84AL (2)
Limits 240-300 g/l 30-37% by volume
SUBTASK 70-00-99-809-145 D. Regeneration. (1) (2) (3) Every day remove surface scum and sludge from top and bottom of tank. Add the correct products to keep the solution in the check limits. Make up for losses through evaporation by filling the tank to the working level with water.
Consumable Product Ferlon SUBTASK 70-00-99-809-146 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill tank two-thirds full with water. Heat to 1208-1408F (508-608C). Add the Ferlon slowly and carefully while stirring to mix. Fill tank with water to working level.
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STANDARD PRACTICES MANUAL AS907-1-1A (5) (6) Stir again to mix thoroughly. For initial make-up of tank, add 16 oz (454.4 g) of wetting agent for every 400 lb (181.6 kg) of Ferlon.
SUBTASK 70-00-99-809-147 C. Check. (1) Checks Ferlon (2) Do a check of the solution in accordance with the manufacturers instructions. Limits 200-300 g/l Recommended Interval Monthly
TASK 70-00-99-801-029 46. Solution S1029 SUBTASK 70-00-99-99G-049 A. Composition. No. C04-072 C04-074 Concentration (Initial Mix) 60-65 fl oz/US gal (475-525 ml/l) 4 fl oz/US gal (30 ml/l)
Consumable Product Nitric acid Ardrox 1635
EFFECTIVITY: ALL
70-00-99
WARNING: (1) (2) (3) (4) (5)
Fill tank one-third full with water. Add nitric acid slowly and carefully while stirring the solution to mix. Add Ardrox 1635 product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-150 C. Check. (1) Checks Nitric acid (428Be = 1.41d) Ardrox 1635 (a) Reagents. 1 2 3 (b) Titrated solution of 0.5 N sodium hydroxide. TASHIRO indicator solution made up of 0.2 g of methyl red and 0.1 g of methyl blue in 100 ml of ethanol. Distilled water. Determination of the Nitric Acid Quantity: Limits 475-525 ml/l 20-30 ml/l Recommended Interval Weekly Weekly
Procedure. 1 2 3 4 Transfer exactly 10 ml of the solution into a 100 ml calibrated vial. Make up to 100 ml with distilled water and stir to mix. Transfer exactly 10 ml of this solution into a 300 ml Erlenmeyer flask and dilute to approximately 100 ml with distilled water. Add a few drops of TASHIRO indicator solution and titrate with A ml of 0.5 N sodium hydroxide until a violet color is obtained.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (c) Quantitative formula: HNO3 g/l = A x 31.5 (2) Determination of the Ardrox 1635 Quantity: (a) Reagents. 1 Solution of Cerium (IV) sulfate. In a 1000 ml calibrated flask, dilute 100 ml of concentrated nitric acid in 500 ml of distilled water. Dissolve 5 g of Ce (SO4)24H2O and fill up to 1000 ml with distilled water. Distilled water.
2 (b)
Procedure. 1 2 3 4 5 6 Transfer exactly 10 ml of the solution into a 100 ml Erlenmeyer flask and fill up to 100 ml with distilled water. Shake the Erlenmeyer flask to mix. Transfer exactly 10 ml of this solution into a 100 ml calibrated vial and add 50 ml of Cerium (IV) sulfate solution. Fill up to 100 ml with distilled water and shake well. Using a spectrophotometer, measure the extinction point in a 0.5 cm thick cell at 420 15 nanometers. Establish the calibration curves as follows: Use the procedure described above, but replace the solution from the bath by solutions containing 500 g/l nitric acid and solutions of known concentrations of fluoride ions. The use of ammonium bifluoride in the range of concentration 1-15 g/l is appropriate for obtaining the calibration curve. The calibration curve, expressing the strength in g/l of HF as a function of the extinction, should be linear.
(c)
Calculation of Ardrox 1635 addition. 1 2 3 Using the extinction point measured from the bath solution, read the fluoride ion concentration F- (g/l) from the calibration curve. A = F-(g/l) x 5.215 = ml/l Ardrox 1635 in bath. ((30 - A) / 0.97) x T = Volume of mls of 1635 to add to bath of T liters.
SUBTASK 70-00-99-809-151 D. Regeneration. (1) (2) Remove surface contamination from tank daily. Maintain solution within check limits by adding the appropriate products. For calculation, refer to Subtask 70-00-99-809-150, Check.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (3) (4) Losses through evaporation will be made up by filling the tank to working level with water. Replace the solution if it loses its effectiveness.
Consumable Product Cee-Bee C46 SUBTASK 70-00-99-809-152 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill tank two-thirds full with water. Add Cee-Bee C46 product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-153 C. Check. (1) Checks Cee-Bee C46 (2) Find the Concentration of Cee-Bee C46. Limits 60-75 g/l Recommended Interval Monthly
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-154 D. Regeneration. (1) (2) (3) (4) Each day, remove the surface scum from the tank. Add the correct products to keep the solution in the check limits. Make up for losses through evaporation by filling the tank to the working level with water. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-031 48. Solution S1031 SUBTASK 70-00-99-99G-051 A. Composition. No. C04-064 Concentration (Initial Mix) 6 fl oz/US gal (50 ml/l)
SUBTASK 70-00-99-809-155 B. Preparation. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4)
Fill tank two-thirds full with water. Add Cee-Bee C46 product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-156 C. Check. (1) Find the Concentration of Cee-Bee C46.
EFFECTIVITY: ALL
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Checks Cee-Bee C46 (2)
Limits 60-75 g/l
Recommended Interval Monthly
SUBTASK 70-00-99-809-157 D. Regeneration. (1) (2) (3) (4) Each day, remove the surface scum from the tank. Add the correct products to keep the solution in the check limits. Make up for losses through evaporation by filling the tank to the working level with water. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-034 49. Solution S1034 SUBTASK 70-00-99-99G-054 A. Composition. No. C04-060 C04-108 Concentration (Initial Mix) Full strength See preparation instructions
Consumable Product Cee-Bee R43C Potassium Dichromate SUBTASK 70-00-99-809-158 B. Preparation. WARNING:
(1) (2) (3)
Fill tank with Cee-Bee R43C to within 80 percent of operating volume. Fill tank with water to form protective layer (water seal). Add 1.5 oz (42.5 g) of potassium dichromate per 1 US gal (11.25 g/l) of water seal.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-160 C. Check. (1) Checks Acidity (a) Determine pH: Limits 11-12 pH Equipment. 1 2 (b) pH-meter. pH-paper. Recommended Interval Weekly
Procedure. 1 2 3 4 5 6 Determine depth of water seal and Cee-Bee R43C using hollow tube. Re-establish the initial depth of Cee-Bee R43C and water seal by additions, if necessary. Agitate to mix. Heat to 1408-1508F (608-658C). Water will separate and form seal. Using tube draw out sample of Cee-Bee R43C. Determine pH value of sample.
SUBTASK 70-00-99-809-161 D. Regeneration. (1) Maintain acidity of Cee-Bee R43C at 11-12 pH. Add caustic potash to raise pH. Table 5. Caustic Potash Addition/Volume of Cee-Bee R43C pH 9.5 10.0 10.5 11.0 (2) (3) lb/100 gal 6 4 2 0 g/100 liters 750 500 250 0
Maintain levels by addition of Cee-Bee R43C and water at original ratio. Replace solution if it loses its effectiveness.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-035 50. Solution S1035 SUBTASK 70-00-99-99G-055 A. Composition. No. C04-059 C04-108 C04-127 Concentration (Initial Mix) Full strength See preparation instructions
Consumable Product Turco 2538 Potassium Dichromate Potassium Hydroxide SUBTASK 70-00-99-809-162 B. Preparation. WARNING:
(1) (2) (3) (4)
Fill tank with Turco 2538 to within three-fourths of operating volume. Fill tank with water to form protective layer (water seal). Add 1.3 oz (36.9 g) of potassium hydroxide per 1 US gal (9.75 g/l) of water seal. Add 1.5 oz (42.5 g) of potassium dichromate per 1 US gal (11.25 g/l) of water seal.
SUBTASK 70-00-99-809-163 C. Check. (1) Temperature Monitoring. The Turco 2538 bath has an optimum operating temperature of 1408F (608C) and a maximum upper temperature of 1508F (658C). Monitor the bath temperature to prevent the 1508F (658C) limit from being exceeded. (2) Protective Layer Thickness Check. Measure the layer thickness using a sufficiently long glass tube of 0.3-0.5 inch (1012 mm) diameter. The thickness must be between 3.9 and 5.9 inches (100-150 mm). (3) Tank Level Check. Add Turco 2538 product to compensate for losses occurring when parts are removed.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-164 D. Regeneration. (1) (2) Each day remove surface scum from tank. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-036 51. Solution S1036 SUBTASK 70-00-99-99G-056 A. Composition. No. C04-059 C04-108 C04-127 Concentration (Initial Mix) Full strength See preparation instructions
Consumable Product Turco 2538 Potassium Dichromate Potassium Hydroxide SUBTASK 70-00-99-809-165 B. Preparation. WARNING:
WARNING: (1) (2)
Fill tank with Ardrox 690 to within three-fourths of operating volume. Fill up with water to form a protective layer using Ardrox 690-I inhibitor at a strength of 30 g/l in the water seal.
SUBTASK 70-00-99-809-166 C. Check. (1) Checks Water Volatile fractions pH 10.8-11 Determination of Water Quantity: Limits Recommended Interval Daily Daily Daily
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Checks Emulsifying agent Corrosion inhibitor Chloride (NaCl) (a) Reagent. 1 (b)
Limits
Recommended Interval Daily Daily
Max 0.2 percent
Daily
500 ml/l sulfuric acid.
Procedure. 1 2 3 4 Pour 100 ml of a 500 ml/l sulfuric acid solution into a graduated 200 ml test tube with an emery stopper. Add 100 ml of the homogeneous solution sample. Stir this mix for approximately 5 minutes. Allow to stand for several hours (at least 1-1/2 hours).
(c)
Results. Two layers will form, the lower one being clear and slightly colored. Read off lower layer volume, and subtract 100 ml to obtain the percentage of water contained in the Ardrox tank.
(2)
Volatile Fractions Content Check (Mixture of Orthodichloro-benzene and a Fraction of the Emulsifying Agent). (a) Equipment. 1 (b) Heavy Baume hydrometer.
Procedure. 1 2 Determine the relative density by means of a heavy Baume hydrometer. The value measured should be 188Be or over. Add 4 percent Ardrox 690 restorer for each 8Be short of this figure.
(3)
PH Value Check. The alkaline restorer Ardrox 690 is added in the proportion of 1 gallons/liter of solution for each 0.1 pH decrement below 10.8 pH value. NOTE: Experience has shown in practice that the need to use this alkaline restorer arises extremely rarely since the emulsifying agent and the corrosion inhibitors in the anti-evaporation seal layer are the most readily eliminated part.
(4)
Ardrox 690 Seal Layer Check.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A This layer of inhibited water consists of an aqueous solution containing 30 g/l corrosion inhibitor. As there is no need to measure out all the inhibitors involved, one product may be used. (a) Reagents. 1 2 3 4 (b) Distilled water. Concentrated sulfuric acid. Titrated 0.1 N ferrous ammonium sulfate. Titrated 0.1 N potassium permanganate solution.
Procedure. 1 2 3 4 5 6 7 8 9 Take a sample from the tank, and separate the aqueous layer from the active phase by heating and centrifuging. Pipette 10 ml out of the test solution, and evaporate the water in a porcelain dish. Finish oxidizing the organic substances by heating the evaporating dish over a Bunsen burner flame for 10 minutes. Place the dish in an oven at approximately 9318F (5008C) for 45 minutes. Place the dish into a desiccator to cool. Add 20 ml distilled water and stir gently until all solids are dissolved. Transfer solution into a 250 ml Erlenmeyer flask, and rinse dish with distilled water. Add 3 ml concentrated sulfuric acid and exactly 50 ml 0.1 N ferrous ammonium sulfate. Titrate excess ferrous ammonium sulfate with A ml 0.1 N potassium permanganate until it turns mauve.
(c)
Quantitative formula: 1 2 A freshly prepared solution of Ardrox 690 protective layer should yield 30 5 ml 0.1 N ferrous ammonium sulfate. 2 ml 0.1 N ammonium sulfate provides a concentration of 2 g/l corrosion inhibitor for an Ardrox 690 protective layer.
(5)
Determination of the Chloride (NaCl) Quantity. If the water used is not demineralized, evaporation and the periodic additions of water will steadily increase the mineral-salt concentration. These salts cause a rapid decline in corrosion inhibiting power, attack metals, and lead to embrittlement through hydrogen absorption in high strength steels.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A The admissible limit on the NaCl content is 0.2 percent in the seal layer. If the chloride content exceeds this value, the seal layer should be siphoned off completely and replaced by a layer of fresh inhibited water. (a) Reagents. 1 2 3 (b) Titrated 0.1 N silver nitrate solution. 100 g/l potassium chromate solution. Distilled water.
Equipment. 1 Potentiometer complete with Ag indicating electrode and a mercury sulfate reference electrode.
(c)
Procedure. 1 2 3 Pour exactly 20 ml test solution into a 250 ml beaker. Add 100 ml distilled water, and titrate with B ml 0.1 N silver nitrate, keeping track of the amounts measured out by potentiometer. Stop at inflection point. NOTE: If a potentiometer is not available, add 10 drops of potassium chromate, and titrate with the 0.1 N silver nitrate until it turns a brownish orange color.
(d)
Quantitative formula: Cl g/l = B x 0.177
SUBTASK 70-00-99-809-167 D. Regeneration. (1) (2) (3) (4) Every day remove surface scum from tank. Maintain solution within check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank with water up to working level. Replace the solution if it loses its effectiveness.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-037 52. Solution S1037 SUBTASK 70-00-99-99G-057 A. General. (1) Not Used.
TASK 70-00-99-801-038 53. Solution S1038 SUBTASK 70-00-99-99G-058 A. Composition. No. C04-048 C04-128 Concentration (Initial Mix) Full strength To maintain solution alkalinity.
Consumable Product Turco 4008 Turco 3976 SUBTASK 70-00-99-809-171 B. Preparation. WARNING:
WARNING:
CAUTION: TURCO 4008 IS A SEPARATE PRODUCT FROM TURCO 4008-3. THE PRODUCTS MUST NOT BE MIXED. TURCO 4008 HAS A SIGNIFICANTLY HIGHER BOILING POINT AND OPERATING TEMPERATURE. (1) (2) Slowly and carefully fill tank to its operating level with Turco 4008. Heat to the operating temperature specified by the stripping process. NOTE: Turco 4008 is a highly alkaline, specialized product. Read the manufacturers Technical Data Bulletin, Solution Maintenance Procedure, and Material Safety Data Sheet prior to using this product. SUBTASK 70-00-99-809-172 C. Check. (1) Maintain the boiling point and concentration of the solution as follows:
EFFECTIVITY: ALL
70-00-99
Check Boiling Point
Limits 270-2808F (132-1388C) Adjust to 2758F (1358C)
Recommended Interval Daily when in use Weekly or more often depending on usage. As required See D.(2). As required See D.(2).
Alkalinity Solution level (2)
Adjust with Turco 3976 Maintain with Turco 4008
Follow the manufacturers control procedures to maintain the solution within the check limits.
SUBTASK 70-00-99-809-173 D. Regeneration. (1) (2) Every day, remove surface contamination from the tank. Maintain solution within check limits by the addition of appropriate products. (a) Maintain solution level by addition of Turco 4008 after having brought the boiling point of the solution to 2758F (1358C) and adjusted the alkalinity, if necessary. NOTE: Drainage losses from the Turco 4008 bath will not require more than once or twice weekly additions of compound in order to maintain the level required for work. (b) Maintain solution alkalinity by addition of Turco 3976. NOTE: Additions of Turco 3976 C04-128 are not required until the tank has had considerable use and then should never exceed 20 percent of replenishment additions of Turco 4008. (3) Replace the solution if it loses its effectiveness or is contaminated.
TASK 70-00-99-801-039 54. Solution S1039 SUBTASK 70-00-99-99G-059 A. Composition. No. C04-030 Concentration (Initial Mix) Full strength
Consumable Product Trichloroethane 1-1-1
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-174 B. Preparation. WARNING: THIS SOLVENT IS TOXIC AND IS TO BE USED IN CONJUNCTION WITH AN EFFICIENT VENTILATION. AVOID PROLONGED INHALATION OF VAPOR AS WELL AS PROLONGED CONTACT WITH SKIN.
(1)
Ready for use (full strength).
SUBTASK 70-00-99-809-175 C. Checks Acidity Oily materials Check. Limits pH: 7 35% maximum Recommended Interval Semi-weekly Weekly
NOTE: These intervals can be modified according to use.
(1)
Acidity Check. NOTE: This sample can be removed from either sump. (a) (b) (c) (d) (e) Remove 50 ml of the solution to be checked. Add 50 ml of distilled water of pH 7.0, previously verified. Stir well for several minutes. Allow to settle out. Measure the pH of the aqueous layer with a pH-meter for an exact measurement, or with an indicator paper for an approximate measurement.
(2)
Oily Materials Checks. NOTE: This sample must be obtained from the boiling sump for this test. (a) The maximum value acceptable before regeneration is 35 percent by volume. A rough estimate of the proportion of oil materials can easily be made using: 1 2 A density bottle as per Curve 1 see ( Figure 1, Page 82) with a sample at 688F (208C). A thermometer (for measurement of boiling point) as per Curve 2. See Figure 1, Page 82.
EFFECTIVITY: ALL
70-00-99
Boiling Point and Relative Density of Mineral Oil and Trichloroethane 1-1-1 Mixtures Figure 1
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-249 D. Regeneration. WARNING: DO NOT USE CAUSTIC SODA OR CAUSTIC POTASH AS A TANK CLEANING MEDIUM. BOTH REACT TO FORM DICHLOROACETYLENE WHICH WILL RESULT IN EXPLOSION AND FIRE. LIKEWISE, DO NOT MIX LIME AND SODIUM CARBONATE.
(1) (2)
Replace the solution when it exceeds acidity or oil limits. Cleaning of the Tank. (a) (b) (c) A complete cleaning will be carried out if necessary with a neutralization using hot water to which has been added 5 percent of sodium carbonate. Rinse in water and dry. Examine the tank and the tubing for possible corrosion.
Consumable Product Stoddard Solvent SUBTASK 70-00-99-809-176 B. Preparation. WARNING:
SOLVENT IS TOXIC. AVOID INHALATION OF VAPORS. AVOID PROLONGED CONTACT WITH EYES, SKIN, OR CLOTHING. OPERATOR SHOULD USE ONLY IN WELL VENTILATED AREA. SOLVENT IS FLAMMABLE. TAKE PRECAUTIONS AGAINST FIRE.
WARNING: (1)
SUBTASK 70-00-99-809-177 C. Check. (1) Determination of Oil Quantity in Solution:
EFFECTIVITY: ALL
70-00-99
Checks Oil in solution
Limits 10 percent
Recommended Interval Weekly
NOTE: These intervals can be modified according to use. (a) Test sample. 1 Make as standard test sample by adding 10 percent oil, by volume, to a quantity of solvent. NOTE: The oil used to make the test sample should be the same type of oil that is used on parts which are cleaned by the solution. (b) Procedure. 1 2 Visually compare the color of a sample of the working solution with the standard test sample. When color of solution becomes darker than test sample, the solution has exceeded allowable oil quantity.
SUBTASK 70-00-99-809-178 D. Regeneration. WARNING: DO NOT USE CAUSTIC SODA OR CAUSTIC POTASH AS A TANK CLEANING MEDIUM. BOTH REACT TO FORM DICHLOROACETYLENE WHICH WILL RESULT IN EXPLOSION AND FIRE. LIKEWISE, DO NOT MIX LIME AND SODIUM CARBONATE.
(1)
Replace solution when it exceeds the allowable oil quantity.
TASK 70-00-99-801-041 56. Solution S1041 SUBTASK 70-00-99-99G-061 A. Composition. No. C05-088 C05-088 C04-181 Concentration (Initial Mix) 5 g/US gal 5 g/US gal 1 US gal (3.785 liters) 1 US gal (3.785 liters)
Consumable Product Magnaglo Powder 14A Ardrox SY 8000 A/1 Powder Suspension Fluid, AMS 2641 Water
EFFECTIVITY: ALL
70-00-99
Consumable Product WA-4 liquid water conditioner SUBTASK 70-00-99-809-179 B. Preparation. (1) (2) (3) (4) (5)
No. C05-090
Concentration (Initial Mix) 1.33 fl oz (39.3 ml)/US gal
Place a known quantity of water or AMS 2641 suspension fluid C04-181 in tank. Add the required amount of powder C05-088 to liquid vehicle while stirring thoroughly. Add WA-4 liquid water conditioner C05-090 if water vehicle process and Magneglo 14A powder is used. Stir and agitate for approximately 30 minutes, and then check concentration per Subtask 70-00-99-809-180, Check. Fill two centrifuge tubes and retain as master samples for comparison tests.
SUBTASK 70-00-99-809-180 C. Check. (1) Checks Particle concentration Contamination of suspension Fluorescence of liquid Check Limits: Limits 0.15-0.25% of total volume None allowed No significant differences between test sample liquid and master sample liquid shall exist
(2)
Preparation of Test Samples. (a) Equipment required. 1 2 Centrifuge tubes - pear shaped, 100 ml nominal capacity and graduated in 0.10 milliliters. Centrifuge (optional) - hand-driven type such as Boekel Model 1163 or equivalent is recommended. (Refer to Boekel Scientific in the List of Suppliers in Step 1.D. of 70-80-00).
(b)
Gravity method. 1 Allow suspension solution to flow through hose and nozzle for a few seconds before drawing sample. This will ensure that sample is representative of tank contents.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A 2 3 4 5 (c) Draw 100 ml sample into centrifuge tube. Demagnetize sample. Place tube in stand or rack free from vibration and magnetic fields. Allow tube to stand for 30 minutes or until particles have settled to bottom of tube.
Centrifugal method. 1 Allow suspension solution to flow through hose and nozzle for a few seconds before drawing sample. This will ensure that sample is representative of tank contents. Draw 2 separate 100 ml samples in centrifuge tubes. For fluorescence test only, one sample is required. Place filled tubes opposite one another in hand-driven centrifuge. Crank centrifuge 40 turns, at a speed sufficient to make tubes swing out to a horizontal position.
2 3 4 (3) Tests. (a)
Concentration test. 1 2 Prepare samples per Step C.(2), Preparation of Test Samples. Observe level of concentrated particles at bottom of tube. The amount of concentrate should be within the limits of Step C.(1), Check Limits.
(b)
Contamination test. 1 2 Prepare samples per Step C.(2), Preparation of Test Samples. Examine precipitate at bottom of tube. If any distinct layers can be seen, it is contaminated.
(c)
Fluorescence test. 1 2 3 Thoroughly mix the master sample by shaking it. Prepare samples per Step C.(2), Preparation of Test Samples. Compare fluorescence of liquid above precipitate between the test sample and the master sample.
(d)
Wettability test (water vehicle only). 1 2 Flow suspension bath over parts normally inspected or a known defect test part. Inspect part for complete wetting.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A 3 4 If surface is completely wet, there is sufficient wetting agent in the bath. If water beads or dry spots are evident, add sufficient WA-4 liquid water conditioner to ensure complete wetting.
SUBTASK 70-00-99-809-181 D. Regeneration. (1) Concentration. Add more magnetic particles or more liquid vehicle to the solution to bring it within limits. (2) Contamination. Discard solution when it becomes contaminated. (3) Fluorescence. Discard solution when the liquid becomes more fluorescent than the master sample. TASK 70-00-99-801-046 57. Solution S1046 SUBTASK 70-00-99-99G-062 A. Composition. No. C04-191 Concentration (Initial Mix) 1 fl oz/US gal (7.8 ml/l)
Consumable Product MagChem Aerodet SUBTASK 70-00-99-809-182 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill the tank to two-thirds of its working level with water. Heat to the operating temperature. Add the compound cleaner C04-191 while stirring to mix. Add water to top off tank to full the working level.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (5) Stir the solution again to mix.
SUBTASK 70-00-99-809-183 C. Check. (1) Checks MagChem Aerodet (2) Determination of the compound cleaner C04-191 quantity. Limits 4-8 ml/l Recommended Interval Weekly
SUBTASK 70-00-99-809-184 D. Regeneration. (1) (2) (3) (4) Every day, remove the surface scum from tank. Maintain the solution within the check limits by addition of appropriate products. Losses through evaporation will be made up by filling the tank to the working level with water. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-047 58. Solution S1047 SUBTASK 70-00-99-99G-063 A. Composition. No. C04-123 C04-015 Concentration (Initial Mix) 4 oz/US gal (30 g/l) 0.6 fl oz/US gal (5 ml/l)
Consumable Product Sodium carbonate Wetting Agent
EFFECTIVITY: ALL
70-00-99
WARNING: (1) (2) (3) (4) (5) (6)
Fill tank with water to two-thirds of its working level. Heat to approximately 1408F (608C). Add sodium carbonate while stirring to mix thoroughly. Add Triton X100 (or equivalent wetting agent). Add water to top up to working level. Stir to mix thoroughly.
SUBTASK 70-00-99-809-186 C. Checks Sodium carbonate Wetting agent Check. Limits 15-30 g/l 2.5-7.5 ml/l Recommended Interval Weekly Weekly
(1)
Determination of the Sodium Carbonate Quantity. (a) Reagents. 1 2 3 4 (b) 100 g/l solution of barium chloride. Helianthine solution. Titrated 0.1 N hydrochloric acid solution. Distilled water.
Procedure. 1 2 Pour exactly 2 ml of the solution into a 250 ml beaker. Add 25 ml of distilled water and 10 ml of 100 g/l barium chloride solution.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A 3 4 5 6 (c) Filter through a close-textured filter and scour with a 10 g/l BaCl2 solution. Transfer filter and precipitate into the original beaker. Add 20 ml distilled water and a few drops of helianthine. Titrate with A ml 0.1 N hydrochloric acid.
Quantitative formula: Na2CO3 g/l = A x 2.65
SUBTASK 70-00-99-809-187 D. Regeneration. (1) (2) Every day remove surface scum from tank. Maintain solution within check limits by the addition of appropriate products. (a) (b) (3) (4) Addition of sodium carbonate. If V is tank volume in liters, the quantity of sodium carbonate to be added is V (30-A x 2.65) grams.
Losses through evaporation will be made up by filling tank to working level with water. Replace solution if it loses its effectiveness.
TASK 70-00-99-801-048 59. Solution S1048 SUBTASK 70-00-99-99G-064 A. Composition. No. C10-042 C04-109 C04-110 C04-111 C04-108 Concentration (Initial Mix) 54 oz/US gal (405 g/l) 0.4 oz/US gal (3 g/l) 0.19 fl oz/US gal (1.5 ml/l) 0.8 oz/US gal (6 g/l) 0.4 oz/US gal (3 g/l)
Consumable Product Novaculite 1250 No-pack Surfacto (optional) Metrolux (optional) or Potassium dichromate (optional)
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-188 B. Preparation. WARNING: CHROMIC SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4) (5) (6) (7)
Fill tank one-third full with water. Add Novaculite 1250 product while stirring the solution to mix. Slowly add the No-pack while stirring. Add Metrolux or Potassium Dichromate rust preventative if required by vapor blast equipment manufacturer. Carefully add the product while stirring solution. Slowly add Surfacto liquid wetting agent if desired. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-189 C. Check. (1) Blasting Machine Mixture Check. (a) Test of the concentration by sedimentation. 1 Remove a 250 ml sample of the abrasive mixture with a graduated test tube. NOTE: Make sure the mixture is uniform by operating the machine for at least 15 minutes. 2 3 4 Let the abrasive material settle out for 15 minutes. The average concentration must be 33 percent (one third of the height of the test tube). In the case of incorrect concentration, modify the mixture.
SUBTASK 70-00-99-809-190 D. Regeneration. (1) Additions shall be made as required.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-050 60. Solution S1050 SUBTASK 70-00-99-99G-065 A. Composition. No. C04-220 C04-109 C04-110 C04-111 C04-108 Concentration (Initial Mix) 30 oz/US gal (225 g/l) 0.4 oz/US gal (3 g/l) 0.19 fl oz/US gal (1.5 ml/l) 0.8 oz/US gal (6 g/l) 0.4 oz/US gal (3 g/l)
Consumable Product Alumina 325 No-pack Surfacto (optional) Metrolux (optional) or Potassium dichromate (optional) SUBTASK 70-00-99-809-191 B. Preparation. WARNING:
CHROMIC SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH AN ABUNDANT QUANTITY OF WATER. AVOID BREATHING THE VAPORS. THE OPERATOR SHOULD WEAR A FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4)
Fill tank one-third full with water. Add the Aluminum Oxide 325 product while you stir the solution to mix them together. Slowly add the No-pack while stirring. Add the Metrolux or Potassium Dichromate rust preventative if required by the vapor blast equipment manufacturer. Carefully add the product while stirring the solution. Slowly add Surfacto liquid wetting agent if necessary. Add more water as required to put the solution level at the necessary height in the tank. Stir the solution again to mix.
(5) (6) (7)
SUBTASK 70-00-99-809-192 C. Check. (1) Blasting Machine Mixture Check.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (a) Test of the concentration by sedimentation. 1 2 3 4 5 Operate the machine for at least 15 minutes to make sure the abrasive material has mixed equally. Remove a 100 ml sample of the abrasive mixture as it leaves the gun with a graduated test tube. Let the abrasive material collect at the bottom of the test tube for 15-30 minutes. The average concentration must be 30-35 percent (one third of the height of the test tube). Modify the mixture as required if the concentration is not correct.
SUBTASK 70-00-99-809-193 D. Regeneration. (1) Add more solution as required.
TASK 70-00-99-801-053 61. Solution S1053 SUBTASK 70-00-99-99G-066 A. Composition. No. C10-115 C04-109 C04-110 C04-111 C04-108 Concentration (Initial Mix) 54 oz/US gal (405 g/l) 0.4 oz/US gal (3 g/l) 0.19 fl oz/US gal (1.5 ml/l) 0.8 oz/US gal (6 g/l) 0.4 oz/US gal (3 g/l)
Consumable Product Novaculite 200 No-pack Surfacto (optional) Metrolux (optional) Potassium dichromate (optional)
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-194 B. Preparation. WARNING: CHROMIC SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4) (5) (6) (7)
Fill tank one-third full with water. Add Novaculite 200 product while stirring the solution to mix. Slowly add the No-pack while stirring. Add Metrolux or Potassium Dichromate rust preventative if required by vapor blast equipment manufacturer. Carefully add the product while stirring solution. Slowly add Surfacto liquid wetting agent if desired. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-195 C. Check. (1) Blasting Machine Mixture Check. (a) Test of the concentration by sedimentation. 1 Remove a 250 ml sample of the abrasive mixture with a graduated test tube. NOTE: Make sure the mixture is uniform by operating the machine for at least 15 minutes. 2 3 4 Let the abrasive material settle out for 15 minutes. The average concentration must be 33 percent (one third of the height of the test tube). In the case of incorrect concentration, modify the mixture.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-054 62. Solution S1054 SUBTASK 70-00-99-99G-067 A. Composition. No. C04-112 C04-109 C04-110 C04-111 C04-108 Concentration (Initial Mix) 30 oz/US gal (225 g/l) 0.4 oz/US gal (3 g/l) 0.19 fl oz/US gal (1.5 ml/l) 0.8 oz/US gal (6 g/l) 0.4 oz/US gal (3 g/l)
Consumable Product Alumina 500 No-pack Surfacto (optional) Metrolux (optional) or Potassium dichromate (optional) SUBTASK 70-00-99-809-197 B. Preparation. WARNING:
CHROMIC SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4) (5) (6) (7)
Fill tank one-third full with water. Add the Aluminum Oxide 500 product while you stir the solution to mix them together. Slowly add the No-pack while stirring. Add Metrolux or Potassium Dichromate rust preventative if required by vapor blast equipment manufacturer. Carefully add the product while stirring solution. Slowly add Surfacto liquid wetting agent if necessary. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-198 C. Check. (1) Blasting Machine Mixture Check. (a)

EFFECTIVITY: ALL
Test of the concentration by sedimentation.
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A 1 Remove a 100 ml sample of the abrasive mixture as it leaves the gun with a graduated test tube. NOTE: Make sure the mixture is uniform by operating the machine for at least 15 minutes. 2 3 4 Let the abrasive material settle out for 15 - 30 minutes. The average concentration must be 30 - 35 percent (one third of the height of the test tube). If you find an incorrect concentration, modify the mixture.
TASK 70-00-99-801-103 63. Solution S1103 SUBTASK 70-00-99-99G-068 A. Composition. No. C04-142 C04-142 Concentration (Initial Mix) 16 fl oz/US gal (120 g/l) 20% V/V
Consumable Product Cee-Bee J-19 Cee-Bee J-19L SUBTASK 70-00-99-809-200 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill the tank half-full with water. Add the Cee-Bee J-19 or Cee-Bee J-19A Part A while heating the solution and stirring to mix. Add the Part B (inhibitor) and dissolve completely. Fill the tank with water to a working level. Stir the solution again to mix thoroughly.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-201 C. Check. (1) Determine the concentration of the Cee-Bee J-19 or Cee-Bee J-19L solution.
Checks Cee-Bee J-19 Cee-Bee J-19L Stock loss test per ARP 1755 on AMS 5504 panel (2)
Limits 80-120 g/l 17-20% V/V 0.05 mils (1.25 mm) total
Recommended Interval Bi Monthly Bi Monthly Weekly
SUBTASK 70-00-99-809-202 D. Regeneration. (1) (2) (3) Add water daily to replace evaporation losses. Add the correct products to keep the solution in the check limits. Replace the solution if it loses its effectiveness or the stock loss test exceeds the limits specified in Subtask 70-00-99-809-201, Check.
Consumable Product Cee-Bee C-623
EFFECTIVITY: ALL
70-00-99
WARNING: (1) (2) (3) (4)
Fill the tank to 40% of its working level with water. Add the inhibited phosphoric acid C04-143 slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix thoroughly.
SUBTASK 70-00-99-809-204 C. Check. (1) Checks Cee-Bee C-623 (2) Determine the concentration of inhibited phosphoric acid C04-143: Limits 30-35% V/V Recommended Interval Monthly
SUBTASK 70-00-99-809-205 D. Regeneration. (1) (2) (3) (4) (5) Every day remove surface scum from the tank. Periodic additions: Maintain the solution within the check limits by adding the appropriate products. Losses through evaporation will be made up by filling the tank with water to the working level on a daily basis. Replace the solution when it loses its effectiveness.
EFFECTIVITY: ALL
70-00-99
Consumable Product Ardrox 9D71 SUBTASK 70-00-99-809-206 B. Preparation. (1) (2) (3) (4)
Fill tank with a known quantity of water. Add developer to water, stirring thoroughly as developer is being added. Measure specific gravity of developer bath. Add developer or water, as required, to adjust specific gravity within limits of Subtask 70-00-99-809-207, Check.
SUBTASK 70-00-99-809-207 C. Check. (1) Checks Specific Gravity (a) Equipment. Hydrometer (b) Method. Measure specific gravity when solution is at room temperature. SUBTASK 70-00-99-809-208 D. Regeneration. (1) Adjust specific gravity by adding developer or water, as required. Specific Gravity Test: Limits 1.012 - 1.024
EFFECTIVITY: ALL
70-00-99
SOLUTION SHEETS Page 98.1 Dec 01/03
Consumable Product Zyglo ZP5A SUBTASK 70-00-99-809-209 B. Preparation. (1) (2) (3) (4)
Fill tank with known quantity of water. Add developer to water, stirring thoroughly as developer is being added. Measure specific gravity of developer bath. Add developer or water, as required, to adjust specific gravity within limits of paragraph 3.
SUBTASK 70-00-99-809-210 C. Checks Specific Gravity (1) Specific Gravity Test. (a) Equipment. Hydrometer (b) Method. Measure specific gravity when solution is at room temperature. SUBTASK 70-00-99-809-211 D. Regeneration. (1) Adjust specific gravity by adding developer or water, as required. Check. Limits 1.012 - 1.024
EFFECTIVITY: ALL
70-00-99
Consumable Product Zyglo ZP13A SUBTASK 70-00-99-809-213 B. Preparation. (1) (2) (3) (4)
EFFECTIVITY: ALL
70-00-99
Consumable Product Fluro-Chek WD SUBTASK 70-00-99-809-216 B. Preparation. (1) (2) (3) (4)
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-127 69. Solution S1127 SUBTASK 70-00-99-99G-074 A. Composition. No. C05-059 Concentration (Initial Mix) For immersion: One part to 4 parts water For spray: One part to 20 parts water SUBTASK 70-00-99-809-219 B. Preparation. (1) (2) Place a known quantity of water in tank. Add remover to water to obtain the specified concentrations.
Consumable Product Ardrox 9PR4
SUBTASK 70-00-99-809-220 C. Check. (1) None required.
SUBTASK 70-00-99-809-221 D. Regeneration. (1) (2) The working level is gradually reduced by water evaporation. The working level should be restored by adding water only. Discard remover when it loses its effectiveness.
TASK 70-00-99-801-128 70. Solution S1128 SUBTASK 70-00-99-99G-075 A. Composition.
EFFECTIVITY: ALL
70-00-99
Consumable Product Consumable Product Zyglo ZR10A No. No. C05-053 Concentration (Initial Mix) Concentration (Initial Mix) For immersion: One part to 4 parts water For spray: One part to 20 parts water SUBTASK 70-00-99-809-222 B. Preparation. (1) (2) Place a known quantity of water in tank. Add remover to water to obtain the specified concentrations.
TASK 70-00-99-801-129 71. Solution S1129 SUBTASK 70-00-99-99G-076 A. Composition. No. C05-055 Concentration (Initial Mix) For immersion: One part to 4 parts water For spray: One part to 20 parts water
Consumable Product Fluro-Chek E41
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-225 B. Preparation. (1) (2) Place a known quantity of water in tank. Add remover to water to obtain the specified concentrations.
Consumable Product Turco 6045 SUBTASK 70-00-99-809-228 B. Preparation. WARNING:
ACID SOLUTIONS ARE VERY ACTIVE AND MAY CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1)
Charge tank with Turco 6045 product up to the working level, stirring while adding.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-229 C. Tank Control and Regeneration. (1) When the tank solution becomes contaminated with digested polymers and is no longer effective, it should be discarded. A new solution should then be made up for use.
Consumable Product Cee-Bee C-105 H.F. SUBTASK 70-00-99-809-230 B. Preparation. WARNING:
WARNING: (1)
Charge tank with Cee-Bee C-105 H.F. product up to the working level, stirring while adding.
SUBTASK 70-00-99-809-231 C. Tank Control and Regeneration. (1) It is frequently desirable to use two tanks of Cee-Bee C-105 H.F. One tank is used to remove the bulk of the silicone rubber and the second tank for final cleaning. When the first tank solution becomes contaminated with digested polymers and is discarded, the solution in the second tank can be transferred to the first tank and the second tank recharged with fresh solution.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-132 74. Solution S1132 SUBTASK 70-00-99-99G-079 A. Composition. No. C04-147 Concentration (Initial Mix) Full strength
Consumable Product Ardrox 2204 SUBTASK 70-00-99-809-232 B. Preparation. WARNING:
WARNING: (1)
Fill tank with Ardrox 2204 product up to the working level, stirring while adding.
SUBTASK 70-00-99-809-233 C. Check. (1) Acid and solvent content check. (a) (b) Checks Acid and solvent content Adjust tank level to account for drag-out losses by adding fresh Ardrox 2204 solution. Mix solution and remove sample for analysis. Limits 14-14.8 ml. Recommended Interval Weekly (more frequently if solution is in constant use)
(c)
Pipette 10 ml of sample solution (using a safety pipette) into a 250 ml conical flask, add 100 ml of distilled/de-ionized water and shake the flask and contents thoroughly. Titrate flask solution with 0.5M potassium hydroxide solution, using 5-6 drops of phenolphthalein indicator solution until a pink end point persists for 20 seconds. Record the titer obtained in mls.
(d) (2)
Calculation of Acid and Solvent Content.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Titer obtained with fresh solution is 14.4 0.4 ml. (a) If titer is low: For every ml of titer below 14, 32 ml of acid additive should be added per liter of tank solution. (b) If titer is high: Let the titer = X ml. The amount of solvent additive required per liter of tank solution = (X/14.4 x 1000 - 1000) ml For example, the titration on a used tank resulted in a figure of 16.7 ml. The amount of solvent additive required would be: (16.7/14.4 x 1000 - 1000) ml = (1160 - 1000 ml) = 160 ml The amount of solvent additive required would be 160 ml/liter of tank solution. NOTE: It has been found from practice that a tank of Ardrox 2204 will normally need additions of solvent additive only and will only rarely need additions of acid additive. TASK 70-00-99-801-133 75. Solution S1133 SUBTASK 70-00-99-99G-080 A. Composition. No. C04-155 C04-155 C04-084 C04-157 Concentration (Initial Mix) 40 percent solution by volume 8 oz/US gal (60 g/l) 2 oz/US gal (15 g/l) To maintain solution
Consumable Product Enstrip EN-79A Enstrip EN-79B Sodium Hydroxide Enstrip Regenerator
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-234 B. Preparation. WARNING: NEVER ADD WATER TO ALKALINE CONCENTRATE. ADD ALKALINE CONCENTRATE TO WATER WHILE STIRRING VIGOROUSLY. LOCALIZED HEAT OF SOLUTION CAN CAUSE BOILING OR SPLATTERING. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES AND PROTECTIVE CLOTHING AND SHOES. DO NOT MIX ENSTRIP EN-79B AND DRY SODIUM HYDROXIDE TOGETHER AS THIS MAY CAUSE AUTO-IGNITION. ENSTRIP EN-79B IS A FLAMMABLE SOLID. DO NOT STORE NEAR EXCESSIVE HEAT OR OPEN FLAMES. ENSTRIP EN-79A AND THE ENSTRIP EN-79 OPERATING SOLUTION ARE STRONGLY ALKALINE IN NATURE AND MAY CAUSE SKIN AND EYE BURNS. AVOID SKIN AND EYE CONTACT. IN CASE OF CONTACT, FLUSH SKIN AND EYES WITH PLENTY OF COOL, CLEAN WATER FOR 15 MINUTES; FOR EYES, OBTAIN IMMEDIATE MEDICAL ATTENTION. ENSTRIP EN-79A, ENSTRIP EN-79B AND THE FINAL STRIPPING SOLUTION SHOULD BE HANDLED WITH CARE AND PROPER PROTECTIVE CLOTHING SUCH AS RESPIRATOR, RUBBER GLOVES AND SAFETY GLASSES, SHOULD BE WORN TO PREVENT CONTACT WITH THE SKIN OR EYES. DO NOT INHALE DUST OR MIST FROM THE BATH COMPONENTS OR FROM THE OPERATING SOLUTION.
WARNING: WARNING: WARNING:
WARNING:
(1)
Enstrip EN-79 is supplied as two components: Enstrip EN-79A, a liquid material, and Enstrip EN-79B, a powder. Both components are then combined with sodium hydroxide to make up the working solution. Prepare the solution as follows: (a) (b) (c) (d) (e) (f) Fill the stripping tank with warm water to within 1/2 the operating volume of the tank. Add EN-79B equal to 8 oz/gal (60 g/liter) of the final working solution to the warm water. Stir the EN-79B solution until all powder is completely dissolved. Cautiously add the EN-79A equal to 40 percent by volume of the final working solution. Cautiously add, with continuous stirring, sodium hydroxide equal to 2 oz/gal (15 g/liter) by volume of the final working solution. Stir the solution until the sodium hydroxide is completely dissolved.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (g) (h) Fill the stripping tank to its final working volume with water and heat to the operating temperature. Cover solution when not in use.
SUBTASK 70-00-99-809-235 C. Checks Enstrip EN-79A Enstrip EN-79B Sodium Hydroxide Enstrip Regenerator Check. Limits See NOTE 1. See NOTE 2. See NOTE 3. See NOTE 4. Recommended Interval Weekly Weekly Weekly Weekly
NOTE: 1. Replenish the Enstrip EN-79A concentration to 50 percent by volume of the operating solution. To determine the amount needed see solution regeneration section. NOTE: 2. For each 10 percent by volume of Enstrip EN-79A replenished add 2 oz/gal (15 g/l) of Enstrip EN-79B. NOTE: 3. Add 1 to 2 oz/gal (7.5 to 15 g/l) sodium hydroxide after stripping 5 to 10 mil/ft 2 of electroless nickel per gallon of solution (82.4 to 165 micron/dm2 per liter). NOTE: 4. Replenish the Enstrip Regenerator concentration after analyzing and adjusting the solution for Enstrip EN-79A and pH. To determine the amount needed see solution regeneration section.
SUBTASK 70-00-99-809-236 D. Regeneration. (1) Perform the quality control analysis of the Enstrip EN-79 solution as follows: (a) Enstrip EN-79A. 1 Gather the following laboratory apparatus. 5 ml pipette 50 ml burette 250 ml beaker 250 ml Erlenmeyer flask Filter paper, Whatman #41 2 Prepare the following reagents: a For 1 percent methyl orange indicator solution dissolve 1 gram of methyl orange salt in 100 ml of deionized or distilled water.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A b 3 For 1.0N sulfuric acid (H2SO4) solution purchase from local laboratory supply house.
Procedure: a b c Adjust the volume of the Enstrip EN-79 operating solution to the volume of the original make-up by adding water. Mix well. Take a 150 ml sample of the adjusted operating solution, cool to room temperature and filter to remove particulate matter. Pipette a 5 ml aliquot of the filtered solution into an Erlenmeyer flask and add 75 ml of deionized or distilled water and several drops of 1 percent methyl orange indicator. Using a white background, titrate to the endpoint using 1.0N H2SO4 solution. The color of the solution will change from yellow to pink.
Calculation: a Perform the following calculation: Factor A = ml H2SO4 titrated x Normality H2SO4 b Calculate the percent by volume of Enstrip EN-79A in the sample as follows: Percent Enstrip = 1.235 x Factor A - 3.71
Replenishment of EN-79A. a Restore the solution to the original concentration of 50 percent by volume Enstrip EN-79A as follows: Subtract the percent Enstrip found in paragraph 4.A(1)(d)2. from 50 percent. The result is the percent of EN-79A to be replenished by volume. For example, if Factor A is 20 then percent Enstrip is 1.235 x (2) -3.71 or 21. The replenishment required is 50-21 or 29 percent by volume. For each 10 percent by volume Enstrip EN-79A replenished, add 2 oz/gal (15 g/liter) Enstrip EN-79B and 1 oz/gal (7.5 g/liter) sodium hydroxide.
(b)
Analysis for Enstrip Regenerator. 1 Gather the following apparatus. 1 ml pipette - graduated in 0.1 ml units 2 ml pipette - dropper type 5 ml pipette - graduated in 0.50 ml units 10 ml pipette 10 ml graduated cylinder
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A 100 ml volumetric flask 1 liter volumetric flask 20 ml pyrex test tubes, stoppered (7 required) white paper background 2 Prepare the following reagents: a For copper sulfate solution add 5 ml of ammonium hydroxide (NH4OH) to 75 ml of water and dissolve 1.5 grams of copper sulfate pentahydrate (CuSO45H2O) in the mixture. Add water to bring to exactly 100 ml. NOTE: Chemicals for the copper sulfate solution must be added in the order given or a solid will precipitate. b c For 1-1-1 Trichlorethane, Analytical Reagent Grade purchase from local chemical supply house. For standard Enstrip Regenerator solution add 0.70 ml of Enstrip Regenerator into a one liter volumetric flask and dilute to exactly one liter with water.
Procedure: a b Number the pyrex test tubes 1 through 7. Into each test tube place 10 ml of trichlorethane and 2 ml of copper sulfate solution. This results in the formation of two layers, blue on top and clear on the bottom. Make the following additions to test tubes 1 through 6. ml of diluted Standard Enstrip Regenerator Solution None 1.0 1.5 2.0 2.5 3.0 d e Stopper each test tube and shake well. The bottom layers will take on varying shades of amber yellow, the top will remain blue. Take a 150 ml sample of the Enstrip EN-79 operating solution. Ensure that the operating solution has been adjusted to the recommended concentrations of Enstrip EN-79A, EN-79B and sodium hydroxide as outlined under the Enstrip EN-79A replenishment paragraph, 4.A.(1)(e).
c Test Tube No. 1 2 3 4 5 6
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A f g h i Allow sample to cool to room temperature; then filter to remove particulate matter. Pipette 1 ml of the filtered EN-79 operating solution into a 100 ml volumetric flask and dilute to exactly 100 ml. Pipette 1 ml of the diluted Enstrip EN-79 operating solution into test tube number 7; stopper and shake well. Using a white background, compare the amber yellow color of the bottom layer of test tube number 7 against color standards 1 through 6. Select the color standard whose color is closest to the sample. Add Enstrip Regenerator to the Enstrip EN-79 operating solution per the following table.
j k
Matching Color Standard Test Tube Number 1 2 3 4 5 6
Amount of Enstrip Regenerator to Add oz/gal (ml/liter) 3.00 (23.43) 2.10 (16.40) 1.60 (12.50) 1.10 ( 8.59) 0.65 ( 5.10) 0.20 ( 1.56)
TASK 70-00-99-801-134 76. Solution S1134 SUBTASK 70-00-99-99G-081 A. Composition. Concentration (Initial Mix) 10 fl oz/US gal (78.1 ml/l) 2 oz/US gal (15 g/l)
Consumable Product Nitric Acid ASC 2-N
No. C04-072 C04-158
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-237 B. Preparation. WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND MAY CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH LARGE QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
(1)
Prepare the ASC 2-N stripping solution as follows: (a) Mix the solution in a locally-manufactured acid-resistant tank. Tank must maintain solution at 858F 58F (298C 38C). NOTE: The following quantities represent a final solution volume of 50 gallons. If the final solution volume is not 50 gallons, the following relative proportions must be maintained. (b) Ratios ASC 2-N C04-158 - 2 ounces (56.7 g) per gallon Nitric Acid C04-072 - 10 fl. ounces (0.3 l) per gal. Tap Water - balance to make 1 gal. (3.8 l) (c) Mixing Instructions 1 2 3 Dissolve 6 lb. 4 oz. (2838 g.) of ASC 2-N C04-158 in approximately 25 gallons of water. Add 3 gal. 116 oz. (14.8 l) of nitric acid C04-072. Add the remaining water (to make 50 gallons) while stirring with a wooden or plastic paddle. This will ensure a uniform mixture.
(2)
Qualify the ASC 2-N stripping solution as follows. Prior to stripping the first batch of parts, each new stripping solution must be qualified by processing a specimen, for metallographic examination, through the stripping cycle. (a) (b) (c) Obtain a scrap part of the same material as the parts to be stripped. Grind one surface of the part (such as the dovetail shank face) to expose a fresh surface for metallographic evaluation. Process the control specimen separately through the stripping cycle and metallographically examine for intergranular attach (IGA). No IGA is allowed on the ground surface.
(3)
If the control specimen from item B.(2). shows evidence of IGA, the stripping solution may be discarded. Prepare a new ASC 2-N strip solution per item B.(1). Qualify the solution per item B.(2).
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (a) Alternate procedure. If the control specimen from item B.(2). shows evidence of IGA, analyze the ASC 2-N acid solution as follows: NOTE: Only trained personnel should be used for analyzing stripping solution. NOTE: Results of the ASC 2-N acid analysis, batch number, date, time, and tank identification must be recorded and maintained for a period of two years. 1 Reagents required. a b c d e f 0.5 N NaOH. Approximately .02 N Th(NO3)44 H2O solution (2.76 grams Th(NO3)44 H2O per liter). Buffer solution (3.78 grams monochloroacetic acid in 60 ml. of distilled water plus 40 ml. of 0.5 N NaOH - mix well). Sodium Alizarin Sulfonate (S.A.S.) Indicator (one percent in distilled water). Nitric acid solution (two percent). Standard (two oz/gl ASC 2-N in water + eight percent by volume 408 or 428 Be Nitric acid). Use same concentration acid that was used in mix of original tank. Phenolphthalein Indicator Solution.
g 2
Determine the amount of HNO3 and ASC 2-N in the solution: a b Transfer one ml. of solution into a 250 ml. beaker. Dilute with 50 ml. of distilled water. Add a few drops of Phenolphtalein indicator. Titrate with .5N NaOH to a pink end point. The number of mls. of NaOH x 0.5="A" (See 2 e). Add one ml. excess of NaOH. Filter the solution thru a #41 Whatman filter into a 200 ml. volumetric flask. Vacuum filtration is recommended to reduce the filtration time. Wash the precipitate 3-4 times with distilled water and dilute to 200 ml. Mix well. Pipette 20 mls. of the above solution into a 250 ml. Erlenmeyer flask. Add ten drops of S.A.S. indicator. The solution should be pink. If not, adjust the pH by adding .5N NaOLH drop by drop until a faint paint color appears. Add two percent HNO3 solution drop by drop until the solution turns yellow. Add 2.5 mls. of monochloroacetic acid solution. Titrate immediately with Th(NO3)4 solution. Record the mls, Th(NO3)4 solution used.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A f Determine Th(NO3)4 Factor (F) as follows by following the same procedure used for analyzing the solution but using one ml. of the standard solution and performing the following calculation. F= oz/gal ASC 2-N used in the standard solution / mls. of Th(NO3)4 from the above analysis g h F x mls. Th(NO3)4 used = oz/gal ASC 2-N. Oz/gal ASC 2-N x .22 = B. NOTE: Use formula (i) if 408 Be acid is used. i Percent volume of 408Be HNO3 = (A-B) x 7.25. NOTE: Use formula in (j) if 428 Be acid is used. j 3 4 TASK 70-00-99-801-135 77. Solution S1135 SUBTASK 70-00-99-99G-082 A. Composition. No. C04-072 C04-093 Concentration (Initial Mix) 50% by volume 50% by volume Percent volume of 428 Be HNO3 acid = (A-B) x 6.67.
Compare the results of the analysis with the proportions identified in paragraph B.(3). Add ASC 2-N, nitric acid or water as necessary. Qualify the replenished solution per paragraph B.(2).
Consumable Product Nitric Acid Phosphoric Acid
SUBTASK 70-00-99-809-238 B. Preparation. WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND MAY CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH LARGE QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
(1)
Fill a locally-manufactured acid-resistant tank with a continuously mechanically agitated solution of 50 percent by volume commercial grade nitric acid C04-072 and 50 percent by volume commercial grade phosphoric acid C04-093.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (2) Maintain mixture at a uniform temperature of 1708F 108F (778C 58C) throughout the tank.
SUBTASK 70-00-99-809-239 C. Analysis. WARNING: NEVER ADD WATER TO ACIDS. ADD ACIDS TO WATER WHILE STIRRING VIGOROUSLY. LOCALIZED HEAT OF SOLUTION CAN CAUSE BOILING AND SPATTERING. WEAR CLOSE FITTING GOGGLES OR A FACE MASK, RUBBER OR NEOPRENE GLOVES, AND PROTECTIVE CLOTHING.
(1)
Analyze the 50/50 nitric/phosphoric acid solution as follows: NOTE: Ensure that persons performing the analysis are properly trained. NOTE: Record the results of the nitric/phosphoric acid analysis, batch number, time and tank identification. Maintain records for two years. (a) Place 50-75 ml of distilled water into a 100 ml volumetric flask and thoroughly mix in 5 ml of the stripping solution at room temperature. Refer to Subtask 70-00-99-809-238, Preparation. Fill flask to 100 ml total with distilled water. Place 20 ml of diluted solution into 250 ml beaker. Add 50 ml of distilled water and 5 drops of phenolphthalein indicator solution (10 grams per liter) (Reagent 117, ASTM E50). Titrate with sodium hydroxide (1.0 N) -(Reagent No. 16, ASTM E50) to pink end point. Record as volume A. Add 4 drops of methyl orange indicator solution (one gram per liter - Reagent No. 118, ASTM E50) to titrated solution; titrate again to pink end point, using sulfuric acid (1.0 N) - (Standardized with sodium hydroxide standard solution). Record as volume B. Calculate nitric acid percentage as follows: NOTE: If the nitric aid content is below 39 percent, replace the stripping solution with new. Before replacing with new solution, the tank must be flushed with water. 1 Percent HNO3 = 6.34 (A-2B). Where A = Volume of 1.0 N sodium hydroxide solution used in titration B = Volume of 1.0 N sulfuric acid solution used in titration
(b)
(c)
(d)
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-136 78. Solution S1136 SUBTASK 70-00-99-99G-083 A. Composition. No. C04-072 C04-093 Concentration (Initial Mix) See paragraph B. See paragraph B.
Consumable Product Nitric Acid Phosphoric Acid Crystalline Sodium Chloride (Food Grade Salt) SUBTASK 70-00-99-809-056 B. Preparation. WARNING:
ACID SOLUTIONS ARE VERY ACTIVE AND MAY CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH LARGE QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
(1)
Mix the solution in a locally manufactured acid resistant tank as follows: NOTE: Tank must be capable of maintaining solution at 1558 58F (688 38C). NOTE: The following procedure produces 50.6 gallons (191.5 liters) of solution. For other values of final volume adjust the composition proportionally. (a) (b) Place 100 lbs (45.4 kg) of crystalline sodium chloride (food grade salt) in the tank. Add 9.6 gal (36.3 l) of hot water at 1508 108F (668 68C). Mix until slushy. NOTE: Salt should not dissolve completely. (c) (d) (e) Add 41.0 gals (155.2 l) of a blend of 30 percent by volume phosphoric acid C04-093 and 70 percent by volume nitric acid C04-072. Stir solution with wood or plastic paddle to mix thoroughly. Heat to 1558 58F (688 38C).
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-240 C. Analysis. NOTE: Ensure that persons performing the analysis are properly trained. NOTE: Record the results of the AIO acid analysis, batch number, date, time, and tank identification. Maintain records for two years. (1) Transfer a five ml sample of the acid solution (see Subtask 70-00-99-809-056, Preparation.) to a 100 ml volumetric flask using a class A pipette. Dilute to the mark with distilled water. Close the flask with a stopper and shake to mix solution. Alternative procedure available. Determine acid content - METHOD 1. NOTE: This method assumes that the only acids present are HNO3 and H3PO4. If the actual HNO3 content is required, the NO3 present can be reduced with Devardas alloy in basic solution and the ammonia produced can then be distilled and titrated. (a) Transfer a 20 ml aliquot (by pipette) from the 100 ml volumetric flask to a 400 ml beaker. Dilute to approximately 175 ml with distilled water and insert a teflon covered magnetic stirring bar into the solution. Place the beaker on a magnetic stirrer and insert the electrodes of a previously calibrated pH meter. Position a 25 ml burette containing 1.0 Normal NaOH over the beaker and titrate slowly to pH 9.50-9.75. Record as volume A. Replace the burette with one containing 1.0 Normal H2SO4 and titrate the same solution to pH 4.50-4.75. Record as volume "B". Calculate percentages as follows: 1 2 (c) Volume percent HNO3 = 6.34 (A-2B) Volume percent H3PO4 = 6.75 X B
(2)
(b)
The HNO3 volume obtained ignores the presence of Cl- (Chloride Ion), and is based on HNO3 of specific gravity 1.42 and 70 percent by weight. The H3PO4 volume is based on H3PO4 of specific gravity 1.70 and 85.5 percent by weight. The following limit must be met. If not met, dump the tank and remix: 1 2 Volume percent Nitric Acid (HNO3): 34-55 Volume percent Phosphoric Acid (H3PO4): 20-30
(3)
Alternative procedure. Determine acid content - METHOD 2. (a) Transfer a 20 ml aliquot (by pipette) from the 100 ml volumetric flask to a 400 ml beaker. Dilute to approximately 175 ml with distilled water and insert a Teflon covered magnetic stirring bar into the solution. Place the beaker on a magnetic stirrer to continuously stir the solution during evaluation. Add five drops of phenolphthalein indicator solution (10 grams per liter) (Reagent 117, ASTM E50).
(b)
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STANDARD PRACTICES MANUAL AS907-1-1A (c) (d) Position a 25 ml burette containing 1.0 Normal NaOH over the beaker and titrate slowly to a pink end point. Record as volume A. Add 4 drops of methyl orange indicator solution (one gram per liter) (Reagent No. 118, ASTM E50) to titrated solution. Replace the burette with one containing 1.0 Normal H2SO4 - (Standardized with sodium hydroxide standard solution). Titrate to pink end point. Record as volume "B". Calculate percentages as follows: 1 2 (e) Volume percent HNO3 = 6.34 (A-2B) Volume percent H3PO4 = 6.75 X B
The HNO3 volume obtained ignores the presence of Cl- (Chloride Ion), and is based on HNO3 of specific gravity 1.42 and 70 percent by weight. The H3PO4 volume is based on H3PO4 of specific gravity 1.70 and 85.5 percent by weight. The following limit must be met. If not met, dump the tank and remix: 1 2 Volume percent Nitric Acid (HNO3): 34-55 Volume percent Phosphoric Acid (H3PO4): 20-30
(4)
Determine chloride level. (Required for initial set up.) (a) Reagents 1 2 3 0.1 N silver nitrate: dissolve 16.987 grams of reagent grade AgNO3 in distilled water and dilute to one liter in a volumetric flask. 0.1 N ammonium thiocyanate: dissolve approximately nine grams of NH4CNS in distilled water and dilute to one liter in a volumetric flask. Ferric indicator solution: prepare a saturated solution of ferric ammonium sulfate. Adjust enough nitric acid to bleach the brown color somewhat (to a dark yellow) and transfer to a bottle.
(b)
Determine the AgNO3 equivalent of the NH4CNS solution. 1 To a 250 ml conical flask, add 75 ml of distilled water, five ml of 1:1 HNO3 (428Be), one ml of ferric indicator, and three ml of nitrobenzene. Place the flask on a magnetic stirrer and insert a stirring bar in the solution. Set up two 25 ml burettes containing the AgNO3 and NH4CNS solutions, respectively. Add 15 to 20 ml of AgNO3 to the flask. While stirring, titrate with the NH4CNS solution to a permanent reddish end point. Calculate "E" as follows: a b E = ml AgNO3/ml NH4CNS AgNO3 equivalent = E
(c)
Sample Titration
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A 1 With a pipette, transfer a 20 ml aliquot from the 100 ml volumetric flask (See Step C.(1).) to a 240 ml conical flask. Add 75 ml distilled water, five ml of 1:1 HNO3, and 1 ml of ferric indicator. While stirring, add 0.1 N AgNO3 until no additional silver chloride appears to form. Allow the solution to continue stirring until the precipitate coagulates; turn off the stirrer and allow to settle. Test for completeness of precipitation by adding little more AgNO3 to see if any more silver chloride forms in the clear supernatant. Add two to five ml excess of AgNO3. Add three ml of nitrobenzene to the flask and stir vigorously for one minute. Titrate to a reddish-brown end point with the NH4CNS solution. Calculate the chloride ion (Cl-) content in grams per liter (g/l) as follows: a Cl- (g/l) = [(ml AgNO3) - (ml NH4CNSxE) x 0.003545 x 1000] NOTE: E - AgNO3 equivalent of the NH4CNS solution from Step C.(4)(b) 2 a. b If the chloride ion, Cl-, concentration is not between 26 to 31 grams/liter, dump the tank and remix.
TASK 70-00-99-801-137 79. Solution S1137 SUBTASK 70-00-99-99G-084 A. Composition. No. C04-071 C04-072 Concentration (Initial Mix) See below See below
Consumable Product Hydrochloric Acid 228Be (3136%) Nitric Acid 428Be (69-71%) SUBTASK 70-00-99-809-241 B. Preparation.
NOTE: A controlled specific gravity procedure is used to prepare each of the acid solutions prior to combining them into the final 15 percent hydrochloric/15 percent nitric/70 percent water solution. This procedure allows precise control of the final two-acid solution concentration so that laboratory analysis is not required.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A WARNING: WARNING: DO NOT POUR WATER INTO ACID. THE HEAT OF THE REACTION WILL CAUSE BOILING AND SPATTERING AND COULD BURN YOU. HYDROCHLORIC ACID C04-071 AND NITRIC ACID C04-072 ARE TOXIC. DO NOT LET THESE MATERIALS TOUCH YOU. USE PERSONAL PROTECTION EQUIPMENT. USE VAPOR/FUME CONTROL OR A RESPIRATOR.
(1)
Prepare hydrochloric acid solution as follows: (a) Fill supply tank A by adding hydrochloric acid (228 Baume) C04-071 to room temperature water at the ratio of 13 gallons (49.2 liters) of acid to 30 gallons of (113.5 liters) of water. Mix thoroughly and measure the temperature and specific gravity of solution A. Add water or hydrochloric acid as required to obtain a specific gravity equivalent to 1.052 0.002 at 608F (15.68C). See Step B.(1)(d) for equivalent specific gravity versus measured solution temperature value. NOTE: Measure specific gravity with a hydrometer having 0.002 specific gravity sub-divisions. (d) The following table lists hydrochloric acid specific gravity versus measured solution temperature: Required Specific Gravity ( 0.002) 1.054 1.053 1.052 1.051 1.050 1.049 1.048 1.047 1.046
(b) (c)
Temperature 8F (8C) 50 (10.0) 55 (12.8) 60 (15.6) 65 (18.3) 70 (21.1) 75 (23.9) 80 (26.7) 85 (29.4) 90 (32.2) (2)
Prepare nitric acid solution as follows: (a) Fill supply tank "B" by adding nitric acid (428 Baume) C04-072 to room temperature water at the ratio of 13 gallons (49.2 liters) of acid to 30 gallons (113.5 liters) of water. Mix thoroughly and measure the temperature and specific gravity of solution "B".
(b)
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STANDARD PRACTICES MANUAL AS907-1-1A (c) Add water or nitric acid as required to obtain a specific gravity equivalent to 1.150 0.002 at 608F (15.68C). See paragraph 2.B.(4) for equivalent specific gravity versus measured solution temperature values. NOTE: Measure specific gravity with a hydrometer having 0.002 specific gravity sub-divisions. (d) The following table lists nitric acid specific gravity versus measured solution temperature: Required Specific Gravity ( 0.002) 1.153 1.152 1.150 1.148 1.147 1.146 1.144 1.143 1.141 (3) Prepare stripping solution as follows: (a) Fill stripping tank using carefully measured equal volumes of solution A and solution "B". Mix thoroughly. NOTE: Do not attempt to measure or control the specific gravity of the combined stripping solution. NOTE: The combined stripping solution has a relatively long tank life. Open tanks should be covered to minimize evaporation and contamination with debris. SUBTASK 70-00-99-809-242 C. Regeneration. (1) Discard stripping solution when it is no longer effective. NOTE: Dispose of exhausted stripping solutions following procedures for toxic wastes.
Temperature of (8C) 50 (10.0) 55 (12.8) 60 (15.6) 65 (18.3) 70 (21.1) 75 (23.9) 80 (26.7) 85 (29.4) 90 (32.2)
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-138 80. Solution S1138 SUBTASK 70-00-99-99G-085 A. Composition. No. C04-156 C04-156 C04-156 Concentration (Initial Mix) 50% by volume 20% by volume 5% by volume 25% by volume
Consumable Product Enstrip GT-317A Enstrip GT-317B Enstrip GT-317C Water SUBTASK 70-00-99-809-243 B. Equipment.
CAUTION: DO NOT ATTEMPT TO REPLENISH ACID CONTENT. (1) Tank. Tanks constructed of polyethylene, polypropylene or polyvinyl chloride with a minimum wall thickness of 0.25 inch (6.4 mm) are suitable for Enstrip GT-317 solutions. Heating/Cooling. A DuPont Teflon supercoil or Lufran Teflon exchanger is recommended. Agitator. A Lightening mixer fitted with a plastisol-coated propeller and shaft or equivalent is recommended. Ventilation. Exhaust ventilation is recommended to remove fumes and vapors that may be generated during make-up and operation.
(2) (3) (4)
SUBTASK 70-00-99-809-244 C. Preparation. (1) Prepare Enstrip GT-317 solution in a suitable tank constructed of polyethylene, polypropylene, or polyvinyl chloride as follows: NOTE: Enstrip GT-317A, B, and C are available from Enthone Corporation, P.O. Box 1900, New Haven, CT, 06508.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A WARNING: ENSTRIP GT-317A AND GT-317C ARE ACIDIC. ENSTRIP GT-317B CONTAINS HYDROGEN PEROXIDE WHICH IS A STRONG OXIDIZING AGENT AN IS VERY CORROSIVE. WEAR FACE SHIELD, RUBBER GLOVES, PROTECTIVE SHOES AND PROTECTIVE CLOTHING WHEN PREPARING AND USING THE STRIPPING SOLUTION. IN CASE OF CONTACT WITH SKIN OR EYES FLUSH WITH LARGE AMOUNTS OF COOL, CLEAN WATER AND GET IMMEDIATE MEDICAL ATTENTION. STORE ENSTRIP GT-317B IN A COOL, DRY PLACE AWAY FROM HEAT, SPARKS OR OPEN FLAMES. KEEP ENSTRIP GT-317B AWAY FROM COMBUSTIBLE MATERIALS SUCH AS WOOD, SAWDUST, PAPER AND CLOTH. ALSO KEEP AWAY FROM CHEMICAL REDUCING AGENTS AND ORGANIC MATERIALS.
(2) (3) (4) (5)
Fill tank with a measured volume of tap water equal to 25 percent of the total volume of prepared solution required. Add Enstrip GT-317A equal to 50 percent of the total volume of prepared solution required. Add Enstrip GT-317B equal to 20 percent of the total volume of solution required. Add Enstrip GT-317C equal to 5 percent of the total volume of solution required.
SUBTASK 70-00-99-809-245 D. Analysis and Regeneration. (1) (2) (3) (4) (5) Analyze and regenerate Enstrip GT-317 solution as follows: Pipette a 5 milliliter (ml) sample of the working solution into a 150 ml Erlenmeyer flask. Add approximately 50 ml of deionized water and several drops of phenolphthalein solution. Titrate contents of flask with 1.000 Normal sodium hydroxide (NaOH) solution to a faint pink end point. Calculate the working solution percent activity (Cs) as shown below. The acceptable limits of Cs are 70-100 percent with 90 percent being preferred. Cs = ml NaOH solution x normality of NaOH solution x 7 (6) Calculate the volume of GT-317A to be added to the working solution as follows: V = Vt (90.0-Cs) / 94.5 Where V = volume (gallons) of GT-317A Vt = volume (gallons) of working solution in tank Cs = percent activity calculated in paragraph D.(4). (7) Pipette a 10 ml sample of the working solution into a 100 ml volumetric flask and dilute to 100 ml with deionized water.
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STANDARD PRACTICES MANUAL AS907-1-1A (8) (9) Pipette a 5 ml sample of the diluted working solution into a 150 ml Erlenmeyer flask. Add 5-10 ml of 4.0 Normal sulfuric acid (H2SO4) solution to the Erlenmeyer flask.
(10) Add approximately 1 gram of potassium iodine (KI) crystals and 2-3 drops of 3 percent ammonium molybdate [(NH4)6 Mo7O244H2] solution to the flask and swirl to promote iodide dissolution. (11) Titrate the iodide formed, using a 1 percent starch solution indicator, with a 0.100 Normal sodium thiosulfate (Na2S2O35H2O) solution. The end point is observed as a change from blue-black to colorless. (12) Calculate the working solution GT-317B volume percent (Ds) as shown below. The acceptable limits of Ds are 15-30 percent with 20-25 percent being preferred. Ds = ml Na2S2O3 solution X Normality Na2S2O3 solution X 5.7 (13) Calculate the volume of GT-317B to be added to the working solution as follows: V = Vt (20.0 - Ds) / 80 Where V = volume (gallons) of GT-317B to be added Vt = volume (gallons) of working solution in tank Ds = volume percent calculated in paragraph D.(11). TASK 70-00-99-801-139 81. Solution S1139 SUBTASK 70-00-99-99G-086 A. Composition. No. C04-049 C04-049 Concentration (Initial Mix) 16 oz/US gal (120 g/l) 13% by volume
Consumable Product Cee-Bee J84A Cee-Bee J84AL
EFFECTIVITY: ALL
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WARNING: (1)
Alternative procedure available. If using Cee-Bee J84AL, do these steps: (a) (b) (c) (d) Fill the tank with water to 80% of the working level. Add the Cee-Bee J84AL slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix.
(2)
Alternative procedure. If using Cee-Bee J84A, do these steps: (a) (b) (c) (d) Fill the tank with water to two-thirds of the working level. Add the Cee-Bee J84A slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-247 C. Check. (1) Checks Cee-Bee J84A Cee-Bee J84AL (2) Determine the concentration of Cee-Bee J84A or Cee-Bee J84AL. Limits 90-120 g/l 8-13% by volume Recommended Interval Monthly Monthly
SUBTASK 70-00-99-809-248 D. Regeneration. (1) Every day remove surface scum from tank.
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STANDARD PRACTICES MANUAL AS907-1-1A (2) (3) (4) Maintain solution within check limits by the addition of appropriate products per the manufacturers requirements. Losses through evaporation will be made up by filling the tank to working level with water. Replace the solution if it loses its effectiveness.
Consumable Product Ardrox 185 Ardrox 185L SUBTASK 70-00-99-809-250 B. Preparation. WARNING:
WARNING: (1)
Alternative procedure available. If using Ardrox 185L, do these steps: (a) (b) (c) (d) Fill the tank with water to 75% of the working level. Add the Ardrox 185L slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix.
(2)
Alternative procedure. If using Ardrox 185, do these steps: (a) (b) (c) (d) Fill the tank with water to two-thirds of the working level. Add the Ardrox 185 slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-251 C. Check. (1) Checks Ardrox 185 Ardrox 185L (2) Determine the concentration of the Ardrox 185 or Arcrox 185L. Limits 60-90 g/l 10-15% by volume Recommended Interval Monthly Monthly
SUBTASK 70-00-99-809-252 D. Regeneration. (1) (2) (3) (4) Every day remove surface scum from tank. Maintain solution within check limits by the addition of appropriate products per the manufacturers requirements. Losses through evaporation will be made up by filling the tank with water up to working level. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-141 83. Solution S1141 SUBTASK 70-00-99-99G-088 A. Composition. No. C04-163 C04-163 Concentration (Initial Mix) 20 %V/V 20 %V/V
Consumable Product Ardrox 6333 Ardrox 6333L
EFFECTIVITY: ALL
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(1) (2) (3) (4)
Ready for use (full strength). Add Ardrox 6333 or Ardrox 6333L product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-254 C. Check. (1) Checks Ardrox 6333 Ardrox 6333L (2) Do a check of the solution in accordance with the manufacturers instructions: Limits 15-20 %V/V 15-20 %V/V Recommended Interval Weekly Weekly
SUBTASK 70-00-99-809-255 D. Regeneration. (1) (2) (3) Remove scum layer from top of tank at least every day, preferable every shift, and also as needed. Maintain solution strength within check limits. Increase strength (if necessary) by adding concentrate as required. Decrease strength by diluting with water. Recover evaporation losses by filling tank to "working level" with water on daily basis.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-142 84. Solution S1142 SUBTASK 70-00-99-99G-089 A. Composition. No. C04-152 Concentration (Initial Mix) 20 %V/V
Consumable Product Turco 5948R SUBTASK 70-00-99-809-256 B. Preparation. WARNING:
(1) (2) (3) (4)
Fill tank two-thirds full with water. Add Turco 5948R product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-257 C. Check. (1) Checks Turco 5948R (2) Do a check of the solution in accordance with the manufacturers instructions. Limits 15-20 %V/V Recommended Interval Weekly
Determination of the T5948R Quantity. Use process materials and procedures as recommended by Turco products.
SUBTASK 70-00-99-809-258 D. Regeneration. (1) Remove scum layer from top of tank at least every day, preferable every shift, and also as needed.
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STANDARD PRACTICES MANUAL AS907-1-1A (2) Maintain solution strength within check limits. Increase strength (if necessary) by adding concentrate as required per calculated amount from analysis procedure. Decrease strength by diluting with water. Recover evaporation losses by filling tank to "working level" with water on daily basis.
(3)
TASK 70-00-99-801-143 85. Solution S1143 SUBTASK 70-00-99-99G-090 A. Composition. No. C04-164 Concentration (Initial Mix) 10 %V/V
Consumable Product Blue-Gold Industrial Cleaner SUBTASK 70-00-99-809-259 B. Preparation. WARNING:
ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
(1) (2) (3) (4)
Fill tank two-thirds full with water. Add alkaline cleaner C04-164 product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-260 C. Check. (1) Checks Blue-Gold Industrial Cleaner (2) Determine the concentration of the solution as follows: Limits 5-10 %V/V Recommended Interval Weekly
Follow the manufacturers control procedures to maintain the solution within check limits.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-261 D. Regeneration. (1) (2) (3) (4) Every day, remove surface scum from the tank. Maintain solution within check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank with water up to working level on a daily bases. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-144 86. Solution S1144 SUBTASK 70-00-99-99G-091 A. Composition. No. C04-165 Concentration (Initial Mix) 20 %V/V
Consumable Product Cee-Bee A7X7 SUBTASK 70-00-99-809-262 B. Preparation. WARNING:
(1) (2) (3) (4)
Fill tank two-thirds full with water. Add Cee-Bee A7X7 product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
EFFECTIVITY: ALL
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Checks Cee-Bee A7X7 (2)
Limits 15-25 %V/V
Determination of the Cee-Bee A7X7 Quantity. Use process materials and procedures as recommended by McGean Rohco, Inc.
SUBTASK 70-00-99-809-264 D. Regeneration. (1) (2) Remove scum layer from top of tank at least every day, preferably every shift, and also as needed. Maintain solution strength within check limits. Increase strength (if necessary) by adding concentrate as required per calculated amount from analysis procedure. Decrease strength by diluting with water. Recover evaporation losses by filling tank to "working level" with water on daily basis.
(3)
TASK 70-00-99-801-145 87. Solution S1145 SUBTASK 70-00-99-99G-092 A. Composition. No. C04-168 C04-168 Concentration (Initial Mix) 2.5% to 10% V/V 10 %V/V
Consumable Product Daraclean 282 Daraclean 282GF SUBTASK 70-00-99-809-265 B. Preparation. WARNING:
(1) (2)
Fill tank two-thirds full with water. Add the Daraclean product slowly and carefully while stirring the solution to mix.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (3) (4) Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-266 C. Check. (1) Checks Daraclean 282 Daraclean 282GF (2) Make operational check per the following: Limits 8-12 %V/V 2-12 %V/V Recommended Interval Weekly or sooner as needed Weekly or sooner as needed
TASK 70-00-99-801-146 88. Solution S1146 SUBTASK 70-00-99-99G-093 A. Composition. No. C04-015 C04-139 Concentration (Initial Mix) 0.64 ounces/gallon water 0.44 pounds/gallon water
Consumable Product Wetting Agent, Versene 220 SUBTASK 70-00-99-809-269 B. Preparation. WARNING:
VERSENE 220 (TETRASODIUM SALT OF ETHYLENEDIAMINE TETRACETIC ACID) IS RATED AS A LIGHTLY TOXIC CHEMICAL. AVOID REPEATED OR PROLONGED CONTACT WITH THE SKIN AND USE WITH ADEQUATE VENTILATION. THE SOLUTION IS SLIGHTLY ALKALINE WITH PH OF APPROXIMATELY 10.
(1) (2)
Mix Wetting Agent and Versene material into water per the above concentration to fill tank. Heat solution to 1308F-1508F (548C-668C) with agitation until Versene is completely dissolved.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-270 C. Checks. (1) (2) (3) This is a reprint of the Dow Chemical Company procedure, Method 90692B. Perform quality control of Versene 220 solution (if required) as follows: Spread several grams of Versene 220 crystals chelating agent on a sheet of white paper and visually examine for white color and crystalline form. Weigh to the nearest milligram, 2.5-3.0 g of ultrapure EDTA into a 200 ml beaker. Add 80 ml of water and sufficient 50 percent NaOH to raise the pH to 11-12. Add 20 ml of 3 percent ammonium oxalate solution and titrate with the calcium chloride solution until the first permanent turbidity is noted. The pH at this endpoint must be 11 or higher. If the pH is below 11, add enough 50 percent NaOH to bring the pH above 11. If the turbidity disappears, continue the titration with calcium chloride to the first permanent turbidity. Calculate the concentration of the standardized calcium chloride. Weigh to the nearest milligram, about 8 g of Versene 220 crystals chelating agent into a clean 200 ml beaker. Add 80 ml of deionized water and 20 ml of 3 percent ammonium oxalate solution. Adjust the pH of the solution to 11-12 with 50 percent sodium hydroxide. Place the beaker on a magnetic stirrer which has a black top or cover. Locate a light source so that the beaker is illuminated from behind. Titrate the sample with standard calcium chloride to the first faint permanent turbidity. Check with pH paper after the end point has been reached. (a) If the pH is below 11, use the 50 percent sodium hydroxide to raise the pH above 11. After the pH has been adjusted, complete the titration. Perform the titration slowly, especially when nearing the end point.
(4)
(5)
(6) (7) (8) (9)
Calculate the concentration of the standard calcium chloride solution as follow: A = (B x 3.422)/C where A = molar concentration of the calcium chloride solution B = weight of the EDTA sample, in grams
(10) C = volume of calcium chloride titrant, in ml (11) Calculate the chelation value as follows: (12) D = (E x A x 100)/F (13) where D = chelation value, mg CaCO3 per gram of chelating agent (14) E = volume of titrant required for the sample, ml (15) F = Weight of the sample, in grams (16) Calculate the active ingredient content as follows:
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (17) G = (E x A x 45.2)/F (18) where G = percent active ingredient (as Ha4EDTA4H2O) (19) E = volume of titrant required for the sample, in ml (20) F = weight of the sample, in grams (21) The data obtained by this procedure indicate a relative standard deviation of 0.16 percent. The values obtained may be expected to vary from the average by not more than 0.32 percent relative at the 95 percent confidence level. (22) The color of Versene 220 crystals chelating agent is measured by colorimetric comparison of a 30 percent solution of the product in water with appropriate APHA standards. NOTE: The colorimeter must be capable of measurement at approximately 450 nm, equipped with a 2 or 4 cm solution cell. (a) (b) (c) Zero the colorimeter with distilled water. Use the No. 42 blue filter and the 4 cm solution cell. Prepare a standard curve by plotting the observed Klett reading vs APHA color. Measure the Klett reading for a 30 percent solution of Versene 220 crystals chelating agent. Use the standard curve to determine the APHA color of the sample.
(23) Obtain pH meter reading. NOTE: The pH meter must be equipped with glass and reference electrodes. (a) (b) Prepare a one percent solution (by weight) of Versene 220 Crystals chelating agent in water. Adjust the temperature of the solution to 258C. Follow the manufacturers instructions for operation and calibration of the pH meter. Refer to ASTM Designation E 70-77 for further useful information on such measurements. Report the pH meter reading obtained for the solution of the sample as the pH of the sample.
(c)
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-147 89. Solution S1147 SUBTASK 70-00-99-99G-094 A. Composition. No. C04-171 Concentration (Initial Mix) Ambient
Consumable Product Degreasol 99R SUBTASK 70-00-99-809-271 B. Preparation. WARNING:
SOLVENT IS TOXIC. AVOID INHALATION OF VAPORS. AVOID PROLONGED CONTACT WITH EYES, SKIN, OR CLOTHING. OPERATOR SHOULD USE ONLY IN WELL VENTILATED AREA. SOLVENT IS FLAMMABLE. TAKE PRECAUTIONS AGAINST FIRE.
WARNING: (1)
SUBTASK 70-00-99-809-272 C. Check. NOTE: If this tank is to be used for the SPM TASK 70-22-09-110-049, Special Cleaning Procedure No. 9 Fluorescent Penetrant Removal Between Special Repetitive Fluorescent Penetrant Inspections, ensure that tank controls are sufficient for the high degree of cleanliness required for this particular operation. It is advisable that operations with heavy soils or oils use a different tank than the one used for TASK 70-22-09-110-049, Special Cleaning Procedure No. 9 Fluorescent Penetrant Removal Between Special Repetitive Fluorescent Penetrant Inspections. NOTE: Limit for oil in solution is to be used as a guideline and should be modified by the shop to a new limit if the particular oils used in the shop require a lower limit for satisfactory performance. Checks Turbidity Oil in solution (1) Limits Set up by shop 10 percent Recommended Interval Weekly Weekly
Determination of Oil Quantity in Solution (alternate method available). (a) Test sample.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A 1 Make as standard test sample by adding 10 percent oil, by volume, to a quantity of solvent. NOTE: The oil used to make the test sample should be the same type of oil that is used on parts which are cleaned by the solution. (b) Procedure. 1 2 (2) Visually compare the color of a sample of the working solution with the standard test sample. When color of solution becomes darker then test sample, the solution has exceeded allowable oil quantity.
Determination of oil quantity in solution (alternate method). (a) (b) Oil quantity in sample may be measured by means of specific gravity change using a hydrometer. Test sample. 1 Make standard test samples of the contaminated solution by adding oils that are cleaned from the part with the solution. These may include EDM, cutting, tapping, antiseize, or penetrant oils. These samples should then be checked for specific gravity value. Also take hydrometer reading of uncontaminated cleaning fluid. Make a graph showing the specific gravity value versus the percent oil contamination. Establish a limit of oil concentration based on the representative oils that are contamination in the cleaning fluid and the observations of the cleaning tank and its effectiveness. When the tank no longer provides clean parts, determine the oil concentration at that point and use it for the endpoint in process control.
2 3
SUBTASK 70-00-99-809-273 D. Regeneration. (1) (2) (3) Replace solution when the soluble oil quantity exceeds the allowable limit. Non-soluble oil should be filtered or skimmed from the tank when the allowable oil limit is exceeded. Particulate contamination should be filtered from the tank when the amount of particulate matter impairs the cleaning effectiveness of the solution.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-148 90. Solution S1148 SUBTASK 70-00-99-99G-095 A. Composition. No. C04-172 Concentration (Initial Mix) 20 %V/V
Consumable Product Jettacin SUBTASK 70-00-99-809-274 B. Preparation. WARNING:
(1) (2) (3) (4)
Fill tank two-thirds full with water. Add Jettacin product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-275 C. Check. (1) Checks Jettacin (2) Do a check of the solution in accordance with the manufacturers instructions. Limits 15-20 %V/V Recommended Interval Weekly
SUBTASK 70-00-99-809-276 D. Regeneration. (1) Remove scum layer from top of tank at least every day, preferable every shift, and also as needed.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (2) Maintain solution strength within check limits. Increase strength (if necessary) by adding concentrate as required per calculated amount from analysis procedure. Decrease strength by diluting with water. Recover evaporation losses by filling tank to "working level" with water on daily basis. Remove non soluble oils and particulates by filtration. When soluble oils contamination reaches limit for effective bath operation, dump and replace solution.
(3) (4) (5)
TASK 70-00-99-801-150 91. Solution S1150 SUBTASK 70-00-99-99G-096 A. Composition. No. C04-169 Concentration (Initial Mix) Use full strength as supplied
Consumable Product Diammonium Versene SUBTASK 70-00-99-809-280 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill the tank half-full with water. Add the MagChem HDL-202 product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
EFFECTIVITY: ALL
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Checks MagChem HDL-202 (2)
Limits 30-40% V/V
Consumable Product MagChem HDL-202 SUBTASK 70-00-99-809-277 B. Preparation. WARNING:
(1) (2)
Add Diammonium Versene liquid into working tank to level necessary for processing parts. Heat solution to working temperature of 170-1908F (77-888C).
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-278 C. Checks. (1) Analysis on chemistry of the Diammonium Versene bath is optional and is not required per the procedure. If the analysis is desired, the following is a reprint of the Dow Chemical Company procedure, Method No. 90602A and QA No. 1837. NOTE: This method is applicable to the analysis of Versene Diammonium EDTA chelating agent in the range of 10-50 percent EDTA. (2) Weigh, to the nearest milligram, about 8 g Versene Diammonium EDTA chelating agent into a clean 200 ml beaker. Add 80 ml of distilled water and 20 ml 3 percent ammonium oxalate solution. Adjust the pH to 11-12 with 50 percent sodium hydroxide. Place the beaker on a magnetic stirrer which has a black top. Place a light to shine down on the beaker from behind. Titrate the sample with the standard calcium chloride to the first faint turbidity. Check with pH paper after the end point has been reached. (a) If the pH is below 11, use the 50 percent sodium hydroxide to raise the pH above 11. After the pH has been adjusted, complete the titration. NOTE: It is important that the titration be performed slowly, especially when nearing the end point. (4) Calculate as follows: ml x M x 100 divided by grams of sample = mg CaCO3 per gram of Versene Diammonium EDTA Chelating Agent where ml = ml of CaCl2 solution M = molarity of CaCl2 (5) Obtain pH meter reading. NOTE: The pH meter must be equipped with glass and reference electrodes. (a) (b) Adjust the temperature of the solution to 258C. Follow the manufacturers instructions for operation and calibration of the pH meter. Refer to ASTM Designation E 70-77 for further useful information on such measurements. Report the pH meter reading obtained for the solution of the sample as the pH of the sample.
(3)
(c) (6)
Specific Gravity. The specific gravity in air is determined by a means of a hydrometer at 258C.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (a) The apparatus as given for Method B of ASTM Designation D 891 is used with modifications. The water bath is set at 258C. A hydrometer with a range of 1.00-1.22 is used. NOTE: Methods A or C of ASTM Designation D 891 are acceptable alternates. (7) Calculate the active ingredients as follows: NOTE: The percent active ingredients is calculated as ethylenediaminetetraacetic acid (EDTA) from the titration performed for chelation value. NOTE: ml x M x 29.22 NOTE: grams of sample NOTE: where NOTE: ml = ml of CaCl2 solution NOTE: M = molarity of CaCl2 (8) The data obtained by this procedure for chelation value and active ingredients indicates a relative standard deviation of 0.1 percent. The values obtained may be expected to vary from the average by not more than 0.2 percent relative at the 95 percent confidence level.
SUBTASK 70-00-99-809-279 D. Regeneration. (1) (2) If the working solution level goes low due to excess evaporation, add Diammonium Versene liquid into the tank to restore working level. If the pH of the working bath goes below 5.0, the pH may be raised by adding water and small amounts of Ammonium Hydroxide (NH4OH). Add small increments until a pH above 5.0 is reached. Practice reveals that the working solution will become very dirty long before the chelation value of the tank requires the solution to be changed. It is recommended that the solution be filtered through a suitable filter (example, spun element in the size range of 5 to 20 micron) to remove the bulk of particulate contaminate if it is observed that the solution effectiveness is decreasing. If the solution is determined not to be effective, as indicated by repetitive cleaning cycles with poor and in sufficient cleaning, the bath may be decanted by half and regenerated by adding fresh Diammonium Versene or by dumping the entire tank and starting with a tank of fresh solution. The solution life will depend of the number of pieces cleaned and the amount of "dirt" on the individual pieces. The solution life is not hard timed and should be tied to the cleaning effectiveness. Take steps to replace the bath only when it is determined that the solution in the tank is no longer effective.
(3)
(4)
(5)
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-151 93. Solution S1151 SUBTASK 70-00-99-99G-098 A. Composition. No. C04-182 Concentration (Initial Mix) 18% V/V
Consumable Product MagChem HDL-202 SUBTASK 70-00-99-809-283 B. Preparation. WARNING:
ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING OF VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4)
Fill the tank half-full with water. Add the MagChem HDL-202 product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-284 C. Check. (1) Checks MagChem HDL-202 (2) Do a check of the solution in accordance with the manufacturers instructions. Limits 12-18% V/V Recommended Interval Monthly
SUBTASK 70-00-99-809-285 D. Regeneration. (1) Each day remove surface scum from tank.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) (3) (4) Add applicable materials to keep the solution within the check limits. Each day, fill the tank with water to the working level. Replace the solution if it loses its effectiveness or is contaminated.
WARNING: (1) (2) (3) (4)
Fill the tank with the cold water to 50 percent of its operating volume. Add MagChem AP-988 product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-287 C. Check. (1) Checks MagChem AP-988 Stock loss test per ARP 1755 B on AMS 5504 panel Do a check of the solution in accordance with the manufacturers instructions. Limits 15-20% V/V 0.05 mil (1.25 micrometers) total Recommended Interval Bi-monthly Weekly
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) Follow the manufacturers control procedures to maintain the solution within check limits.
Consumable Product MagChem DG-Kleen SUBTASK 70-00-99-809-289 B. Preparation. WARNING:
ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4)
Fill the tank to two-thirds of its working level with water. Add MagChem DG-Kleen product slowly and carefully while stirring the mix. Fill the tank with water to working level. Stir solution again to mix.
EFFECTIVITY: ALL
70-00-99
Checks MagChem DG-Kleen (2)
Limits 5-10% V/V
TASK 70-00-99-801-155 96. Solution S1155 SUBTASK 70-00-99-99G-101 A. Composition. No. C04-185 C04-185 C04-185 C04-185 Concentration (Initial Mix) Full strength To maintain oil seal thickness. To maintain solvent content. To maintain solution alkalinity.
Consumable Product MagChem Kemstrip-596 MagChem OIS-96 MagChem S-96 MagChem A-96 SUBTASK 70-00-99-809-292 B. Preparation. WARNING:
ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1)
Slowly and carefully fill tank to its operating level with MagChem Kemstrip-596.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) Withdraw a sample of the solution for initial analysis. NOTE: See Subtask 70-00-99-809-293, Check. (3) Heat to the operating temperature specified by the stripping process.
SUBTASK 70-00-99-809-293 C. Check. (1) (2) Determine the concentration of the solution as follows: Using the sample of the solution for initial analysis from 2.B. (a) Follow the manufacturers control procedures to determine and record the following: 1 2 Checks Solvent content Alkaline base content Water content per ASTM E203 Oil seal height Initial solvent content. Initial alkaline base content. Limits Within 5% of initial content 23-30% 4% maximum 5-7 inches (127-178 mm) Recommended Interval Weekly or more often depending on usage Weekly Every two months* Weekly
NOTE: * Only if corrosion sensitive alloys are processed in this product.
(3)
SUBTASK 70-00-99-809-294 D. Regeneration. (1) (2) Every day, remove surface contamination from the tank. Maintain solution within check limits by the addition of appropriate products. (a) (b) (c) (3) Maintain alkaline base content by addition of MagChem A-96. Maintain oil seal height by addition of MagChem OIS-96. Maintain solvent content by addition of MagChem S-96.
Replace the solution if it loses its effectiveness or is contaminated.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-156 97. Solution S1156 SUBTASK 70-00-99-99G-102 A. Composition. No. C02-072 Concentration (Initial Mix) 1.5% V/V
Consumable Product MagChem Corrotek SUBTASK 70-00-99-809-295 B. Preparation. WARNING:
AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3)
Fill the tank to 98.5 percent of its operating level with water. Add the MagChem Corrotek product. Mix by mechanical or air agitation for five minutes maximum.
CAUTION: DO NOT USE AIR AGITATION FOR MORE THAN FIVE MINUTES BEFORE USE. (4) This solution can be made up in a spray container for local application. Be sure to shake the container before you apply the solution.
SUBTASK 70-00-99-809-296 C. Check. (1) Checks MagChem Corrotek (2) Do a check of the solution in accordance with the manufacturers instructions. Limits 1-2% V/V Recommended Interval Monthly
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-297 D. Regeneration. (1) (2) Replace the solution when there is contamination of the solution or once a month. If the solution is premixed in a sprayer, the monthly disposal does not apply.
WARNING: (1) (2) (3) (4) (5)
Fill the tank one-quarter full with water. Heat to approximately 858F (308C). Add the acid descaler cleaner C04-189 slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix.
EFFECTIVITY: ALL
70-00-99
Checks MagChem AP-9186 (2)
Limits 75-120 g/l
SUBTASK 70-00-99-809-300 D. Regeneration. (1) (2) (3) (4) Each day, remove the surface scum from the tank. Add applicable materials to keep the solution within the check limits. Each day, fill the tank with water to the working level. Replace the solution if it loses its effectiveness or is contaminated.
Consumable Product MagChem Soluwax SUBTASK 70-00-99-809-301 B. Preparation. WARNING:
WARNING: (1) (2) (3)
Fill the tank two-thirds of its working level with water. Add MagChem Soluwax product slowly and carefully while stirring to mix. Fill tank with water to working level.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (4) Stir solution again to mix.
SUBTASK 70-00-99-809-302 C. Check. (1) Checks MagChem Soluwax (2) Determine the concentration of the MagChem Soluwax: Limits 5-10% V/V Recommended Interval Weekly
SUBTASK 70-00-99-809-303 D. Regeneration. (1) (2) (3) (4) Every day, remove surface scum from the tank. Maintain solution within check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank with water up to working level on a daily basis. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-159 100. Solution S1159 SUBTASK 70-00-99-99G-105 A. Composition. No. C04-195 Concentration (Initial Mix) 25 percent by volume (250 ml/l)
Consumable Product Turco Scale Gon 5 SUBTASK 70-00-99-809-304 B. Preparation. WARNING:
ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID BREATHING VAPORS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
WARNING: (1)
Fill the tank to 50 percent of working volume with cold water.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) (3) (4) Add the Turco Scale Gon 5 product slowly and carefully while stirring the solution to dissolve the product. Fill up the tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-305 C. Check. (1) Checks Turco Scale Gon 5 Quantity Stock loss test per ARP 1755 on AMS 5504 panel (2) Determination of the Turco Scale Gon 5 Quantity: Limits 200-300 ml/l 0.05 mils (1.25 micrometers) total Recommended Interval Biweekly Weekly
TASK 70-00-99-801-160 101. Solution S1160 SUBTASK 70-00-99-99G-106 A. Composition. No. C04-194 C04-194 C04-194 Concentration (Initial Mix) Full strength To maintain solution alkalinity To maintain oil seal thickness
Consumable Product Cee-Bee A-477 Cee-Bee A-477 Additive A Cee-Bee A-477 Additive O
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-306 B. Preparation. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2)
Slowly and carefully fill a clean, dry tank to its operating level with well-mixed CeeBee A-477. Allow the oil seal to form before heating the solution.
SUBTASK 70-00-99-809-307 C. Check. (1) Checks Oil Seal Thickness Cee-Bee A-477 Additive A Determine the concentration of the solution as follows: Limits 6-8 inches (152-203 mm) Maintain per manufacturers control procedures Recommended Interval Biweekly Weekly
(2)
SUBTASK 70-00-99-809-330 D. Regeneration. (1) (2) Every day, remove surface contamination from the tank. Maintain solution within check limits as follows: (a) (b) (3) Alkaline base content by addition of Cee-Bee A-477 Additive A: per manufacturers directions. Maintain oil seal height by addition of CeeBee Additive O.
Replace the solution if it loses its effectiveness or is contaminated.
EFFECTIVITY: ALL
70-00-99
Consumable Product Eldorado HTP-1150 SUBTASK 70-00-99-809-308 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill tank two-thirds full with water. Add Eldorado HTP-1150 product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-309 C. Check. (1) Checks Eldorado HTP-1150 (2) Determine the concentration of the solution as follows: Limits 240-360 g/l Recommended Interval Monthly
EFFECTIVITY: ALL
70-00-99
TASK 70-00-99-801-162 103. Solution S1162 SUBTASK 70-00-99-99G-108 A. Composition. No. C04-213 Concentration (Initial Mix) 50% by Volume
Consumable Product Eldorado HTP-1150L SUBTASK 70-00-99-809-310 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill tank to 50% of working level with water. Add Eldorado HTP-1150L product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-311 C. Check. (1) Checks Eldorado HTP-1150L (2) Determine the concentration of the solution as follows: Limits 2-3 lb/gal (240-360 g/l) Recommended Interval Monthly
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-381 D. Regeneration. (1) (2) (3) (4) Each day remove surface scum from tank. Add applicable materials to keep the solution within the check limits. Each day, fill the tank with water to the working level. Replace the solution if it loses its effectiveness or is contaminated.
Consumable Product Eldorado HTP-1190 SUBTASK 70-00-99-809-312 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill the tank two-thirds full with water. Add Eldorado HTP-1190 product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-313 C. Check. (1) Determine the concentration of the solution as follows:
EFFECTIVITY: ALL
70-00-99
Checks Eldorado HTP-1190 (2)
Limits 240-360 g/l
TASK 70-00-99-801-164 105. Solution S1164 SUBTASK 70-00-99-99G-110 A. Composition. No. C04-215 Concentration (Initial Mix) As Received
Consumable Product Eldorado HTP-1190L SUBTASK 70-00-99-809-314 B. Preparation. WARNING:
WARNING: (1)
Fill the tank to 100% of working level with Eldorado HTP-1190L.
EFFECTIVITY: ALL
70-00-99
Checks Potassium permanganate Caustic Soda Specific gravity (2)
Limits 6-12 oz/US gal 20-30 oz/US gal 1.20 to 1.34
TASK 70-00-99-801-165 106. Solution S1165 SUBTASK 70-00-99-99G-111 A. Composition. No. C04-216 Concentration (Initial Mix) 20% by Volume
Consumable Product Eldorado AC-111 SUBTASK 70-00-99-809-316 B. Preparation. WARNING:
ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1)
Fill tank to 50% of working level with water.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) (3) (4) Add Eldorado AC-111 product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-317 C. Check. (1) Checks Eldorado AC-111 (2) Determine the concentration of the solution. Limits 15-25% by Volume Recommended Interval Monthly
Consumable Product Eldorado AC-183
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-318 B. Preparation. WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4)
Fill tank to 50% of working level with water. Add inhibited phosphoric acid C04-217 slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-319 C. Check. (1) Checks Eldorado AC-183 (2) Determine the concentration of the inhibited phosphoric acid C04-217: Limits 15-20% V/V Recommended Interval Monthly
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-167 108. Solution S1167 SUBTASK 70-00-99-99G-113 A. Composition. No. C04-218 Concentration (Initial Mix) 25% by Volume
Consumable Product Eldorado ED-306LF SUBTASK 70-00-99-809-320 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill tank to 50% of working level with water. Add Eldorado ED-306LF product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-321 C. Check. (1) Checks Eldorado ED-306LF (2) Determine the concentration of the solution as follows: Limits 20-25% by Volume Recommended Interval Monthly
EFFECTIVITY: ALL
70-00-99
TASK 70-00-99-801-168 109. Solution S1168 SUBTASK 70-00-99-99G-114 A. Composition. No. C04-212 C04-213 Concentration (Initial Mix) 16 oz/US gal (90 g/l) 16.7% by Volume
Consumable Product Eldorado HTP-1150 Eldorado HTP-1150L SUBTASK 70-00-99-809-322 B. Preparation. WARNING:
WARNING: (1) (2) (3) (4)
Fill tank to 50% of working level with water. Add Eldorado HTP-1150 or HTP-1150L product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-323 C. Check. (1) Checks Eldorado HTP-1150 Eldorado HTP-1150L Determine the concentration of the solution as follows: Limits 90-120 g/l 12-16 oz/gal Recommended Interval Monthly Monthly
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) Follow the manufacturers control procedures to maintain the solution within the check limits.
TASK 70-00-99-801-169 110. Solution S1169 SUBTASK 70-00-99-99G-115 A. Composition.
Concentration Consumable Product Kodak Photo-Flo 200 Kodak Photo-Flo 600 Kodak Photo-Flo 2100
No. C05-110 C05-110 C05-110
Initial Mix 0.64 - 3.2 oz/US gal (5 - 25 ml/l) 0.21 - 1.1 oz/US gal (1.66 - 8.3 ml/l) 0.06 - 0.3 oz/US gal (0.48 - 2.4 ml/l)
SUBTASK 70-00-99-809-324 B. Preparation (1) (2) (3) (4) Fill tank with water to two-thirds of its working level. Add proper amount of Kodak Photo-Flo while stirring to mix thoroughly. Add water to top up to working level. Stir to mix thoroughly.
SUBTASK 70-00-99-809-325 C. Check. (1) (2) Every day remove surface scum from tank. Discard solution when it becomes discolored or contaminated with foreign material.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-170 111. Solution S1170 SUBTASK 70-00-99-809-326 A. Composition. No. C04-221 Concentration (Initial Mix) 20% by volume
Consumable Product Super Bee 300LF SUBTASK 70-00-99-809-327 B. Preparation. WARNING:
(1) (2) (3) (4)
Fill tank two-thirds full with water. Add Super Bee 300LF product slowly and carefully while stirring the solution to mix. Fill tank with water to working level. Stir solution again to mix.
SUBTASK 70-00-99-809-328 C. Check. (1) Checks Super Bee 300LF (2) Make operational check per the following: Limits 15-20% by volume Recommended Interval Weekly
Determination of the Super Bee 300LF Quantity. Use process materials and procedures as recommended by McGean Rohco, Inc.
SUBTASK 70-00-99-809-329 D. Regeneration. (1) Remove scum layer from top of tank at least every day, preferably every shift, and also as needed.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) Maintain solution strength within check limits. Increase strength (if necessary) by adding concentrate as required per calculated amount from analysis procedure. Decrease strength by diluting with water. Recover evaporation losses by filling tank to "working level" with water on daily basis.
(3)
TASK 70-00-99-801-171 112. Solution S1171 SUBTASK 70-00-99-99G-117 A. Composition. No. C04-105 C04-105 Concentration (Initial Mix) Full strength For solution control
Consumable Product Turco 5668 Additives 1, 2, and 3 SUBTASK 70-00-99-809-331 B. Preparation. WARNING: WARNING:
CONTACT MAY CAUSE SEVERE BURNS TO SKIN AND EYES. HARMFUL IF SWALLOWED. TURCO 5668 CONTAINS POTASSIUM HYDROXIDE, AMINES, AND PARAFFIN OIL. AVOID CONTACT WITH EYES, SKIN, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. DO NOT TAKE INTERNALLY. USE WITH ADEQUATE (EQUIVALENT TO OUTDOOR) VENTILATION. PROTECTIVE CLOTHING SUCH AS A CHEMICAL FACE SHIELD OR GOGGLES, GLOVE, APRON, AND BOOTS MADE FROM SOLVENTRESISTANT NEOPRENE SHOULD BE WORN WHEN HANDLING AND USING TURCO 5668.
WARNING:
(1) (2)
Ensure that the working tank is clean and dry before adding Turco 5668 to the tank. Add Turco 5668 as received in the drums to the tank. When less than a full drum is required, thoroughly agitate the drum prior to making additions to ensure proper stripper-to-seal ratio. Allow the seal to form before heating the solution.
(3)
EFFECTIVITY: ALL
70-00-99
Checks Thickness of Seal Alkaline content
Limits 4 in. (102 mm)(15-17 Vol % of total solution volume) Maintain per manufacturers control procedure
Recommended Interval Biweekly when tank is in use Weekly when tank is in use
(2)
SUBTASK 70-00-99-809-333 D. Regeneration. (1) (2) Every day, remove the accumulated paint film and debris from the tank. Maintain the seal layer thickness by addition of Additive 1. Maintain the lower layer alkalinity by additions of Additive 2 or Additive 3 per manufacturers control instructions. Replace the solution if it loses its effectiveness.
(3)
TASK 70-00-99-801-172 113. Solution S1172 SUBTASK 70-00-99-99G-118 A. General. (1) The following commercial products are recommended for applying an abradable plastic seal compound. For general usage, refer to Subtask 70-00-99-809-334, Compound Type 1. For a localized area, refer to Subtask 70-00-99-809-335, Compound Type 2.
SUBTASK 70-00-99-809-334 B. Compound Type 1. (1) The following commercial products are recommended for general usage of an abradable seal plastic compound. Mixing Instructions 98-102 parts by weight plus Reducer, Catalyst 9.5-10.5 parts by weight C01-024
Description Resin, Epoxy (MIL-R-9300, Type I, Class I)
EFFECTIVITY: ALL
70-00-99
Description Filler, Phenolic Microballoons (Type BJO-0930)
Mixing Instructions plus 20-28 parts by weight
Particle size requirements are as follows: Range: 0.0002-0.005 in. (0.005-0.13 mm), Average: 0.0017 in. (0.043 mm). (2) Be sure the phenolic microballoons C10-093 are dry before mixing. Acceptable methods for drying are as follows: (a) (b) (c) Heat in an air circulating oven for 12 hours at 1508F (668C) immediately before using. Batch dry for 12 hours at 1508F (668C) and store in sealed plastic containers which excludes the atmosphere. Store microballoons in an area when temperature and humidity are controlled adequately to keep the microballoons in a dry state. DIETHYLENETRIAMINE C01-024 IS TOXIC, AND CAN CAUSE SEVERE DERMATITIS AND PERMANENT TISSUE DAMAGE. HIGH CONCENTRATIONS OF VAPOR ARE IRRITATING TO THE EYES AND MUCOUS MEMBRANES. USE ADEQUATE VENTILATION, EYE AND SKIN PROTECTION, AND KEEP WORKING AREA THOROUGHLY CLEAN AT ALL TIMES. IF DIETHYLENETRIAMINE CONTACTS THE SKIN, WASH THOROUGHLY WITH SOAP AND WATER AT ONCE.
WARNING:
CAUTION: USE SEAL COMPOUND IMMEDIATELY AFTER MIXING. THE EFFECTIVE WORKING OR "POT" LIFE OF A 140-GRAM BATCH OF COMPOUND IS 30-45 MINUTES AT ROOM TEMPERATURE. WHEN MIXED, THIS MATERIAL INCREASES IN TEMPERATURE THROUGH EXOTHERMIC REACTION. POT LIFE DECREASES WITH INCREASING QUANTITY AND TEMPERATURE. (3) Mix resin C01-017 and diethylenetriamine C01-024 thoroughly in a clean, oil-free container. Add dry phenolic microballoons C10-093 within the limits stated, as required to obtain the desired consistency. Application by hand-spreading or trowelling requires a thick mixture, approaching or equalling the 28-parts-byweight limit of microballoons. Application by pouring/molding requires a thinner mixture of microballoons, down to the low limit of 20 parts by weight.
SUBTASK 70-00-99-809-335 C. Compound Type 2. (1) The following commercial products are recommended for applying an abradable plastic seal compound in a localized area.
EFFECTIVITY: ALL
70-00-99
Description Abradable Compound ((GE Spec P6TF1), Class A) (2)
For minor local repairs, mix resin C01-017 and catalyst C01-024 in the tube kit as follows: (a) (b) (c) Pull handle all the way out. Insert rod into handle cavity, and break seal between resin and catalyst. Push handle all the way in and place tube kit on a portable mixer (portable electric Semkit mixer, Model No. 285; SEMCO, 18881 South Hoover Street; Los Angeles, CA 90061, or equivalent). Insert driving spindle into handle cavity, and mix for 3-5 minutes, moving tube up and down the handle during mixing. Upon completion of the mixing cycle, remove cap from opposite end of tube and use handle to force compound from tube. NOTE: Compound may be mixed manually by running handle in and out of the tube for 15-20 minutes.
(d) (e)
TASK 70-00-99-801-173 114. Solution S1173 SUBTASK 70-00-99-99G-119 A. Description Alodine 1200S or Alocrom 1200 Dip Composition. Consumable No. C03-006 C03-083 Concentration (Initial Mix) 1.0 oz/US gal (7.5 g/l) 1.0 oz/US gal (7.5 g/l)
NOTE: The recommended concentration will produce suitable coatings on most alloys. If the desired coating is not obtained, add product in 0.25 oz/gal (1.9 g/l) increments until the desired coating is obtained. Do not exceed 3.0 oz/gal (22.5 g/l).
EFFECTIVITY: ALL
70-00-99
WARNING: (1) (2) (3) (4)
Fill the tank 3/4 full with water. Add the chromate conversion coating C03-006 or C03-083 slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix and heat to the operating temperature.
SUBTASK 70-00-99-809-337 C. Check (1) Determine the concentration of the chromate conversion coating C03-006 or C03083. Limits 0.85-1.15 oz gal (6.5-8.5 g/l) 1.3-2.0 Recommended Interval Weekly Weekly
Description Alodine 1200S or Alocrom 1200 Dip pH of solution
NOTE: When the concentration is adjusted to produce suitable coatings on a particular alloy or alloys, maintain the concentration within 0.15 oz/gal (1.0 g/l) of the established concentration. Do not exceed 3.0 oz/gal (22.5 g/l).
(2)
SUBTASK 70-00-99-809-338 D. Regeneration. (1) (2) (3) Add the correct products/chemicals to keep the solution in the check limits per the manufacturers instructions. Losses due to evaporation must be replaced by filling the tank with water to the working level. Remove the sludge and clean the tank when accumulated solids interfere with processing.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (4) Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-174 115. Solution S1174 SUBTASK 70-00-99-99G-120 A. Description Parcolene 41 Composition. Consumable No. C03-046 Concentration (Initial Mix) 13 oz/100 gal (1.0 ml/l)
SUBTASK 70-00-99-809-339 B. Preparation. WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1)
Fill the tank 3/4 full with water. NOTE: The tank should have an automatic level (water make-up) device, or the solution will decompose rapidly.
(2) (3) (4)
Add the chromate conversion coating C03-046 slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix and heat to the operating temperature.
SUBTASK 70-00-99-809-340 C. Check. (1) Description Parcolene 41 pH of solution Determine the concentration of the chromate conversion coating C03-046. Limits 10-16 oz/100 gal (0.8-1.3 ml/m) 4.0-5.0 Recommended Interval Weekly Weekly
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) Follow the manufacturers control procedures to maintain the solution.
SUBTASK 70-00-99-809-341 D. Regeneration. (1) (2) (3) Add the correct products/chemicals C03-046 to keep the solution in the check limits per the manufacturers instructions. Losses due to evaporation must be replaced by filling the tank with water to the working level. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-175 116. Solution S1175 SUBTASK 70-00-99-99G-121 A. Description Cleaner, Alkaline Deruster SUBTASK 70-00-99-809-342 B. Preparation. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. Composition. Consumable No. C04-233 Concentration (Initial Mix) 50 g/l
WARNING: (1) (2) (3) (4)
Fill the tank to two-thirds of its working level with water. Add the alkaline deruster C04-233 slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir solution again to mix.
SUBTASK 70-00-99-809-343 C. Check. (1) Determine the concentration of the alkaline deruster C04-233.
EFFECTIVITY: ALL
70-00-99
Description Cleaner, Alkaline Deruster (2)
Limits 35-50 G/L
TASK 70-00-99-801-176 117. Solution S1176 SUBTASK 70-00-99-99G-122 A. Description Cleaner, Alkaline Deruster SUBTASK 70-00-99-809-345 B. Preparation. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. Composition. Consumable No. C04-233 Concentration (Initial Mix) 250 g/l
WARNING: (1) (2) (3)
Fill the tank to two-thirds of its working level with water. Add the alkaline deruster C04-233 slowly and carefully while stirring to mix. Fill the tank with water to the working level.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (4) Stir solution again to mix.
SUBTASK 70-00-99-809-346 C. Check. (1) Description Cleaner, Alkaline Deruster (2) Determine the concentration of the alkaline deruster C04-233. Limits 100-250 g/l Recommended Interval Monthly
TASK 70-00-99-801-177 118. Solution S1177 SUBTASK 70-00-99-99G-123 A. Description Cleaner, Alkaline Permanganate Composition. Consumable No. C04-234 Concentration (Initial Mix) 200 g/l
EFFECTIVITY: ALL
70-00-99
WARNING: (1) (2) (3) (4)
Fill the tank to two-thirds of its working level with water. Add the alkaline permanganate cleaner C04-234 slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir solution again to mix.
SUBTASK 70-00-99-809-349 C. Check. (1) Description Cleaner, Alkaline Permanganate Permanganate (2) Determine the concentration of the alkaline permanganate cleaner C04-234. Limits 100-250 g/l 40-60 g/l Recommended Interval Bi-weekly Monthly
SUBTASK 70-00-99-809-350 D. Regeneration. (1) (2) (3) (4) Maintain solution within check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank with water up to working level on a daily basis. Remove oxide slurries that have collected on the tank bottom. Replace the solution if it loses its effectiveness.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-178 119. Solution S1178 SUBTASK 70-00-99-99G-124 A. Description Applied 2-690 SUBTASK 70-00-99-809-351 B. Preparation. WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. Composition. Consumable No. C04-235 Concentration (Initial Mix) 22% V/V
WARNING: (1) (2) (3) (4)
Fill the tank to 50% of its working level with water. Add the inhibited phosphoric acidC04-235 slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir solution again to mix.
SUBTASK 70-00-99-809-352 C. Check. (1) Description Applied 2-690 (2) Determine the concentration of the inhibited phosphoric acidC04-235. Limits 17-22 % V/V Recommended Interval Monthly
SUBTASK 70-00-99-809-353 D. Regeneration. (1) (2) Every day, remove surface scum from the tank. Maintain solution within check limits by the addition of appropriate products.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (3) (4) Losses through evaporation will be made up by filling the tank with water up to working level on a daily basis. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-179 120. Solution S1179 SUBTASK 70-00-99-99G-125 A. Description Cleaner, Acid Descaler SUBTASK 70-00-99-809-354 B. Preparation. WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. Composition. Consumable No. C04-236 Concentration (Initial Mix) 75 g/l
WARNING: (1) (2) (3) (4)
Fill the tank to two-thirds of its working level with water. Add the acid descaler cleaner C04-236 slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir solution again to mix.
SUBTASK 70-00-99-809-355 C. Check. (1) Description Cleaner, Acid Descaler (2) Determine the concentration of acid descaler cleaner C04-236. Limits 65-75 g/l Recommended Interval Weekly
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-356 D. Regeneration. (1) (2) (3) (4) Every day, remove surface scum from tank. Maintain solution within check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank with water up to working level on a daily basis. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-180 121. Solution S1180 SUBTASK 70-00-99-99G-126 A. Description Cleaner, Compound SUBTASK 70-00-99-809-357 B. Preparation. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. Composition. Consumable No. C04-208 Concentration (Initial Mix) 20% V/V
WARNING: (1) (2) (3) (4)
Fill the tank to two-thirds of its working level with water. Add the compound cleanerC04-208 slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-358 C. Check. (1) Determine the concentration of compound cleaner C04-208.
EFFECTIVITY: ALL
70-00-99
Description Cleaner, Compound (2)
Limits 15-20% V/V
SUBTASK 70-00-99-809-359 D. Regeneration. (1) (2) (3) (4) Every day, remove surface scum from tank. Maintain solution within check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank with water up to working level on a daily basis. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-181 122. Solution S1181 SUBTASK 70-00-99-99G-127 A. Description Cleaner, Mild Alkaline SUBTASK 70-00-99-809-360 B. Preparation. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. Composition. Consumable No. C04-193 Concentration (Initial Mix) 20% V/V
WARNING: (1) (2) (3)
Fill the tank to two-thirds of its working level with water. Add the mild alkaline cleanerC04-193 slowly and carefully while stirring to mix. Fill the tank with water to the working level.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (4) Stir the solution again to mix.
SUBTASK 70-00-99-809-361 C. Check. (1) Description Cleaner, Mild Alkaline (2) Determine the concentration of mild alkaline cleanerC04-193. Limits 15-25% V/V Recommended Interval Weekly
TASK 70-00-99-801-182 123. Solution S1182 SUBTASK 70-00-99-99G-128 A. Description Cleaner, Light Duty Alkaline SUBTASK 70-00-99-809-363 B. Preparation. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. Composition. Consumable No. C04-237 Concentration (Initial Mix) 20% V/V
WARNING: (1)
Fill the tank to two-thirds of its working level with water.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (2) (3) (4) Add the Alkaline Cleaner product C04-237 slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-364 C. Check. (1) Description Cleaner, Mild Alkaline (2) Determine the concentration of Alkaline Cleaner C04-237. Limits 15-20% V/V Recommended Interval Weekly
SUBTASK 70-00-99-809-365 D. Regeneration. (1) (2) (3) (4) Every day, remove surface contamination from tank. Maintain solution within check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank with water up to working level on a daily basis. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-183 124. Solution S1183 SUBTASK 70-00-99-99G-129 A. Description Cleaner, Acid Descaler Composition. Consumable No. C04-239 Concentration (Initial Mix) 20% V/V
EFFECTIVITY: ALL
70-00-99
WARNING: (1) (2) (3) (4)
Fill the tank to two-thirds of its working level with water. Add the Cleaner, Acid Descaler C04-239 product slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-367 C. Check. (1) Description Cleaner, Acid Descaler (2) Determine the concentration of Cleaner, Acid Descaler C04-239. Limits 15-20% V/V Recommended Interval Weekly
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-184 125. Solution S1184 SUBTASK 70-00-99-99G-130 A. Description Cleaner, Acid Descaler SUBTASK 70-00-99-809-369 B. Preparation. WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. Composition. Consumable No. C04-240 Concentration (Initial Mix) 25% V/V
WARNING: (1) (2) (3) (4)
Fill the tank to two-thirds of its working level with water. Add the Cleaner, Acid Descaler C04-240 product slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-370 C. Check. (1) Description Cleaner, Acid Descaler (2) Determine the concentration of Cleaner, Acid Descaler C04-240. Limits 20-25% V/V Recommended Interval Weekly
SUBTASK 70-00-99-809-371 D. Regeneration. (1) (2) Every day, remove surface scum from tank. Maintain solution within check limits by the addition of appropriate products.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (3) (4) Losses through evaporation will be made up by filling the tank with water up to working level on a daily basis. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-185 126. Solution S1185 SUBTASK 70-00-99-99G-131 A. Description Corrosol 853 SUBTASK 70-00-99-809-375 B. Preparation. WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. Composition. Consumable No. C04-122 Concentration (Initial Mix) 35% V/V
WARNING: (1) (2) (3) (4)
Fill the tank to 40% of its working level with water. Add the inhibited phosphoric acid C04-122 slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-376 C. Check. (1) Description Corrosol 853 (2) Determine the concentration of inhibited phosphoric acid C04-122. Limits 30-35% V/V Recommended Interval Monthly
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-377 D. Regeneration. (1) (2) (3) (4) Every day, remove the surface scum from the tank. Maintain the solution within the check limits by the addition of appropriate products. Losses through evaporation will be made up by filling the tank with water up to working level on a daily basis. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-186 127. Solution S1186 SUBTASK 70-00-99-99G-132 A. Composition. No. C04-244 C04-244 C04-084 C04-157 Concentration (Initial Mix) 33% by volume 8 oz/gal (60 g/l) To maintain pH To maintain solution
Consumable Product Enstrip EN-86A Enstrip EN-86B Sodium Hydroxide Enstrip Regenerator
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-397 B. Preparation. WARNING: NEVER ADD WATER TO ALKALINE CONCENTRATE. ADD ALKALINE CONCENTRATE TO WATER WHILE STIRRING VIGOROUSLY. LOCALIZED HEAT OF SOLUTION CAN CAUSE BOILING OR SPLATTERING. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND SHOES. ENSTRIP EN-86B IS A FLAMMABLE SOLID, DO NOT STORE NEAR EXCESSIVE HEAT OR OPEN FLAMES. ENSTRIP EN-86A AND THE ENSTRIP EN-86 OPERATING SOLUTION ARE STRONGLY ALKALINE IN NATURE AND MAY CAUSE SKIN AND EYE BURNS. AVOID SKIN AND EYE CONTACT. IN CASE OF CONTACT, FLUSH SKIN AND EYES WITH PLENTY OF COOL, CLEAN WATER FOR 15 MINUTES; FOR EYES, OBTAIN IMMEDIATE MEDICAL ATTENTION. ENSTRIP EN-86A, ENSTRIP EN-86B AND THE FINAL STRIPPING SOLUTION SHOULD BE HANDLED WITH CARE AND PROPER PROTECTIVE CLOTHING SUCH AS RESPIRATOR, RUBBER GLOVES, AND SAFETY GLASSES, SHOULD BE WORN TO PREVENT CONTACT WITH THE SKIN OR EYES. DO NOT INHALE DUST OR MIST FROM THE BATH COMPONENTS OR FROM THE OPERATING SOLUTION.
WARNING: WARNING:
WARNING:
(1)
Enstrip EN-86 is supplied as two components: Enstrip EN-86A, a liquid material, and Enstrip EN-86B, a powder. Both components are then combined with water to make up the working solution. Prepare the solution as follows: (a) (b) (c) (d) (e) (f) Fill the stripping tank with warm water to within 1/2 the operating volume of the tank. Add EN-86B equal to 8 oz/gal (60 g/liter) of the final working solution to the warm water. Stir the EN-86B solution until all powder is completely dissolved. Cautiously add the EN-86A equal to 33% by volume of the final working solution. Fill the stripping tank to its final working volume with water and heat to the operating temperature. Cover solution when not in use.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-398 C. Check. (1) Checks Enstrip EN-86A pH Enstrip Regenerator (2) Determine the concentration of the plating remover: Limits 33% by volume 12.0-12.4 See NOTE Recommended Interval Weekly Weekly Weekly
Follow the manufacturers control procedures to maintain the solution. NOTE: Analysis and replenishment of the Enstrip EN-86 operating solution is required after each mil ft2/gallon (4.5 g/l nickel metal) is stripped. NOTE: Follow the control procedures as recommended by the manufacturer and in the order listed by the manufacturer. NOTE: Replenish the Enstrip Regenerator concentration after analyzing and adjusting the solution for Enstrip EN-86A, EN-86B and pH.
SUBTASK 70-00-99-809-399 D. Regeneration. (1) (2) (3) (4) Each day, remove the surface contamination from the tank. Maintain solution within check limits by addition of appropriate products. Losses through evaporation will be made up by filling the tank with water up to working level on a daily basis. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-187 128. Solution S1187 SUBTASK 70-00-99-99G-133 A. Composition. No. C04-245 C04-245 C04-245 C04-245 Concentration (Initial Mix) Full strength To maintain oil seal thickness To maintain solution alkalinity To maintain solvent content.
Consumable Product Ardrox 2302 Ardrox 2302S Ardrox 2302-AA Ardrox 2302-SA
EFFECTIVITY: ALL
70-00-99
WARNING: (1) (2) (3)
Slowly and carefully fill a clean, dry tank to its operating level with well-mixed Ardrox 2302d. Allow the oil seal to form before heating the solution. Heat to the operating temperature specified by the stripping process.
SUBTASK 70-00-99-809-395 C. Check. (1) Checks Alkali and solvent content Seal Control (2) Determine the concentration of the solution as follows: Limits Maintain per manufacturers control procedure. 7.9 inch (20 cm) Minimum Recommended Interval Weekly Biweekly
SUBTASK 70-00-99-809-396 D. Regeneration. (1) (2) (3) Each day, remove the surface contamination from the tank. Add applicable materials to keep the solution within the check limits. Replace the solution if it loses its effectiveness or is contaminated.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-188 129. Solution S1188 SUBTASK 70-00-99-99G-134 A. Composition. No. C04-246 C04-086 C04-084 Concentration (Initial Mix) 8 oz./gal. (60 g/l) 20 oz./gal. (150 g/l) See NOTE To maintain the alkalinity of the solution.
Consumable Product Enstrip S Sodium Cyanide Sodium Hydroxide
NOTE: Solutions for removing nickel only may use an initial concentration of sodium cyanide C04086 equal to 14 oz. per gal. (105 g/l). Solutions for removing silver or both nickel and silver must use an initial concentration of sodium cyanide C04-086 equal to 20 oz./gal. (150 g/l).
SUBTASK 70-00-99-809-412 B. Preparation. (1) Fill a tank to 60-70 percent of its operating level with tap water. Measure the quantity required. Water may be heated to 1408F (608C) to speed the dissolving of chemicals. SODIUM HYDROXIDE, O-S-598, IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION AND VAPOR CONTROL ARE REQUIRED. AVOID ALL CONTACT. SOLUTION CONTAINS SODIUM CYANIDE AND IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION AND VAPOR CONTROL ARE REQUIRED. AVOID ALL CONTACT.
WARNING:
WARNING:
(2) (3) (4)
Add Enstrip S C04-245 and sodium cyanide C04-086 at the concentration specified, taking care to dissolve each one completely before adding the next. When solution has cooled, add water to bring volume to operating level and mix thoroughly. Adjust the alkalinity of the solution to pH 12-12.5 by the addition of sodium hydroxide C04-084.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-392 C. Check. CAUTION: THE FREE SODIUM CYANIDE CONCENTRATION MUST BE MAINTAINED ABOVE 5 OZ./GAL. (37.5 G/L) TO PREVENT POSSIBLE DAMAGE TO THE PARTS. IF THE FREE CYANIDE CONCENTRATION FALLS BELOW 5 OZ./ GAL. (37.5 G/L), THE SURFACE OF NICKEL MAY BECOME PASSIVE, AND CREATE A GALVANIC ACTION. THE PART MAY BECOME PITTED OR ETCHED. (1) Checks Free Cyanide pH Perform operational check according to the manufacturers instructions. Limits 12-24 oz./gal. (90-180 g/l) See NOTE 12-12.5 Recommended Interval Weekly when in use Daily when in use
NOTE: Solutions for removing only nickel must maintain a sodium cyanide concentration C04-086 of 12-16 oz./gal. (90-120 g/l). Solutions for removing silver or nickel and silver must maintain a sodium cyanide concentration C04-086 of 16-24 oz./gal. (120-180 g/l).
(2)
SUBTASK 70-00-99-809-393 D. Regeneration. (1) (2) Each day, remove the surface contamination from the tank. Maintain solution within check limits as follows: (a) (b) (c) (3) Maintain pH by addition of sodium hydroxide C04-084. Make additions of Enstrip S C04-246 and sodium cyanide C04-086 in the same ratio as original make-up. When the additions of Enstrip S C04-246 equal the original make-up, the bath must be replaced.
Replace the solution if it becomes too weak to work or it becomes contaminated.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-189 130. Solution S1189 SUBTASK 70-00-99-99G-135 A. Composition. No. C04-247 Concentration (Initial Mix) 25% by volume
Consumable Product Ardrox 1618 SUBTASK 70-00-99-809-400 B. Preparation. (1)
Fill the tank with water to one-half (50%) of the working level. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING:
WARNING: (2) (3) (4)
Add the Ardrox 1618 slowly and carefully while stirring to mix. Fill the tank with water to the working level. Stir again to mix thoroughly.
SUBTASK 70-00-99-809-401 C. Check. (1) Checks Ardrox 1618 (2) Determination of the Ardrox 1618 quantity: Limits 20-30% by volume Recommended Interval Monthly
SUBTASK 70-00-99-809-402 D. Regeneration. (1) (2) Every day, remove the surface scum from the tank. Maintain solution within check limits by the addition of appropriate products.
EFFECTIVITY: ALL
70-00-99
STANDARD PRACTICES MANUAL AS907-1-1A (3) (4) Losses through evaporation will be made up by filling the tank with water up to working level. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-190 131. Solution S1190 SUBTASK 70-00-99-99G-136 A. Composition. No. C04-071 C04-010 Concentration (Initial Mix) 20% V/V 0.3% V/V
Consumable Product Acid Chemical Additive, Inhibitor SUBTASK 70-00-99-809-403 B. Preparation. WARNING:
ACID SOLUTIONS ARE VERY ACTIVE AND MAY CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH LARGE QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4) (5)
Fill the tank two-thirds of its working level with water. Add the acid C04-071 slowly and carefully while stirring to mix. Add Chemical Additive Inhibitor C04-010, slowly stirring until the color of the inhibitor is uniformly mixed throughout the acid. Fill the tank with water to the working level. Stir solution again to mix.
SUBTASK 70-00-99-809-404 C. Check. (1) Check Acid Determine the concentration of the acid: Limits 15-25% V/V Recommended Interval Weekly
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STANDARD PRACTICES MANUAL AS907-1-1A (a) Reagents. 1 2 3 (b) Distilled water. Titrated solution of 1N sodium hydroxide. 0.1 percent methyl orange solution in distilled water.
Procedure. 1 2 3 Transfer exactly 5 ml from the solution into a 250 ml beaker. Add 100 ml distilled water and a few drops of methyl orange. Titrate with A ml of 1N sodium hydroxide and stir until the liquid turns yellow.
(c)
Quantitative formula. % V/V HCl = A x 1.72
SUBTASK 70-00-99-809-405 D. Regeneration. (1) (2) Every day, remove the surface scum from the tank. Maintain the solution the within check limits by the addition of appropriate products. (a) Addition of hydrochloric acid. If V is tank volume in liters, then the volume of acid C04-071 to be added is: V (20.0 - % HCl) liters. (b) (3) (4) Inhibitor C04-010 must be added in proportion to amount of acid C04-071 added.
Losses through evaporation will be made up by filling the tank with water up to the working level on a daily basis. Replace the solution if it loses its effectiveness.
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STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-00-99-801-191 132. Solution S1191 SUBTASK 70-00-99-99G-137 A. Composition. No. C04-072 C04-241 Concentration (Initial Mix) 54 fl oz/US gal (420 ml/l) 1.0 oz/US gal (28 g/l)
Consumable Product Nitric Acid Ammonium Bifluoride SUBTASK 70-00-99-809-406 B. Preparation. WARNING:
ACID/FLUORIDE SOLUTIONS ARE VERY DANGEROUS AND POISONOUS. PREVENT CONTACT WITH SKIN, EYES, AND CLOTHING. PREVENT BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH LARGE QUANTITY OF WATER AND OBTAIN IMMEDIATE MEDICAL ASSISTANCE. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4) (5)
Fill the tank one-third of its working level with water. Add the nitric acid C04-072 slowly and carefully while stirring the solution to mix. Add the Ammonium Bifluoride C04-241, slowly and carefully while stirring the solution to mix. Dissolve completely. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-407 C. Check. (1) Checks Nitric Acid Ammonium Bifluoride (a) Determination of the Nitric Acid Quantity: Limits 300-450 ml/l 25-30 g/l Equipment. Recommended Interval Biweekly Biweekly
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STANDARD PRACTICES MANUAL AS907-1-1A 1 2 3 4 5 6 7 8 (b) 500 ml volumetric flask. 2000 ml beaker. 400 ml beaker. 100 ml graduated cylinder. 25 or 50 ml Buret. 2 ml transfer pipette. 5 ml transfer pipette. 2 ml Nalgene (polypropylene) pipette.
Reagents: 1 2 3 4 Titrated solution of 1N caustic soda. Phenolphthalein solution. Distilled water. Reference solution of nitric acid. Put 250 ml of water into a 500 ml calibrated vial. Add 200 ml of nitric acid (d = 1.41). Make up to 500 ml with distilled water and shake to mix. a Determination of the concentration of the reference solution: Put exactly 5 ml of the solution into a 250 ml beaker. Add 75 ml of distilled water and titrate with n1 ml of 1N caustic soda in the presence of the phenolphthalein. Concentration of the solution T1 in g/l HNO3 is equal to n1 x 12.6. 5 Titrated solution of ferrous sulfate. Dissolve 160 g of FeSO4 7 H2O in 900 ml of sulfuric acid (at 250 ml/l). a Determination of concentration of solution: Titrate 2 ml of the reference nitric acid (of concentration T1) with n2 ml of ferrous sulfate solution T2: T2 = T1 / (n2 - 0.2) NOTE: The concentration of the solution of ferrous sulfate will be determined at least once a week.
(c)
Procedure. 1 2 Pour 100 ml of pure H2SO4 into a 400 ml beaker. Place the beaker in a bath of ice water.
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STANDARD PRACTICES MANUAL AS907-1-1A 3 4 5 6 7 Remove 2 ml from the bath with the help of the Nalgene pipette and a safety bulb. Let the sample run out slowly while keeping the end of the pipette under the surface of the H2SO4. While the sample is running out, stir the acid mixture by constantly moving the end of the pipette along the wall of the beaker. Once the sample has run out, do not withdraw the end of the pipette from the acid mixture. Titrate with the ferrous sulfate solution until the initial yellow coloring changes to brown. Use the pipette to stir the mixture. The temperature of the solution must not exceed 1408F (608C) during the titration. Rinse the pipette, sucking the mixture with the help of the bulb and allowing it to run out into the beaker afterward. Complete the titration, if necessary, adding the ferrous sulfate solution drop by drop until the color change from yellow to brown occurs. Let A equal the total volume in ml of ferrous sulfate of concentration T2 used.
8 9 10 (d)
Quantitative formula. HNO3 ml/l = (A - 0.2) x T2 x 1.05
(2)
Determination of the Ammonium Bifluoride Quantity. (a) Equipment. 1 2 3 4 5 6 7 8 9 5 ml transfer pipette. 10 ml transfer pipette. 20 ml transfer pipette. 25 ml transfer pipette. 250 ml volumetric flask (for Fluoride Primary Standard). 100 ml volumetric flask (for Fluoride Standard Solution). 1000 ml beaker. 200 ml Nalgene (polypropylene) beakers (for sample and standards measurement). A pH/Ion meter with internal resolution to a minimum of 1.0 millivolt (0.1 millivolt preferred).
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STANDARD PRACTICES MANUAL AS907-1-1A 10 A Fluoride Ion combination electrode. NOTE: The supplier or manufacturer can provide information regarding selection of a suitable pH/Ion meter and Fluoride Ion combination electrode. (b) Reagents: Total Ionic Strength Adjuster/Buffer: 1 In a large beaker (800-1000 ml) containing about 500 ml DI water, add 57 ml glacial Acetic Acid, 58 g NaCl, and 4.0 g Cyclohexylene Dinotrilotetraacetic Acid (CDTA). Stir to dissolve. Heat may be generated; use of a water bath may help cool the mixture. Adjust the pH by adding 5 M NaOH until the pH is between 5.0 and 5.5. Calibrate the pH meter with an acid range buffer before immersing the electrodes in the cooled solution. Continue cooling the solution to room temperature. Transfer to a 1 liter volumetric flask, rinsing the beaker well. Bring up to the mark (1,000 ml) with DI water. NOTE: Prepared TISAB may be purchased from laboratory supply sources. Fluoride Standard Solutions: 2 Primary Standard: 1000 ppm 0.0526 M (1 x 10-1.279 M). Transfer 50 ml of DI water to a 250 ml volumetric flask. Add 0.5525 g Sodium Fluoride (NaF) and dissolve. Dilute to 250 ml with DI water. Mix well. Calibration Standard: 500 ppm 0.0263 M (1 x 10-1.580 M). Use a pipette to transfer 50 ml of the Primary Standard to a 100 ml volumetric flask. Dilute to the mark with DI water. Mix well. Calibration Standard: 250 ppm 0.0132 M (1 x 10-1.881 M). Use a pipette to transfer 25 ml of the Primary Standard to a 100 ml volumetric flask. Dilute to the mark with DI water. Mix well. Calibration Standard: 100 ppm 0.00526 M (1 x 10-2.279 M). Use a pipette to transfer 10 ml of the 500 ppm Standard to a 100 ml volumetric flask. Dilute to the mark with DI water. Mix well. NOTE: Prepared certified standards may be purchased from laboratory supply sources. NOTE: Store all standards in plastic, not glass. Fluoride reacts with glass. Rinse all glassware used with Fluoride Solutions with DI water immediately after use. (c) Procedure.
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STANDARD PRACTICES MANUAL AS907-1-1A 1 Calibration/Use of the pH-mV Meter and Preparation of the Fluoride Calibration Curve. NOTE: Many pH-mV meters may be calibrated to read concentration directly. Follow the manufacturers instructions for proper calibration. a Replace the pH sensing electrode of the pH-mV meter with the Fluoride (F-) ion specific electrode. NOTE: Follow the manufacturers recommendations for use, storage, and maintenance of this electrode. b Prepare samples for measurement by mixing measured, equal volumes of TISAB and Standard Solution. NOTE: Total volume must be sufficient for use with the meter and electrode. c d e Immerse the electrode into the 100 ppm Standard/TISAB Solution. Stir once and let the solution settle. Select the appropriate mV mode and range. Allow the reading to stabilize. Record the mV value obtained. Read and record the mV value of the other Fluoride (F-) Standard/ TISAB Solutions, in low to high concentration order. NOTE: Solutions must be measured between 20 and 30 C8. f Use semi-log scale paper to plot mV (linear scale) vs. Fluoride (F) Molarity (a plot of mV vs. log [10] of Fluoride (F-) Molarity on normal graph paper may be used). The plot should be a straight line (you may have to draw the best fit straight line). A slope of 59 = or - 4 mV indicates correct electrode operation.
Sample Preparation and Determination of the Fluoride Concentration of Process Solution. a b c d Use a pipette to transfer 1.0 ml of the Process Solution to a 100 ml volumetric flask. Dilute to the mark with DI water. Shake well. Prepare samples for measurement by mixing a measured, equal volume of TISAB and sample. Read and record the mV value of the sample/TISAB solution. Use the constructed Calibration Curve to find the concentration of the sample.
(d)
Quantitative Formula. NH4HF2 g/l = (F- Molarity) x Dilution x gram wt / mole FNH4HF2 g/l = (F- Molarity) x 100 x 28.5
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STANDARD PRACTICES MANUAL AS907-1-1A NH4HF2 g/l = (F- Molarity) x 285 NH4HF2 g/l = (ppm of F-) x 0.15 SUBTASK 70-00-99-809-408 D. Regeneration. (1) (2) Every day, remove the surface scum from the tank. Maintain the solution within the check limits by the addition of appropriate products. (a) Addition of nitric acid. If V is tank volume in liters, then the volume of nitric acid (d = 1.41) to be added is: V [400 - (A - 0.2) x T2 x 1.05] milliliters. (b) Addition of Ammonium Bifluoride. If V is tank volume in liters, then the quantity of Ammonium Bifluoride to be added is: V (28 - NH4HF2 g/l) (3) (4) Losses through evaporation will be made up by filling the tank to the working level with water. Replace the solution if it loses its effectiveness.
TASK 70-00-99-801-192 133. Solution S1192 SUBTASK 70-00-99-99G-138 A. Composition. No. C04-072 C04-255 Concentration (Initial Mix) 63 fl oz/US gal (490 ml/l) 1.5 oz/US gal (11 g/l)
Consumable Product Nitric Acid Cee-Bee P-109B
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-00-99-809-409 B. Preparation. WARNING: ACID/FLUORIDE SOLUTIONS AVE VERY ACTIVE AND CAN CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH LARGE QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1) (2) (3) (4) (5)
Fill tank one-third full with water. Add the nitric acid slowly and carefully while stirring the solution to mix. Add the Cee-Bee P-109B slowly and carefully while stirring the solution to mix. Fill the tank with water to the working level. Stir the solution again to mix.
SUBTASK 70-00-99-809-410 C. Check. (1) Checks Nitric Acid (428Be = 1.41d) Cee-Bee P-109B (2) Do a check of the solution in accordance with the manufacturers instructions. Limits 450-535 ml/l 7.5-15.0 g/l Recommended Interval Weekly Weekly
SUBTASK 70-00-99-809-411 D. Regeneration. (1) (2) (3) (4) Each day, remove surface scum from the tank. Add the appropriate products to keep the solution within the check limits. Each day, fill the tank with water to the working level. Replace the solution if it loses its effectiveness or if it is contaminated.
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TECHNIQUES - ASSEMBLY AND DISASSEMBLY TECHNIQUES TASK 70-10-00-800-009 1. Assembly and Disassembly Techniques SUBTASK 70-10-00-99G-009 A. General. (1) Basic disassembly and assembly practices and techniques are covered in this section. Careful handling of engine parts and proper use of special tools and fixtures specified in this manual are essential. Damage to engine parts, manufactured to close tolerances, can cause serious engine malfunctions.
SUBTASK 70-10-00-800-091 B. Cleanliness. CAUTION: IF ANYTHING IS DROPPED INTO AN ENGINE COMPONENT, STOP THE ASSEMBLY PROCEDURE, THEN LOCATE AND REMOVE THE FOREIGN OBJECT EVEN IF COMPLETE DISASSEMBLY IS REQUIRED. (1) It is important that the assembly shop be clean and dust free, to prevent foreign material from entering the engine or its subassemblies. A major cause of premature engine removal is foreign object damage (FOD). It is recommended that FOD containers be kept at or near each work area. All parts should be inspected for cleanliness before being installed. Mating flanges, fittings, and couplings should be wiped clean to ensure obtaining a good seal. Hands and gloves must be clean when handling machined surfaces. After performing any work, the area should be thoroughly inspected for loose parts, rags, tools, and materials.
(2) (3) (4) (5)
SUBTASK 70-10-00-800-092 C. Overall Assembly. (1) Before starting disassembly or assembly operations, consult the applicable manual. The applicable procedure is described in logical step-by-step sequence. Always read the complete procedure; be sure you understand. It is better to stop and ask than to continue on and cause unnecessary work and/or damage. Lift heavy parts with proper fixtures and hoist to prevent damage to parts or injury to personnel. Perform operations using the tools specified in the applicable engine manual. Maintain tools in good condition and use special tools only for the use intended.
(2) (3)
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ASSEMBLY AND DISASSEMBLY TECHNIQUES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (4) Metal hammers and drifts (including brass) shall not be used to force any part of the engine. To prevent damage, plastic, nylon or rawhide-faced hammers and drifts may be used for driving operations, if necessary. Complete each phase of assembly before proceeding to the next phase. Do not leave bolts untightened or fasteners unlocked unless specified in the applicable manual. Do not remove plugs or coverings from parts until part is to be installed. When installing or removing body-bound bolts, tap them straight through holes. Do not turn them. During assembly, align match marks on all parts which are marked during disassembly or subassembly. Do not mix plated and unplated hardware. Do not use silver or cadmium plated tools or hardware on titanium parts. Plating contains small quantities of chlorine salts which are harmful to titanium. PROLONGED EXPOSURE OF THE SKIN TO ENGINE OIL MAY BE DETRIMENTAL. WASH SKIN THOROUGHLY AFTER CONTACT, AND REMOVE SATURATED CLOTHING IMMEDIATELY.
(5)
(6) (7) (8) (9)
WARNING:
CAUTION: ENGINE LUBE OIL MAY SOFTEN PAINT OR STAIN CLOTHING WITH WHICH IT COMES IN CONTACT. CLEAN SPILLED OIL FROM PAINTED SURFACES. (10) Accessories, tubes, and hoses may have oil or fuel in them at time of removal. Drain these fluids from accessory being removed, and cap all connecting hoses or tubes. (11) Lubricate all gears and splines with oil before installing them, unless otherwise specified. (12) Prior to installation of any part, a quick visual check should be made and any obvious discrepancies noted and reported, so that corrective action can be taken. (13) Do not use external engine piping as a ladder or hand-hold while performing maintenance. Serious engine damage could result. Use only authorized work stands and platforms. (14) The engine should not be used as a shelf for holding tools or parts while work is being performed. SUBTASK 70-10-00-800-093 D. General Assembly Precautions. (1) Do not handle bearings with the bare hands or with any device that could cause contamination or scarring. Use clean rubber or plastic gloves. During assembly of bearings do not apply force to balls or rollers. Refer to TASK 70-14-00-620-003, Handling of Bearings. Use new cotter pins, lockwashers, tabwashers, spring washers, preformed packing (O-rings), and gaskets throughout assembly. All safetywiring and safety cable
(2)
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STANDARD PRACTICES MANUAL AS907-1-1A installation must be done in accordance with the instructions in TASK 70-11-01400-005, Safety Wire Procedure, and TASK 70-11-02-400-006, Safety Cable Procedure. CAUTION: DO NOT PINCH, SQUEEZE, OR OTHERWISE DEFORM ANY SELF-LOCKING NUT TO OBTAIN OR REGAIN SELF-LOCKING TORQUE. (3) Do not use bolts, screws, or nuts which have damaged threads. Check all beamtype (pinched castellated) and elliptically formed self-locking nuts for locking quality, using the procedure in paragraph 9. of TASK 70-51-00-400-004, Tightening Practices and Torque Values. Inspect all blind tapped holes and remove any foreign material before installing studs or screws. The bolts and screws on the engine require a definite tightening torque. Specific torque values are defined in the applicable manual. Tighten sets or groups of fasteners holding a single part by using a staggered or diametrically opposite sequence, and do not tighten to final torque at the first drawdown. When tightening threaded parts that are not rigidly supported, or that are attached to parts that cannot withstand full torque without bending or twisting, use a second wrench and apply countertorque to support the mating part. Use fiber or plastic blocks to protect engine parts being assembled by means of an arbor press. Tube and Tube Connectors. CAUTION: REMOVE PROTECTIVE COVERS AND PLUGS IMMEDIATELY BEFORE ASSEMBLY. (a) (b) (c) (9) Check cleanliness, especially on seals and threaded areas. Inspect the tube assembly to ensure satisfactory general condition and that no handling damage has occurred. Fit the tube assembly without application of force; however, a slight elastic distortion is allowed for engagement of connectors.
(4) (5)
(6)
(7) (8)
Use of motor-driven hydraulic pumps to operate hydraulically actuated special support equipment other than torque multipliers is not recommended. Equipment damage can result from improper power application. Use hand-operated hydraulic pumps to operate hydraulically actuated special support equipment such as pushers or pullers, unless otherwise specified
SUBTASK 70-10-00-800-094 E. Electrical Bonding Straps. (1) Electrical bonding strap contact surfaces shall be prepared by removing all anodic film, grease, paint, lacquer, or other high-resistance material from an area at least one and one-half times the bonding surface contact area.
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-10-00-800-095 F. Marking of Parts. (1) Parts or assemblies designated as matched will be maintained as matched sets throughout the maintenance process. Set numbers, part numbers, and serial numbers will be protected during cleaning or rework to prevent removal. When identification is removed or is no longer legible, the item must be re-marked per the original marking method and location for the part as specified on the applicable drawing. Permanent Marking. (a) Permanent marking of parts should be done in the area of lowest stress as specified on applicable drawing. Methods are listed in order of preference (unless otherwise specified). Electric etch is not approved. 1 2 3 (3) Electro-chemical etch - preferred. Vibropeen - acceptable. Metal stamp - special use only.
(2)
Temporary Marking. CAUTION: WHENEVER IT IS NECESSARY TO MARK ANY ENGINE PARTS, ONLY APPROVED MARKING COMPOUNDS SHALL BE USED. USE OF UNAUTHORIZED MARKING COMPOUNDS CAN CAUSE DAMAGE TO ENGINE PARTS. CAUTION: GREASE PENCILS OR LEAD (GRAPHITE) PENCILS MUST NOT BE USED TO MARK COMBUSTION SECTION AND HOT SECTION PARTS. THESE MATERIALS PLUS HEAT CAN CAUSE PARTS MATERIAL DAMAGE. (a) Refer to TASK 70-16-00-350-001, Marking Practices, for acceptable methods and materials.
SUBTASK 70-10-00-800-096 G. Correction of Leaks. CAUTION: DO NOT OVERTIGHTEN THREADED FASTENERS AS MEANS TO CORRECT LEAKING CONNECTIONS. PARTS FAILURE COULD RESULT. (1) (2) (3) (4) Disassemble connection. Discard seal, gasket, or preformed packing (O-ring), if present. Inspect mating surfaces for contamination, scratches, dents, or other surface defects. Inspect threaded fasteners for thread damage and assure that fasteners seat properly when tightened to specified value.
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STANDARD PRACTICES MANUAL AS907-1-1A (5) Replace nonserviceable parts and assemble connection using new seals, gaskets, or preformed packings (O-rings), as required.
SUBTASK 70-10-00-800-097 H. Unpacking and Repacking. (1) The following general instructions apply during unpacking and repacking to minimize possible part damage and contamination. (a) Initially remove only that portion of the pack necessary to mount the part. Where possible, remove the remainder of the pack, including protective closures, one at a time as each connection (fluid, air, or electrical) is made. Retain protective closures and reusable pack components for repack purposes. Install closures on each connection (fluid, air, or electrical) as it is disconnected. When possible, repack part for storage or shipment using the same pack in which replacement part was received. When original pack components are not available, use locally available packing materials and container to pack the part. Make sure that all ports, openings, connections, and mating surfaces are capped or covered and that the part is protected from potential handling and environmental damage.
(b) (c) (d) (e)
SUBTASK 70-10-00-800-098 I. Jackscrews. (1) When using jackscrews to remove components, do not bend flanges or strip threads. Lubricate jackscrews with engine oil before installing. Turn jackscrews evenly and in small increments. Always check jackscrews for burrs or rough edges before using. Remove all burrs or rough edges. Do not allow components to fall free as jackscrews are tightened. Jackscrew holes are often in flanges only thick enough to accept 3 or 4 threads. If regular bolts are used as jackscrews, the tips must be blunt and polished. The ends of most standard bolts are chamfered, and the first couple of threads are missing or incomplete. These should not be used as jackscrews without modification, since one or 2 threads will engage, and the threads in the flange are likely to strip. Jackscrews, frequently designed as such and identified as special tools, are not chamfered and full thread engagement will occur. If specially manufactured jackscrews are not available and must be locally manufactured, be sure that the ends are ground to remove the chamfers and the incomplete threads, so that a maximum number of threads may be engaged.
(2)
(3)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-10-00-800-099 J. Protective Closures and Caps. (1) Prevent foreign material from lodging in drilled passages, fuel lines, oil lines, air lines, and open engine ports. Machined surfaces must be properly protected to prevent damage. Wrap precision parts and cap or plug all openings and connections. It is most important that all engine parts be kept clean and free of corrosion. All instructions which require special handling of parts must be followed without exception. Accessories, tubes, and hoses may have oil or fuel in them at time of removal. Drain these fluids from accessory being removed, and cap all connecting hoses or tubes - do not use tape. Do not remove plugs, caps, etc., until part is ready for assembly. Check both seating surfaces for removal of plugs, etc., prior to assembly.
(2)
(3)
(4)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-10-00-800-100 K. Gaskets and Preformed Packing (O-Ring) Seals. WARNING: PREFORMED PACKINGS (O-RINGS), GASKETS, AND SEALS MADE FROM FLUOROELASTOMERS ARE FREQUENTLY USED IN HIGH TEMPERATURE SERVICE. WHEN USED UNDER DESIGN CONDITIONS, FLUOROELASTOMERS ARE SAFE. HOWEVER, IF MISUSED BY EXPOSING TO TEMPERATURES AROUND 6008F (3168C) OR GREATER, DECOMPOSITION MAY OCCUR WITH THE FORMATION OF HYDROFLUORIC ACID, WHICH CAN BE EXTREMELY CORROSIVE TO HUMAN TISSUE IF NOT HANDLED PROPERLY. DO NOT TOUCH EITHER THE SEAL OR SURROUNDING EQUIPMENT WITHOUT WEARING NEOPRENE OR PVC GLOVES IF DEGRADATION IS SUSPECTED. A DEGRADED SEAL MAY APPEAR AS CHARRED OR A BLACK STICKY MASS. HYDROFLUORIC ACID MAY BE CONDENSED OUT AS A CLEAR LIQUID ON THE PART OR EQUIPMENT. ALLOW THE EQUIPMENT TO COOL. THEN WEAR NEOPRENE OR HEAVY PVC GLOVES TO SAFELY HANDLE PARTS OR EQUIPMENT. WASH PARTS AND EQUIPMENT WELL WITH 10 PERCENT LIMEWATER (CALCIUM HYDROXIDE SOLUTION) TO NEUTRALIZE ANY HYDROGEN FLUORIDE. DISCARD GLOVES AFTER HANDLING DEGRADED FLUOROELASTOMER PARTS. IF A DEGRADED FLUOROELASTOMER PART TOUCHES YOUR SKIN, WASH AFFECTED AREAS IMMEDIATELY WITH PLENTY OF WATER. THEN RUB A 2.5 CALCIUM GLUCONATE GEL (SEE NOTE) INTO THE SKIN UNTIL THERE IS NO FURTHER IRRITATION, WHILE SEEKING PROMPT MEDICAL ATTENTION. TELL THE DOCTOR THAT A HYDROGEN FLUORIDE (HF OR HYDROFLUORIC ACID) BURN IS SUSPECTED. CONCENTRATED HYDROGEN FLUORIDE SOLUTIONS CAUSE IMMEDIATE PAIN, BUT DILUTE SOLUTIONS MAY NOT CAUSE REDNESS, BURNING OR PAIN UNTIL SEVERAL MINUTES OR EVEN HOURS HAVE ELAPSED. IF SUCH A DELAYED REACTION IS EXPERIENCED, SEEK MEDICAL ATTENTION IMMEDIATELY.
WARNING:
WARNING:
(1)
Calcium Gluconate Gel 2.5 percent is prepared by mixing 3.5 grams of calcium gluconate powder with a 5 ounce tube of surgical water-soluble lubricant (e.g., KY Lubricating Jelly, Johnson & Johnson) or by mixing 1 standard ampule (10 ml, 10 percent) of USP calcium gluconate with 1 ounce of water-soluble lubricant. The shelf life of the gel has not been determined. Storage of the gel has limitations and refrigeration may help. Gaskets and Preformed Packing (O-ring) seals shall not be reused unless otherwise specified. Gaskets and Preformed Packing (O-ring) seals shall be lightly lubricated with engine oil prior to installation unless otherwise specified. Make certain parts are
(2) (3)
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STANDARD PRACTICES MANUAL AS907-1-1A properly seated in the special case of a fitting with a jamnut and preformed packing (O-ring). NOTE: For Preformed Packing Material (O-rings) there is a distinction between shelf life and cure date. Cure date is stamped on the package to indicate a date of manufacture so that the oldest stock may be used first. Shelf life is specified by an age control requirement which must be stamped on the package and represents the maximum period of time after the cure date which guarantees that the desired characteristics of the product are satisfactory. Both AMS 2817 and the applicable MIL-R-83248 require that the cure date be marked on the package. Efforts have been made to eliminate the use of elastomeric O-rings which require age control, therefore if you do not see "age control required" marked on the package, there is no shelf life or restriction on usability relative to time. It is suggested that the oldest date be used first so that this material is cleared out. SUBTASK 70-10-00-800-101 L. Tubes. (1) (2) (3) (4) (5) As tubes are installed, tighten all end fittings and clamps finger-tight. After a complete system is installed, tighten clamps first, then end fittings. Maintain clearance between tube and each adjacent part. Coupling nuts shall thread freely by hand. Mating flanges on tube shall seat flush. If tubes are reworked, bend radii shall not be less than twice the tube diameter and bend angle shall not be changed by more than 3 degrees. No kinks or wrinkles are allowed. Do not bend at fitting or weld areas. Original bends in tube may be bent in the same direction; no reverse bending is allowed. Bend tube in existing straight sections if possible. Use bending tools on tubes, one inch (25.4 mm) or more in diameter, to prevent tube from collapsing.
(6) (7) (8) (9)
(10) On those couplings where sealant is required, allow sealant to dry 10 minutes minimum before assembly. Wipe off any sealant on inside of tube with a clean cloth and water. Do not allow sealant to enter air systems. SUBTASK 70-10-00-800-102 M. Clamps. (1) Chafing of hoses and tubes must be avoided. Clamp parts loosely in place, shift the hoses around to obtain best clearance, then tighten clamps. Clamps must be proper size for piping to permit slippage during engine thermal growth. See Figure
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STANDARD PRACTICES MANUAL AS907-1-1A 1, Page 10.
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Installation of Clamps Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-10-00-800-103 N. Electrical Cables and Connectors - Disconnect and Connect. NOTE: If pliers are used during this process, they must be soft-jawed, Teflon-jawed, or equivalent, to prevent damage to the connector. (1) Connector disconnect. (a) (b) Loosen the electrical connector by hand or by using soft-jawed pliers. Visually inspect the connector and the receptacle for obvious signs of damage, bent pins, or corrosion. 1 (c) If damage is found, repair or replace the connector or receptacle.
Install protective caps on the connector and the receptacle. NOTE: If pliers are used during this process, they must be soft-jawed, Teflon-jawed, or equivalent to prevent damage to the connector.
(2)
Electrical Cable Installation. (a) (b) (c) During electrical installation, adjust the cable through the clamps to get the smoothest and largest radius. Avoid sharp bends, twists, and kinks. Ensure that a minimum clearance of 0.125 inch (3.18 mm) is maintained between electrical cables and any component other than hoses or other electrical cables. NOTE: Chafe-guarded cables are allowed to have incidental contact against smooth surfaces.
CAUTION: DO NOT SHARPLY BEND, KINK, OR TWIST RIGID LEADS. ALWAYS HOLD BOTH MATING CONNECTORS WHEN TIGHTENING THE CONNECTION TO PREVENT DAMAGE TO THE LEAD. (3) Connect the electrical connector. (a) (b) (c) Remove the protective caps from the connector and the receptacle. Inspect the electrical connector pins for straightness before connecting. Ensure that the seal ring is present in the coupling nut of the electrical connector and that it is serviceable. If the seal is not present or is damaged, replace as follows: 1 2 Remove the unserviceable seal. Engage the new seal over the barrel of the connector.
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STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: DO NOT ALLOW THE SEAL TIP TO FLATTEN ON THE CONNECTOR OR THE USEFULNESS OF THE SEAL WILL BE DESTROYED. 3 (d) (e) Push the seal to the seated position against the internal shoulder in the connector using a mating connector or a blunt screwdriver.
Engage the electrical connector with the receptacle by hand. Move the backshell assembly from side to side while turning the knurled ring of the electrical connector until the electrical connector is fully seated, fingertight. If the knurled ring of the electrical connector is accessible, use soft-jawed pliers to tighten the knurled ring of the electrical connector beyond fingertight, 20 degrees maximum. If the knurled ring of the electrical connector is not accessible, tighten as follows: 1 2 Tighten the knurled ring of the electrical connector by hand. Check the connector backshell assembly for side to side movement. If movement is present, disconnect the connector and reconnect, referring to paragraphs 1.N.(1) through 1.N.(3).
(f)
(g)
(h)
Safety-wire the connector if specified in the assembly procedure.
SUBTASK 70-10-00-800-104 O. Hoses. (1) No hose should be bent, especially when the parts are cold, because of possible damage to the Teflon liners. Kinked hoses must not be used. During installation, be sure that no hose is twisted or stretched; never over-tighten connectors. When hoses are removed, cap the open ends. Do not use tape. Figure 2, Page 13. Fluid fittings shall be tightened gradually to the required torque value, backed off 0.25 turn then tightened again. Do not attempt to correct a leak by excessive tightening. Always use two wrenches when tightening swivel coupling nuts on hoses, tubes, or fittings. Hold the stationary part with one wrench while applying torque with second wrench. Apply lube oil between tube-hose coupling nut and ferrule prior to tightening. Figure 2, Page 13. Preformed hoses or hoses of large diameter shall not be bent or straightened. When hoses are removed, cap the open ends. Do not use tape. Before installing preformed hoses, visually inspect the hose interior to assure that the Teflon lining has not been damaged. Replace the hose if the lining has been damaged.
(2)
(3) (4)
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Installation of Hoses Figure 2
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INDUCTION HEAT - INDUCTION HEATING FOR SHRINK FIT ASSEMBLY OF BEARINGS AND SEALS TASK 70-10-01-370-001 1. Induction Heating for Shrink Fit Assembly of Bearings and Seals SUBTASK 70-10-01-99G-001 A. Introduction. (1) General. (a) (b) Induction heating is an electro-magnetic heating method used effectively for electrically conducting materials (generally metals). A power supply provides alternating current to a coil, generating a magnetic field. The magnetic field induces a corresponding electric current (eddy currents) in the work piece producing heat in the material. The work piece is placed in or near the coil. The amount of induction heating is directly related to the magnetic and electric resistance properties of the conducting work piece. Induction heating generates precise amounts of clean, localized heat with no physical contact between the coil and the work piece. Heat is generated only in the part. Induction heating is very efficient because the heating is confined to a specified area of the metal component. This characteristic provides accurate and consistent results.
(c)
(d) (e)
(2)
Applications. (a) (b) Induction heating is used for the shrink fit assembly of main and gearbox bearings and rotating seals. Bearings and other shaft mounted parts can fail prematurely due to improper fitting. Proper shrink fit assembly can significantly extend the life of these components. Oil baths and convection ovens have the disadvantages of slow heating, contamination, loss of bearing pre-lubrication and environmental and safety hazards. Induction heating for assembly fitting offers the following advantages: 1 Mating parts are fitted properly. Work pieces are heated evenly with minimal danger of overheating. Any required maximum temperature may be specified. Bearing pre-lubrication remains in place and is not contaminated.
(c)
(d)
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INDUCTION HEATING FOR SHRINK FIT ASSEMBLY OF BEARINGS AND SEALS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A 3 4 5 Work pieces may be induction heated at the work place very quickly. Minimal set up is involved. Induction heating is very safe. Only the work piece is heated. There is no hot oil or oven. Induction heating is energy efficient. The high speed of the heating requires minimal energy to heat fit the work pieces. Induction heating produces no smoke, vapor, or used contaminants to dispose. Induction heaters demagnetize automatically.
SUBTASK 70-10-01-99G-002 B. Applicable Documents. (1) (2) (3) (4) (5) (6) (7) (8) Standard Practice References. Heat Treating TASK 70-44-04-370-001, Heat Treat Equipment Calibration TASK 70-34-03-220-009, Rockwell Hardness Testing American Society for Testing and Material. ASTM E 230 - Temperature-Electromotive Force (EMF) Tables for Thermocouples ASTM E 220 Manufacturing and Calibration of Thermocouples AMS 2750 Pyrometry
SUBTASK 70-10-01-370-002 C. Definitions (1) (2) (3) Supplier - Source other than Honeywell that provides materials, parts, or services for incorporation into Honeywell products. Temperature Probe - Thermocouple placed within the heating zone to monitor and control the zone or area temperature. Tempering - Tempering is the heating of a ferrous material to an intermediate temperature below the critical temperature. The material is then maintained at this temperature for a suitable time and then cooled slowly. The object of tempering is to decrease the hardness of the material and increase toughness in order to produce the desired combination of mechanical properties. Thermocouple - A pair of dissimilar conductors joined together in series. These conductors exhibit a potential difference, measured in volts, when heated. The heat produces an electrical pressure (EMF) which cause current to flow in the thermocouple circuit.
(4)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-10-01-370-003 D. Materials. (1) None. No materials other than the workpiece and the induction heating equipment are required for this process.
SUBTASK 70-10-01-370-004 E. Equipment. (1) An induction heating system consists of several major components: (a) AC Power Supply. The AC power supply generates the alternating current and the resulting magnetic field. 1 2 (b) (c) (2) (3) The specific requirements of an induction heating power supply depend on the application requirements and production rate. Power levels and heating times are closely related to the physical characteristics of the work piece and the design of the induction coil.
Induction Coil. The induction coil is normally a copper coil wrapped around or placed in or near the object to be heated. Material Handling. The method of material handling is dependent on the application.
For Honeywell applications, the induction heater consists of a compact sealed electrical unit. It may be table mounted or mounted on a movable trolley. An induction heater may possess the following three operating modes: (a) Temperature Hold. 1 During the temperature hold operating mode, the specified final temperature is manually set. The induction heater heats the component to this temperature and maintains this temperature until it is manually stopped. The heater then de-magnetizes the workpiece. The unit then shuts off automatically.
2 3 (b)
Temperature Shutoff. 1 During the temperature shutoff operating mode the specified temperature is manually set. The component is then heated to the set temperature and the heating cycle automatically stops. The heater then demagnetizes the component. The unit then shuts off automatically.
2 3 (c)
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Timed Shutoff.
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STANDARD PRACTICES MANUAL AS907-1-1A 1 During the timed shutoff operating mode the specified heating duration is manually set. The component is then heated for that period of time and the heating cycle automatically stops. The heater then demagnetizes the component. The unit then shuts off automatically.
2 3 (d)
Only the temperature shut off operating mode may be used for induction heating bearings and associated components. This will minimize the possibility of over heating and softening the components. It is also recommended that the induction heater timing feature be disabled to prevent its use and minimize the possibility of over heating the component. NOTE: An induction heater obtains maximum power within 1-2 seconds after starting. Using a time function could heat the part for a length of time that would over temper the part and soften the material.
(e)
(4)
Equipment Type. (a) The following equipment, or equivalent equipment, is required to induction heat bearings and associated seals for fit assembly: 1 2 Eddytherm 1x ETH 7100/ETH 7110 available from PROFTECHNIK AG. Refer to the List of Suppliers in Step D. of SUBTASK 70-80-00-800-003. Foucault Induction Heaters (also known as Betex Induction Heaters) are available from Foucault International. Refer to the List of Suppliers in Step D. of SUBTASK 70-80-00-800-003. SKF Bearing Induction Heaters SKF Model: TIH 030 available from PT. KOGELAHAR INDONUSA. Refer to the List of Suppliers in Step D. of SUBTASK 70-80-00-800-003.
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Induction Heater. Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-10-01-370-005 F. Process. (1) General. (a) (b) The induction heating process usually provides consistent and constant heating over the entire circumference of the bearing or component. Components with non-uniform cross sections may develop hot spots that could cause over-tempering and subsequent loss of strength in the component. If over heating is suspected, the bearing shall be measured for hardness. Refer to TASK 70-34-03-220-009, Rockwell Hardness Testing. The critical components in the induction heating process are temperature control, handling and demagnetization. 1 Temperature Control a The induction heater shall be equipped with a pressure temperature probe and a single point touch temperature probe for use with large parts. Induction heater temperature limits shall be programmable. The induction heater shall be equipped with: Set temperature digital read out. Bearing or component actual temperature digital readout. d The induction heating process shall be temperature controlled, not time controlled. It is recommended that the timing feature be disabled. The induction heater shall be programmed not to exceed maximum temperature limits to prevent over-tempering bearings. It is recommended that 3508F (1778C) be the maximum induction heating temperature for assemble fit components. Table 1, Page 6. The induction heater temperature shall be calibrated within plus or minus 3 degrees.
(c) (d)
b c
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Table 1. Examples of Components Assembled Using Induction Heating Recommended Maximum Recommended Component Temperature Operation Mode No. 3 Bearing Inner Race 4008F (2048C)* Temperature Shutoff Forward Rotating Oil Seal 3508F (1778C) Temperature Shutoff No. 4 Bearing Inner Race 3508F (1778C) Temperature Shutoff No. 4 Ball Bearing Forward Inner Race 3508F (1778C) Temperature Shutoff No. 4 Ball Bearing Rear Inner Race 3508F (1778C) Temperature Shutoff Rear Rotating Air/Oil Seal 3508F (1778C) Temperature Shutoff Rear Rotating Air Seal 3508F (1778C) Temperature Shutoff No. 5 Bearing Inner Race 3508F (1778C) Temperature Shutoff No. 3 Bearing Inner Race 3508F (1778C) Temperature Shutoff No. 4 Bearing Air/Oil Seal 3508F (1778C) Temperature Shutoff No. 4 Bearing Forward Inner Race 3508F (1778C) Temperature Shutoff No. 4 Bearing Aft Inner Race 3508F (1778C) Temperature Shutoff Gearbox Bearings 2658F (1298C) Temperature Shutoff Gearbox Bearings 3008F (1498C) Temperature Shutoff NOTE: *Use a maximum temperature of 3508F (1778C) if it proves to be sufficient for assembly.
Handling a Handle bearings and associated parts with care. Use gloves when handling bearings. Assure that equipment used will not damage bearings. Induction heaters may cause some components to resonate or vibrate during the heating cycle. This vibration may damage the bearing or component.
CAUTION: ELECTRIC ARC DAMAGE COULD OCCUR IF PARTS COME INTO DIRECT CONTACT WITH THE METALLIC CROSSBAR OR POSTS. c It is recommended that the crossbar and vertical bars be coated with teflon to prevent vibration damage. Make sure that the coatings are intact and are not chipped, scratched, or damaged. Non-conductive high temperature hard plastic spacers are recommended to position the part away from the crossbar and post during heating.
Demagnetization NOTE: The induction heating cycle may magnetize the component. a Induction heaters shall have a demagnetization (degauss) cycle following the heating cycle.
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STANDARD PRACTICES MANUAL AS907-1-1A b (2) After the demagnetizing verify that the residual field is less then 5 gauss.
Process Procedure. WARNING: NEVER TOUCH THE BODY OF THE METAL TEMPERATURE PROBE AFTER HEATING A COMPONENT. UNLIKE THE CROSSBAR AND VERTICAL POSTS, THE PROBE WILL BECOME VERY HOT DURING OPERATION.
CAUTION: THE INDUCTION HEATER CREATES A STRONG MAGNETIC FIELD THAT CAN AFFECT ELECTROMAGNETIC EQUIPMENT SUCH AS WRISTWATCHES AND CARDIAC PACEMAKERS. SUCH DEVICES SHOULD BE KEPT AT LEAST 2M (2.6 FT) AWAY FROM THE HEATER DURING OPERATION. CAUTION: FOLLOW THE INDUCTION HEATER MANUFACTURERS OPERATING INSTRUCTIONS. DO NOT ALLOW THE COMPONENTS TO EXCEED THE SHOP MANUAL TEMPERATURE. ASSURE THAT THE HEATER IS SET TO THE APPROPRIATE TEMPERATURE SCALE. (a) (b) (c) (d) Assure that the induction heating unit is within specified calibration. Connect the power supply. Mount components horizontally over one of the vertical posts. If the component diameter does not fit over a vertical post, insert largest possible crossbar through the component and allow the part to hang from the crossbar. This maximizes operating efficiency. Figure 2, Page 10. Handle crossbars with care. Crossbars are constructed of thin laminated steel plate. Crossbars are susceptible to damage. Install crossbars with laminates oriented vertically. (Polished side facing down.) Figure 2, Page 10 Select the operating mode specified for the component. Only the Temperature Shut Off mode may be used. Table 1, Page 6 Attach magnetic temperature probe to component. Set the specified heating temperature for component. Induction heat temperature shall not exceed temperature specified in the applicable shop manual. It is recommended that the maximum temperature be 3508F (1778C). Start the induction heater. Monitor the maximum temperature and heating cycle time. Wait for heating and demagnetization cycle to complete.
(e) (f) (g) (h) (i)
(j)
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STANDARD PRACTICES MANUAL AS907-1-1A WARNING: TEMPERATURE PROBE AND COMPONENT ARE VERY HOT [APPROXIMATELY 3508F (1778C)]. USE THERMAL GLOVES WHEN MOVING OR TOUCHING PROBE OR PART. HOT COMPONENTS CAN CAUSE INJURY.
(k)
Remove probe and crossbar and carefully remove heated component for assembly into engine.
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Induction Heater. Figure 2
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-10-01-370-006 G. Process Control. NOTE: Control the induction heating process quality by using the following methods unless otherwise stated in the applicable manual. (1) Visual Inspection. (a) Procedure. 1 (b) Visually inspect the part for any induction heat discoloration or electrical arc damage.
Frequency. 1 All parts shall be inspected for discoloration or electrical arc damage after induction heating.
(c)
Requirements. 1 If discoloration is observed the component hardness shall be checked. Refer to applicable manual for hardness specification. Refer to TASK 70-34-03-220-009, Rockwell Hardness Testing. The hardness check shall be made on a non-functional surface such as the end face of a bearing. If damage from electrical arc is observed, the part shall be put on hold for a determination of serviceability.
2 3 (2)
Induction Heat Temperature. (a) Procedure. 1 (b) Use temperature probe or other thermocouple to determine maximum temperature of induction heat cycle.
Frequency. 1 All parts shall have maximum induction heating temperature determined. Refer to Table 1, Page 6.
(c)
Requirements. 1 2 Induction heat temperature shall not exceed applicable manual specified temperature. If induction heat specified temperature is exceeded the component hardness shall be checked. Refer to applicable manual for hardness specification. Refer to TASK 70-34-03-220-009, Rockwell Hardness Testing. The hardness check shall be made on a non-functional surface such as the end face of a bearing.
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-10-01-370-007 H. Quality Assurance/Calibration (1) Calibration of equipment shall be accomplished using a secondary thermocouple, traceable to an internationally recognized standards organization, to verify the temperature during heating. Frequency of calibration and verification of the induction heating units capability shall be on a periodic interval established in the maintenance and quality plan/ system for the facility in question. This frequency will be at a minimum of every six months and established to insure that the equipment can reliably and consistently produce the needed tolerances required to process materials. All temperature measuring instruments must have an indicated temperature measuring accuracy of 0.5 percent of the maximum temperature measured over the entire operating range. (a) Calibrate accuracy of temperature display, temperature hold duration and temperature probe. Refer to TASK 70-44-04-370-001, Heat Treat Equipment Calibration. Temperature sensors and recording devices will be calibrated per the procedure of AMS 2750 sections 3.1 (Temperature Sensors) and 3.2 (Instrumentation) unless specified otherwise.
(2)
(3)
(b)
(4) (5)
Thermocouples must be in accordance with ASTM E 220 and ASTM E 230. Record the detailed results of the approved tests in a log document. Record, at least, the following: (a) (b) (c) (d) (e) Induction heating unit identification. Instrumentation procedures including thermocouple type. Temperature records. All calibration records. Traceability for thermocouples wire material.
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FASTENERS - FASTENER RETENTION PROCEDURES TASK 70-11-00-400-001 1. Fastener Retention Procedures SUBTASK 70-11-00-99G-001 A. General. (1) This section gives the necessary instructions to safety parts with safety wire, safety cable, cotter pins, or tab washers. These devices are not designed to hold torque. The function of fastener retention devices is to oppose the forces that would cause the fasteners or other parts to loosen. Unless specified differently, all procedures that refer to safety wire can use safety cable. For safety wire, refer to Subtask 7011-00-400-011, Safety Wire Practices. For safety cable, refer to Subtask 70-11-00400-011, Safety Wire Practices.
SUBTASK 70-11-00-400-011 B. Safety Wire Practices. (1) Safety wire is installed through, or around, two or more parts in such a way that as the fastener or part loosens the safety wire will tighten. When the safety wire tightens it will not permit the fastener or part to turn. Refer to TASK 70-11-01-400005, Safety Wire Procedure, for more information on safety wire practices. Safety cable can be used as an alternative to safety wire.
SUBTASK 70-11-00-400-012 C. Safety Cable Practices. (1) Safety cable is installed through two or more parts in such a way that as the fastener or part loosens the safety cable will tighten. When the safety cable tightens it will not permit the fastener or part to turn. Refer to TASK 70-11-02-400006, Safety Cable Procedure, for more information on safety cable practices. Safety cable can be used when safety wire is specified.
SUBTASK 70-11-00-400-013 D. Cotter Pin Practices. CAUTION: DO NOT EXCEED MAXIMUM TORQUE WHEN TIGHTENING FASTENERS. (1) Tighten the castellated nut to the low side of the specified torque range, and continue tightening until a slot aligns with the hole in the bolt shank. Figure 1, Page 2.
CAUTION: COTTER PINS ARE NOT REUSABLE. USE NEW COTTER PINS FOR EACH ASSEMBLY. (2) Install the cotter pin with the head seated firmly in the slot of the nut. Bend prongs of cotter pin so that the head and upper prong are firmly seated against the bolt.
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FASTENER RETENTION PROCEDURES Page 1 Dec 01/03
Safety with Cotter Pin Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-11-00-400-014 E. Tab Washer Practices. CAUTION: TAB WASHERS ARE NOT REUSABLE. USE NEW TAB WASHERS FOR EACH ASSEMBLY. (1) (2) Fit the tab washer so that the locking tab is butted against any tendency to untighten. Figure 2, Page 4. Bend the locking tab snugly against flat of nut. See Figure 2 for the correct and incorrect method of bending.
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Safety with Tab Washer Figure 2
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SAFETY WIRE - SAFETY WIRE PROCEDURE TASK 70-11-01-400-005 1. Safety Wire Procedure SUBTASK 70-11-01-99G-005 A. General. (1) (2) (3) Safety cable is permitted as an alternative to safety wire. The three safety cable methods are equivalent alternatives and are interchangeable: TASK 70-11-03-400-007, Safety Cable Method 1 (Bergen Tool), Where possible, install stainless steel safety wire C10-071 by twisting two strands together (the double-twist method). One twist is defined as that produced by twisting the wires through an arc of 180 degrees and is equal to one-half a complete turn. The single strand method (see 3, Figure 1, Page 3) may only be used when specified. Allowable materials for use as safety wire are AMS 5685, 5687, 5689 and 5690. Where possible, do not install safety wire in such a way as to cause the wire to be subjected to chafing, fatigue through vibration, or additional tension other than the tension imposed on the wire to prevent disengagement. In all cases, safety wire must be installed through the holes provided. When no hole is provided, attach the wire to a neighboring part so as not to interfere with the function of the part, or surrounding parts, and in accordance with the recommendations of this section. See 6 and 7, Figure 1, Page 3. The maximum span of safety wire between tension points shall be 6.0 inches (152.4 mm), unless otherwise specified. Where several fasteners form a group to be safety-wired together by either the single-strand or the double-twist method, the maximum number of units in a series shall be limited to the number of units that can be safety-wired by a 24.0 inch (609.6 mm) length of wire. When safety-wiring widely spaced units in a group, using the double-twist method, not more than three units shall be safety-wired in a series. See 8 and 9, Figure 1, Page 3.
(4)
(5)
(6)
CAUTION: ALWAYS USE NEW SAFETY WIRE, AND BE SURE THAT IT MEETS THE SPECIFICATIONS NOTED BELOW. (7) Both 0.020 0.001 inch (0.51 0.03 mm) and 0.032 0.001 inch (0.81 0.03 mm) stainless steel safety wire are used throughout the engine. The choice is determined by the size of the hole in the unit to be safety-wired. When possible, use the 0.032 inch (0.81 mm) safety wire. Pull safety wire taut while twisting it. The twisted wire should have 9 to 12 twists per inch for 0.020 inch (0.51 mm) wire, and 7 to 10 twists per inch for 0.032 inch (0.81 mm) wire.
(8)
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SAFETY WIRE PROCEDURE Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (9) Safety-wire hose and electrical coupling nuts in the same manner as the tube coupling nuts. See 6, 7, 10, 11, 12, and 13, Figure 1, Page 3.
CAUTION: DURING THE TWISTING OPERATION KEEP THE SAFETY WIRE TIGHT WITHOUT OVERSTRESSING IT OR PERMITTING IT TO BECOME NICKED, KINKED, OR OTHERWISE MUTILATED. (10) The use of commercially available safety wire twisting tools C10-150 is recommended. Two such tools are shown in Figure 2, Page 4.
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Safety-Wire Practices Figure 1
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Safety Wire Twisting Tools Figure 2
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-11-01-400-006 B. Code No. C10-150 SUBTASK 70-11-01-400-062 C. Code No. C10-071 SUBTASK 70-11-01-400-063 D. Specific Techniques for Safety-wiring. Consumables. Description Safety wire Tools and Equipment. Description Safety wire twisting tools
CAUTION: SAFETY WIRE IS NOT REUSABLE. ALWAYS USE NEW SAFETY WIRE. (1) See Figure 3, Page 7. Insert the safety wire through the first part, and bend the upper end either over the head of the part or around it. If bent around it, the direction of wrap and twist of the strands shall be such that the loop around the part comes under the strand protruding from the hole. Done this way, the loop will stay down and will not tend to slip up and leave a slack loop. See 1 and 2, Figure 3, Page 7. Twist the strands while taut until the twisted part is just short of a hole in the next part. The twisted portion should be within 0.125 inch (3.18 mm) of the hole in the other part. See 3 and 4, Figure 3, Page 7. If the free strand is to be bent around the head of the second part, insert the uppermost strand through the hole in this part, then repeat step (1). If the free strand is to be bent over the unit, the direction of the twist is unimportant. If there are more than two units in the series, repeat the preceding steps. See 5 and 6, Figure 3, Page 7. After safety-wiring the last part, continue twisting the wires to form a pigtail of three to six twists 0.250-0.50 inch (6.4-12.7 mm) long and cut off the excess wire. Bend the pigtail inwards toward the part to prevent it from becoming a snag. See 7 and 8, Figure 3, Page 7. NOTE: Although every possible combination of safety-wiring is not shown in Figure 1, Page 3, all safety-wiring must conform generally to the examples shown.
(2)
(3)
(4)
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STANDARD PRACTICES MANUAL AS907-1-1A (5) After safety-wiring, use the following limits to determine its acceptability. If the length of the wire is between the distances given, use the flex limit for the shorter distance to approve or reject the installation. NOTE: Apply light finger-pressure to the midpoint of the safety wire span, and flex in both directions. Length of Safety wire Between Parts 0.5 in. (12.7 mm) 1.0 in. (25.4 mm) 2.0 in. (50.8 mm) 3.0 in. (76.2 mm) 4.0 in. (101.6 mm) 5.0 in. (127.0 mm) 6.0 in. (152.4 mm) (6) (7) Maximum Permitted Flexing At Center 0.125 in. (3.2 mm) 0.250 in. (6.4 mm) 0.375 in. (9.5 mm) 0.500 in. (12.7 mm) 0.750 in. (19.1 mm) 0.750 in. (19.1 mm) 0.750 in. (19.1 mm)
If safety wire fails to meet these limits, remove it and install new safety wire. Always cut rather than break safety wire so that safety wire holes are not torn or damage.
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Safety-Wiring Technique Figure 3
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SAFETY CABLE - SAFETY CABLE PROCEDURES TASK 70-11-02-400-006 1. Safety Cable Procedures SUBTASK 70-11-02-99G-006 A. General. (1) Safety cable is an alternative to safety wire. Safety cable is installed through two or more parts in such a way that if the fastener or part loosens, the safety cable will tighten. When the safety cable tightens it will not permit the fastener or part to turn. There are three methods used to install safety cables. These three methods are equivalent alternatives and are interchangeable: TASK 70-11-03-400-007, Safety Cable Method 1 (Bergen Tool),
(2) (3)
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SAFETY CABLE PROCEDURES Page 2 Dec 01/03
SAFETY CABLE - SAFETY CABLE METHOD 1 (BERGEN TOOL) TASK 70-11-03-400-007 1. Safety Cable Method 1 (Bergen Tool) SUBTASK 70-11-03-99G-007 A. General. (1) Method 1 is an equivalent alternative to: TASK 70-11-04-400-008, Safety Cable Method 2 (Snap-On Tool), and TASK 70-11-05-400-009, Safety Cable Method 3 (Daniels (DMC) Tool). (2) Safety cable assembly C10-143 is an alternative to safety wire. Safety cable is installed through two or more parts in such a way that as the fastener or part loosens the safety cable will tighten. When the safety cable tightens it will not permit the fastener or part to turn. The safety cable system has three components: the safety cable, ferrules and crimping tool. Figure 1, Page 2. (a) The safety cable C10-145 is available in one size, 0.032 inch (0.81 mm), and is made of AMS 5689 (321 stainless steel) material. One end of the cable will have a cable end fitting swaged to it. The cable end fitting is made of AMS 5674 (347 stainless steel) or AMS 5689 (321 Stainless Steel) material. The strands of the cable on the opposite end of the cable are fused together to prevent the cable from fraying. The ferrules C10-144 are made of AMS 5674 (347 Stainless Steel) or AMS 5689 (321 Stainless Steel) material and are purchased in a spring-loaded, disposable magazine. When the safety cable is installed the ferrule will be crimped on the open end of the cable. The hand-operated crimping tool C10-148 comes in different lengths. The crimping pressure of the tool is set by the manufacturer. The primary parts of the crimping tool are the crimping head, tensioning wheel, slotted wheel and handles. This tool is used to crimp the ferrule on the end of the safety cable. The crimping tool will cut the safety cable even with the ferrule at the same time the ferrule is crimped.
(3)
(b)
(c)
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70-11-03
SAFETY CABLE METHOD 1 (BERGEN TOOL) Page 1 Dec 01/03
Safety Cable System Components Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-11-03-400-061 B. Code No. C10-146 C10-147 C10-148 C10-149 SUBTASK 70-11-03-400-062 C. Code No. C10-143 C10-144 C10-145 SUBTASK 70-11-03-400-063 D. Safety Cable Practices (Method 1). (1) (2) Where possible, install the safety cable so it does not touch other parts. Make sure the cable is not damaged or bent when you install the safety cable through the holes in the fastener or part. Frayed cable assemblies are not permitted. Install the safety cable through existing holes only. Unless specified differently in the applicable engine manual: (a) (b) (c) The maximum length of the safety cable between safety cabled parts is 6.0 inches (152.4 mm). Do not safety more than three bolts with one safety cable. Do not use safety cable on titanium fasteners. Consumables (Method 1). Description Safety Cable Assembly (0.032 inch Dia) Ferrule, Safety Cable (0.032 inch Dia) Cable, Safety (0.032 inch Dia) Tools and Equipment (Method 1). Description Test Block, Safety Cable Tester, Safety Cable Crimping Tool, Safety Cable (0.032 inch dia. wire) Side Cushioned Diagonal Cutter
(3) (4)
SUBTASK 70-11-03-400-064 E. Crimping Tool Verification. (1) Do a pulloff load test as often as necessary to make sure the crimp done by the crimping tool meets the necessary requirements. A pulloff load test is
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STANDARD PRACTICES MANUAL AS907-1-1A recommended at the beginning, middle and end of each shift. Do the pulloff load test as follows: Figure 2, Page 6. (a) (b) (c) If the test block C10-146 is not already set up, set it up at this time. Refer to manufacturers instructions for set up information. Make sure the pivot joint is in the forward direction. Move the cable stop at the end of the test block. Install the safety cable C10145 through the hole that was covered by the cable stop. Pull the safety cable through the hole in the test block and then put it through the hole in the pivot joint. Pull the cable through the hole in the pivot joint. Put the end of the safety cable coming out of the pivot joint through a ferrule C10-144 in the ferrule magazine. Pull the safety cable through the ferrule and use the safety cable to pull the ferrule out of the ferrule magazine. Figure 3, Page 7, block 2. Put the end of the safety cable through the crimping head of the crimping tool C10-148. Make sure the large hole in the crimping head is on the same side as the ferrule. Move the crimping tool along the safety cable until the crimping head is against the part. Make sure the ferrule goes inside the hole in the crimping head. Figure 3, Page 7, blocks 3 and 4. If the ferrule will not go in the crimping head, remove the crimping tool from the cable and push the handles all the way together. When the handles are released they will open automatically. Put the cable back through the crimping head and move the crimping tool along the safety cable until the crimping head is against the part. Make sure the ferrule goes inside the crimping head.
(d)
(e)
(f)
CAUTION: DO NOT PUT TOO MUCH TENSION ON THE SAFETY CABLE. THE CRIMPING TOOL WILL AUTOMATICALLY SET THE TENSION. TOO MUCH TENSION WILL CAUSE UNNECESSARY STRESS ON THE SAFETY CABLE. (g) Put the safety cable across the slotted tensioning wheel on the side of the crimping tool. Make sure the cable is in the two slots in the wheel that are in line with the crimping head. Make sure the crimping tool is held perpendicular to the cable and the ferrule is tightly against the bolt head. Turn the tensioning wheel on the side of the crimping tool until several clicks are heard. Figure 3, Page 7, block 5.
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STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: IF THE HANDLES ON THE CRIMPING TOOL ARE NOT COMPLETELY CLOSED WHEN THE OPERATOR RELEASES THEM, THE HANDLES WILL REMAIN IN THE SAME POSITION AND WILL NOT OPEN. IF THIS SHOULD HAPPEN, APPLY PRESSURE TO CLOSE THE HANDLES AGAIN UNTIL THE HANDLES WILL RELEASE. DO NOT TRY TO REMOVE THE CRIMPING TOOL FROM THE FERRULE WITH THE HANDLES IN THE CRIMPED OR CLOSED POSITION. CAUTION: DO NOT CRIMP THE FERRULE UNLESS THE CORRECT TENSION HAS BEEN APPLIED BY THE TENSIONING WHEEL. (h) (i) (j) (k) Apply constant pressure to close the crimping tool handles. Continue to close the handles until the cable is cut. Release the pressure on the handles. Remove and discard the unused safety cable from the slotted tensioning wheel on the side of the crimping tool. Set a calibrated breakaway torque wrench to 80 lb. in. (9.0 Nm). Install the torque wrench in the pivot joint on the test block C10-146. Find the center of the safety cable in the test block. Use light finger pressure and push the center of the safety cable toward the wall on the test block. The safety cable must not touch the wall. If the safety cable touches the wall, the safety cable is not serviceable. Cut the safety cable with wire cutters C10-149 and remove the safety cable from the test block. Install a new safety cable and do the pulloff load test again. Make sure the tension on the safety cable is correct. Make sure when you crimp the ferrule the crimping tool is perpendicular to the safety cable and the ferrule is tightly against the bolt head. Move the torque wrench handle counter-clockwise until the torque wrench clicks or the ferrule moves. If the ferrule moves before you hear the torque wrench click, remove the crimping tool from service. Do the finger pressure test again. Find the center of the safety cable in the test block. Use light finger pressure and push the center of the safety cable toward the wall on the test block. If the safety cable does not touch the wall the crimping tool can be released for service. Figure 2, Page 6. If the safety cable touches the wall, remove the crimping tool from service.
(l)
(m)
(n)
(o) (2)
Do a test to determine the exact amount of pressure necessary to cause the crimped ferrule or safety cable to fail. It is recommended that this test be done a minimum of once a month. Use a safety cable tester C10-147 to do this test. Figure 2, Page 6. Do the test according to the manufacturers instructions. This test can also be used as an alternative to the test block test.
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70-11-03
Crimping Tool Verification Equipment Figure 2
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Safety Cable Procedure Figure 3
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-11-03-400-065 F. Specific Techniques for Safety Cable. (1) Do a visual inspection of the holes to be safety cabled to find all damage. If the hole is damaged, replace the part or, if possible, use another hole to safety cable. NOTE: Keep the safety cable as straight as possible when you safety cable the fasteners or parts together. Figure 4 (Sheet 1 of 2), Page 10. (2) Put the end of the safety cable C10-145 without the cable end fitting into the hole in the part. Pull the cable through the hole until the cable end fitting is against the part. Figure 4 (Sheet 1 of 2), Page 10, block 1. NOTE: Although every possible combination of safety cabling is not shown in Figure 4 (Sheet 1 of 2), Page 10, all safety cabling must conform generally to the examples shown. NOTE: On a two bolt pattern, do not cable in a negative pull direction. Make sure the cable has a positive or neutral pull. (3) Insert the end of the cable through the second part. Choose the hole in the part that permits the cable to be as straight as possible. Pull the cable through the second part. If three parts must be safety cabled, do the same procedure for the third part. Put the end of the safety cable coming out of the last part to be safety cabled through a ferrule C10-144 in the ferrule magazine. Pull the safety cable through the ferrule and use the safety cable to pull the ferrule out of the ferrule magazine. Figure 4 (Sheet 1 of 2), Page 10, block 2. Put the end of the safety cable through the crimping head of the crimping tool C10148. Make sure the large hole in the crimping head is on the same side as the ferrule. Move the crimping tool along the safety cable until the crimping head is against the part. Make sure the ferrule goes inside the hole in the crimping head. Figure 4 (Sheet 1 of 2), Page 10, blocks 3 and 4. If the ferrule will not go in the crimping head, remove the crimping tool from the cable and push the handles all the way together. When you release the handles they will open again automatically. Put the cable back through the crimping head and move the crimping tool along the safety cable until the crimping head is against the part. Make sure the ferrule goes inside the crimping head. Put the safety cable across the slotted tensioning wheel on the side of the crimping tool. Make sure the cable is in the two slots in the wheel that are in line with the crimping head. Make sure the crimping tool is held perpendicular to the cable and the ferrule is tightly against the bolt head. Turn the tensioning wheel on the side of the crimping tool until a click is heard. Figure 4 (Sheet 1 of 2), Page 10, block 5.
(4)
(5)
(6)
(7)
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STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: IF THE HANDLES ON THE CRIMPING TOOL ARE NOT COMPLETELY CLOSED WHEN THE OPERATOR RELEASES THEM, THE HANDLES WILL REMAIN IN THE SAME POSITION AND WILL NOT OPEN. IF THIS SHOULD HAPPEN, APPLY PRESSURE TO CLOSE THE HANDLES AGAIN UNTIL THE HANDLES WILL RELEASE. DO NOT TRY TO REMOVE THE CRIMPING TOOL FROM THE FERRULE WITH THE HANDLES IN THE CRIMPED OR CLOSED POSITION. CAUTION: DO NOT CRIMP THE FERRULE UNLESS THE CORRECT TENSION HAS BEEN APPLIED BY THE TENSIONING WHEEL. (8) Apply constant pressure to close the crimping tool handles. Continue to close the handles until the cable is cut. Release the pressure on the handles. Look at the crimped ferrule to make sure it has a good crimp. Figure 4 (Sheet 1 of 2), Page 10, block 6. Visually inspect safety cable for kinks, frayed wires, or improper crimps. Remove and replace safety cable if a problem exists.
(9)
(10) Remove and discard the unused safety cable from the slotted tensioning wheel on the side of the crimping tool. (11) Push against the safety cable with light finger pressure halfway between the safety cabled parts. If the cable feels loose, do a dimensional check to make sure the safety cable is serviceable as follows: Figure 4 (Sheet 1 of 2), Page 10. (a) Measure the distance between the safety cabled parts. Write this measurement down as Dimension A. If three parts are safety cabled together, measure the distance between each of the parts and add the two measurements together to get Dimension A. Push against the safety cable with light finger pressure halfway between two safety cabled parts. Measure the distance the safety cable moves laterally. Write this measurement down as Dimension C. Compare the dimensions that were written down to the limits given in Figure 4 (Sheet 1 of 2), Page 10.
(b)
(c)
CAUTION: DO NOT TRY TO BREAK THE SAFETY CABLE. IF THE SAFETY CABLE MUST BE REMOVED, CUT THE SAFETY CABLE TO AVOID DAMAGE TO THE HOLES IN THE PARTS. (12) If the safety cable is not in the limits given in Figure 4 (Sheet 1 of 2), Page 10, cut the safety cable with wire cutters C10-149 and remove the safety cable. Install new safety cable.
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Safety Cable Patterns Figure 4 (Sheet 1 of 2)
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Safety Cable Patterns Figure 4 (Sheet 2)
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Safety Cable Flex Limits Figure 5
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SAFETY CABLE - SAFETY CABLE METHOD 2 (SNAP-ON TOOL) TASK 70-11-04-400-008 1. Safety Cable Method 2 (Snap-On Tool) SUBTASK 70-11-04-99G-008 A. General. (1) (2) (3) (4) Method 2 is an equivalent alternative to: TASK 70-11-03-400-007, Safety Cable Method 1 (Bergen Tool), and TASK 70-11-05-400-009, Safety Cable Method 3 (Daniels (DMC) Tool). Safety cable is an alternative to safety wire. Safety cable is installed through two or more parts in such a way that as the fastener or part loosens the safety cable will tighten. When the safety cable tightens it will not permit the fastener or part to turn. The safety cable system has three components: The safety cable, ferrules and crimping tool. Figure 1, Page 2. (a) The safety cable C10-145 is available in one size, 0.032 inch (0.81 mm), and is made of AMS 5689 (321 stainless steel) material. One end of the cable will have a cable end fitting swaged to it. The cable end fitting is made of AMS 5674 (347 stainless steel) or AMS 5689 (321 stainless steel) material. The strands of the cable on the opposite end of the cable are fused together to prevent the cable from fraying. The ferrules C10-144 are made of AMS 5674 (347 Stainless Steel) or AMS 5689 (321 stainless steel) material and are purchased in a spring-loaded, disposable magazine. When the safety cable is installed the ferrule will be crimped on the open end of the cable. The hand-operated crimping tool C10-148 operates in one direction only and has a cycle end dead stop to tell the operator when the ferrule is fully crimped. The crimping pressure of the tool is set by the manufacturer. If necessary, the crimping pressure can be adjusted with standard hand tools. The Snap-On tool has a spring-loaded crimp rod to hold the ferrule in place during the crimping procedure. Cable tension is done automatically by the internal retraction mechanism.
(5)
(b)
(c)
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SAFETY CABLE METHOD 2 (SNAP-ON TOOL) Page 1 Dec 01/03
Safety Cable System Components (Method 2) Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-11-04-400-071 B. Code No. C10-146 C10-147 C10-148 C10-149 SUBTASK 70-11-04-400-072 C. Code No. C10-143 C10-144 C10-145 SUBTASK 70-11-04-400-073 D. Safety Cable Practices (Method 2). (1) (2) Where possible, install the safety cable so it does not touch other parts. Make sure the cable is not damaged or bent when you install the safety cable through the holes in the fastener or part. Frayed cable assemblies are not permitted. Install the safety cable through existing holes only. Unless specified differently in the applicable manual: (a) (b) (c) The maximum length of the safety cable between safety cabled parts is 6.0 inches (152.4 mm). Do not safety more than three bolts with one safety cable. Do not use safety cable on titanium fasteners. Consumables (Method 2). Description Safety Cable Assembly (0.032 inch Dia) Ferrule, Safety Cable (0.032 inch dia cables) Cable, Safety (for 0.032 inch dia cables) Tools and Equipment (Method 2). Description Test Block, Safety Cable Tester, Safety Cable Crimping Tool, Safety Cable (0.032 inch dia) Side Cushioned Diagonal Cutter
(3) (4)
SUBTASK 70-11-04-400-074 E. Crimping Tool Verification (Method 2). (1) Do a pulloff load test as often as necessary to make sure the crimp done by the crimping tool meets the necessary requirements. A pulloff load test is recommended at the beginning, middle and end of each shift. Do the pulloff load test as follows: Figure 2, Page 6.
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STANDARD PRACTICES MANUAL AS907-1-1A (a) (b) (c) If the test block C10-146 is not already set up, set it up at this time. Refer to manufacturers instructions for set up information. Make sure the pivot joint is in the forward direction. Move the cable stop at the end of the test block. Install the safety cable C10145 through the hole that was covered by the cable stop. Pull the safety cable through the hole in the test block and then put it through the hole in the pivot joint. Pull the cable through the hole in the pivot joint. Put the end of the safety cable coming out of the pivot joint through a ferrule C10-144 in the ferrule magazine. Pull the safety cable through the ferrule and use the safety cable to pull the ferrule out of the ferrule magazine. Figure 3, Page 7, step (b). Put the end of the safety cable through the crimping head of the crimping tool C10-148. Make sure the large hole in the crimping head is on the same side as the ferrule. Move the crimping tool along the safety cable until the crimping head is against the ferrule. Pull back on the retraction knob. Put the ferrule in the crimping head and release the retraction knob. Make sure the ferrule is fully in the crimping head. Figure 3, Page 7, steps (c), (d), and (e).
(d)
(e)
CAUTION: DO NOT PUT TOO MUCH TENSION ON THE SAFETY CABLE. THE CRIMPING TOOL WILL AUTOMATICALLY SET THE TENSION. TOO MUCH TENSION WILL CAUSE UNNECESSARY STRESS ON THE SAFETY CABLE. (f) Pull the safety cable to the tension post on the crimping tool. Wrap the cable completely around the post. Make sure the cable is in the groove at the top of the post. Pull the cable toward the drive handle until the cable goes behind the locking ball. Figure 3, Page 7, step (e). Hold the crimping tool perpendicular to the cable in the bolt head. Make sure the ferrule is tightly against the bolt head. Lightly pull on the end of the safety cable to remove slack. Figure 3, Page 7, step (e). Push the start cycle button and turn the drive handle clockwise. At the start of the cycle, the tension block will move backwards. This movement backwards provides the cable tension. When the drive handle is turned, release the start cycle button. Turn the drive handle until it stops (approximately two full turns). Pull up on the end of the safety cable end to remove it from the tension block. Pull back on the retraction knob and remove the crimping tool from the crimped ferrule and the remaining safety cable. Cut the unused safety cable even with the crimped ferrule. Use the side cushioned diagonal cutters C10-149. Discard the safety cable end. Find the center of the safety cable in the test block. Use light finger pressure and push the center of the safety cable toward the wall on the test block. The safety cable must not touch the wall.
(g)
(h)
(i) (j) (k) (l)
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STANDARD PRACTICES MANUAL AS907-1-1A (m) If the safety cable touches the wall, the safety cable is not serviceable. Cut the safety cable with wire cutters C10-149 and remove the safety cable from the test block. Install a new safety cable and do the pulloff load test again. Make sure the tension on the safety cable is correct. Make sure when you crimp the ferrule the crimping tool is perpendicular to the safety cable and the ferrule is tightly against the bolt head. If the cable touches the wall again, remove the crimping tool from service. Set a calibrated breakaway torque wrench to 80 lb. in. (9.0 Nm). Install the torque wrench in the pivot joint on the test block. Move the torque wrench handle counter-clockwise until the torque wrench clicks or the ferrule moves. If the ferrule moves before you hear the torque wrench click, remove the crimping tool from service. Find the center of the safety cable in the test block. Use light finger pressure and push the center of the safety cable toward the wall on the test block. If the safety cable does not touch the wall the crimping tool can be released for service. Figure 2, Page 6 If the safety cable touches the wall, the safety cable is not serviceable. Cut and remove the safety cable from the test block. Do the pulloff load test again with a new cable. Make sure when you crimp the ferrule the crimping tool is perpendicular to the safety cable and the ferrule is tightly against the bolt head. If the new safety cable is unserviceable, remove the crimping tool from service.
(n) (o)
(p)
(q)
(2)
Do a test to determine the exact amount of pressure necessary to cause the crimped ferrule or safety cable to fail. It is recommended that this test be done a minimum of once a month. Use a safety cable tester C10-147 to do this test. Figure 2, Page 6. Do the test according to the manufacturers instructions. This test can also be used as an alternative to the test block test.
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70-11-04
Crimping Tool Verification Equipment (Method 2) Figure 2
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Safety Cable Procedure (Method 2) Figure 3
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70-11-04
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-11-04-400-075 F. Specific Techniques for Safety Cable (Method 2). (1) Do a visual inspection of the holes to be safety cabled to find all damage. If the hole is damaged, replace the part or, if possible, use another hole to safety cable. NOTE: Keep the safety cable as straight as possible when you safety cable the fasteners or parts together. See Figure 4 (Sheet 2), Page 11. (2) Put the end of the cable without the cable end fitting into the hole in the part. Pull the cable through the hole until the cable end fitting is against the part. See Figure 3, Page 7, block 1. NOTE: Although every possible combination of safety cabling is not shown in Figure 4 (Sheet 2), Page 11, all safety cabling must conform generally to the examples shown. (3) Insert the end of the cable through the second part. Choose the hole in the part that permits the cable to be as straight as possible. Pull the cable through the second part. If three parts must be safety cabled, do the same procedure for the third part. NOTE: On a two bolt pattern, do not cable in a negative pull direction. Make sure the cable has a positive or neutral pull. (4) Put the end of the safety cable coming out of the last part to be safety cabled through a ferrule in the ferrule magazine. Pull the safety cable through the ferrule and use the safety cable to pull the ferrule out of the ferrule magazine. See Figure 3, Page 7, block 2. Put the end of the safety cable through the crimping head of the crimping tool. Make sure the large hole in the crimping head is on the same side as the ferrule. Move the crimping tool along the safety cable until the crimping head is against the ferrule. Pull back on the retraction knob. Put the ferrule in the crimping head and release the retraction knob. Make sure the ferrule is fully in the crimping head. See Figure 3, Page 7, blocks 3 and 4.
(5)
CAUTION: DO NOT PUT TOO MUCH TENSION ON THE SAFETY CABLE. THE CRIMPING TOOL WILL AUTOMATICALLY SET THE TENSION. TOO MUCH TENSION WILL BREAK THE SAFETY CABLE. (6) Pull the safety cable to the tension post on the crimping tool. Wrap the cable completely around the post. Make sure the cable is in the groove at the top of the post. Pull the cable toward the drive handle until the cable goes behind the locking ball. See Figure 3, Page 7, block 5. Hold the crimping tool perpendicular to the cable in the bolt head. Make sure the ferrule is tightly against the bolt head. Lightly pull on the end of the safety cable to remove slack. See Figure 3, Page 7, block 5. Push the start cycle button and turn the drive handle clockwise. At the start of the cycle, the tension block will move backwards. This movement backwards provides the cable tension. When the drive handle is turned, release the start cycle button. Turn the drive handle until it stops (approximately two full turns).
(7)
(8)
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STANDARD PRACTICES MANUAL AS907-1-1A (9) Pull up on the safety cable end to remove it from the tension block.
(10) Pull back on the retraction knob and remove the crimping tool from the crimped ferrule and the remaining safety cable. (11) Cut the unused safety cable even with the crimped ferrule. Use the side cushioned cutters C10-149. Discard the unused safety cable. (12) Visually inspect safety cable for kinks, frayed wires, or improper crimps. Remove and replace safety cable if a problem exists. (13) Push against the safety cable with light finger pressure halfway between the safety cabled parts. If the cable feels loose, do a dimensional check to make sure the safety cable is serviceable ( Figure 5, Page 12) as follows: (a) Measure the distance between the safety cabled parts. Write this measurement down as Dimension A. If three parts are safety cabled together, measure the distance between each of the parts and add the two measurements together to get Dimension A. Push against the safety cable with light finger pressure halfway between two safety cabled parts. Measure the distance the safety cable moves laterally. Write this measurement down as Dimension C. Compare the dimensions that were written down to the limits given in Figure 5, Page 12.
(b)
(c)
CAUTION: DO NOT TRY TO BREAK THE SAFETY CABLE. IF THE SAFETY CABLE MUST BE REMOVED, CUT THE SAFETY CABLE TO AVOID DAMAGE TO THE HOLES IN THE PARTS. (14) If the safety cable is not in the limits given in Figure 5, Page 12, cut the safety cable with wire cutters C10-149 and remove the installed safety cable. Install new safety cable.
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70-11-04
Safety Cable Patterns Figure 4 (Sheet 1 of 2)
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Safety Cable Patterns Figure 4 (Sheet 2)
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Safety Cable Flex Limits Figure 5
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70-11-04
SAFETY CABLE - SAFETY CABLE METHOD 3 (DANIELS (DMC) TOOL) TASK 70-11-05-400-009 1. Safety Cable Method 3 (Daniels (DMC) Tool) SUBTASK 70-11-05-99G-009 A. General. (1) Method 3 is an equivalent alternative to: (a) (b) TASK 70-11-03-400-007, Safety Cable Method 1 (Bergen Tool), and TASK 7011-04-400-008, Safety Cable Method 2 (Snap-On Tool). Safety cable is an alternative to safety wire. Safety cable is installed through two or more parts in such a way that as the fastener or part loosens the safety cable will tighten. When the safety cable tightens it will not permit the fastener or part to turn. The safety cable system has three components: The safety cable, ferrules and crimping tool. See Figure 1, Page 2. The safety cable C10-145 is available in one size, 0.032 inch (0.81 mm), and is made of AMS 5689 (321 stainless steel) material. One end of the cable will have a cable end fitting swaged to it. The cable end fitting is made of AMS 5674 (347 stainless steel) or AMS 5689 (321 Stainless Steel) material. The strands of the cable on the opposite end of the cable are fused together to prevent the cable from fraying. The ferrules C10-144 are made of AMS 5674 (347 Stainless Steel) or AMS 5689 (321 Stainless Steel) material and are purchased in a spring-loaded, disposable magazine. When the safety cable is installed the ferrule will be crimped on the open end of the cable. The hand-operated crimping tool C10-148 comes in two different lengths. The crimping pressure of the tool is set by the manufacturer. The primary parts of the crimping tool are the nose assembly and the tool body. This tool is used to crimp the ferrule on the end of the safety cable. The crimping tool will cut the safety cable even with the ferrule at the same time the ferrule is crimped.
(c) (d)
(e)
(f)
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70-11-05
SAFETY CABLE METHOD 3 (DANIELS (DMC) TOOL) Page 1 Dec 01/03
Safety Cable System Components (Method 3) Figure 1
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70-11-05
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-11-05-400-051 B. Code No. C10-146 C10-147 C10-149 C10-148 SUBTASK 70-11-05-400-052 C. Code No. C10-143 C10-144 C10-145 SUBTASK 70-11-05-400-053 D. Safety Cable Practices (Method 3). (1) (2) Where possible, install the safety cable so it does not touch other parts. Make sure the cable is not damaged or bent when you install the safety cable through the holes in the fastener or part. Frayed cable assemblies are not permitted. Install the safety cable through the existing holes only. Unless specified differently in the applicable engine manual: (a) (b) (c) The maximum length of the safety cable between safety cabled parts is 6.0 in. (152.4 mm). Do not safety more than three bolts with one safety cable. Do not use safety cable on titanium fasteners. Consumables (Method 3). Description Safety Cable Assembly (0.032 inch Dia) Ferrule, Safety Cable (0.032 in. Dia) Cable, Safety (0.032 in. Dia) Tools and Equipment (Method 3). Description Test Block, Safety Cable Tester, Safety Cable Side Cushioned Diagonal Cutter Crimping Tool, Safety Cable (0.032 in. dia wire)
(3) (4)
SUBTASK 70-11-05-400-054 E. Crimping Tool Verification (Method 3). (1) Do a pulloff load test as often as necessary to make sure the crimp done by the crimping tool meets the necessary requirements. A pulloff load test is recommended at the beginning, middle and end of each shift. Do the pulloff load test as follows: See Figure 2, Page 6.
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STANDARD PRACTICES MANUAL AS907-1-1A (a) (b) (c) If the test block C10-146 is not already set up, set it up at this time. Refer to manufacturers instructions for set up information. Make sure the pivot joint is in the forward direction. Move the cable stop at the end of the test block. Install the safety cable C10145 through the hole that was covered by the cable stop. Pull the safety cable through the hole in the test block and then put it through the hole in the pivot joint. Pull the cable through the hole in the pivot joint. See Figure 3, Page 7, block 1. Put the end of the safety cable coming out of the pivot joint through a ferrule C10-144 in the ferrule magazine. Pull the safety cable through the ferrule and use the safety cable to pull the ferrule out of the ferrule magazine. See Figure 3, Page 7, block 2. Put the end of the safety cable through the nose of the crimping tool C10-148. Make sure the large hole in the nose is on the same side as the ferrule. Move the crimping tool along the safety cable until the crimping head is against the part. Make sure the ferrule goes inside the hole in the crimping head. See Figure 3, Page 7, blocks 3 and 4. Insert the free end of the cable into the cable entrance. Continue to push the cable into the cavity. When the free end of the cable appears at the bottom of the tool, grab the cable and pull the slack from the cable until resistance is felt. See Figure 3, Page 7, block 5. NOTE: Grip the cable as close to the free end as possible during insertion to prevent buckling of the cable. (g) When all slack is removed from the cable, snug the tool against the fastener by using several short strokes of the handle. Release the handle to the full open position and fully close the handle to affect crimping and cutting.
(d)
(e)
(f)
CAUTION: IT IS IMPORTANT ON THIS FINAL STROKE TO HOLD THE TOOL AS STEADY AND PERPENDICULAR TO THE CABLE AS POSSIBLE WHILE ENSURING THAT A FULL STROKE IS USED TO MAINTAIN A CONSISTENT TENSIONING OF THE CABLE. (h) (i) (j) After crimping and cutting, release the tool handle and slide the tool off the crimped ferrule. Pull the excess cable from the tool. Set a calibrated breakaway torque wrench to 80 lb in. (9.0 Nm). Install the torque wrench in the pivot joint on the test block C10-146. Find the center of the safety cable in the test block. Use light finger pressure and push the center of the safety cable toward the wall on the test block. The safety cable must not touch the wall. If the safety cable touches the wall, the safety cable is not serviceable. Cut the safety cable with wire cutters C10-149 and remove the safety cable from the test block. Install a new safety cable and do the pulloff load test again. Make sure the tension on the safety cable is correct. Make sure when you
(k)
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STANDARD PRACTICES MANUAL AS907-1-1A crimp the ferrule the crimping tool is perpendicular to the safety cable and the ferrule is tightly against the bolt head. (l) Move the torque wrench handle counter-clockwise until the torque wrench clicks or the ferrule moves. If the ferrule moves before you hear the torque wrench click, adjust the crimping tool per Subtask 70-11-05-400-055, Indenter Adjustment (Method 3). Repeat paragraph E. Do the finger pressure test again. Find the center of the safety cable in the test block. Use light finger pressure and push the center of the safety cable toward the wall on the test block. If the safety cable does not touch the wall the crimping tool can be released for service. See Figure 3, Page 7. If the safety cable touches the wall, adjust the crimping tool per Subtask 7011-05-400-055, Indenter Adjustment (Method 3). Repeat paragraph E.
(m)
(n) (2)
Do a test to determine the exact amount of pressure necessary to cause the crimped ferrule or safety cable to fail. It is recommended that this test be done a minimum of once a month. Use a safety cable tester C10-147 to do this test. See Figure 3, Page 7. Do the test according to the manufacturers instructions. This test can also be used as an alternative to the test block test.
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Crimping Tool Verification Equipment (Method 3) Figure 2
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Safety Cable Procedure (Method 3) Figure 3
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-11-05-400-055 F. Indenter Adjustment (Method 3). (1) Remove the nose assembly by removing the two socket head cap screws. See Figure 4, Page 9.
CAUTION: DO NOT ADJUST THE PUSHROD MORE THAN A QUARTER OF A TURN AT A TIME. SEVERE ADJUSTMENTS MAY DAMAGE THE TOOL. (2) Adjust the pushrod adjustment screw using a 0.25 in. (6.4 mm) straight edge screw driver. Turn the pushrod adjustment screw clockwise to loosen the crimp (enlarge the gaging dimension). Turn the adjustment screw counter-clockwise to tighten the crimp (reduce gaging dimension). See Figure 4, Page 9. Replace the nose assembly and the two socket head cap screws. Prevent binding by alternately turning each screw a small amount until tight. Check the calibration of the crimping tool per Subtask 70-11-05-400-054, Crimping Tool Verification (Method 3).
(3) (4)
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Indenter Adjustment (Method 3) Figure 4
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-11-05-400-056 G. Specific Techniques for Safety Cable (Method 3). (1) Do a visual inspection of the holes to be safety cabled to find all damage. If the hole is damaged, replace the part or, if possible, use another hole to safety cable. NOTE: Keep the safety cable as straight as possible when you safety cable the fasteners or parts together. See Figure 7, Page 14. (2) Put the end of the safety cable C10-145 without the cable end fitting into the hole in the part. Pull the cable through the hole until the cable end fitting is against the part. See Figure 5, Page 12, block 1. NOTE: Although every possible combination of safety cabling is not shown in Figure 6, Page 13, all safety cabling must conform generally to the examples shown. NOTE: On a two bolt patterns, do not cable in a negative pull direction. Make sure the cable has a positive or neutral pull. (3) Insert the end of the cable through the second part. Choose the hole in the part that permits the cable to be as straight as possible. Pull the cable through the second part. If three parts must be safety cabled, do the same procedure for the third part. Put the end of the safety cable coming out of the last part to be safety cabled through a ferrule C10-144 in the ferrule magazine. Pull the safety cable through the ferrule and use the safety cable to pull the ferrule out of the ferrule magazine. See Figure 5, Page 12, block 2. Put the end of the safety cable through the crimping head of the crimping tool C10148. Make sure the large hole in the crimping head is on the same side as the ferrule. Move the crimping tool along the safety cable until the crimping head is against the part. Make sure the ferrule goes inside the hole in the crimping head. See Figure 5, Page 12, blocks 3 and 4. Insert the free end of the cable into the cable entrance. Continue to push the cable into the cavity. When the free end of the cable appears at the bottom of the tool, grab the cable and pull the slack from the cable until resistance is felt. See Figure 5, Page 12, block 5. NOTE: Grip the cable as close to the free end as possible during insertion to prevent buckling of the cable. (7) When all slack is removed from the cable, snug the tool against the fastener by using several short strokes of the handle. Release the handle to the full open position and fully close the handle to affect crimping and cutting.
(4)
(5)
(6)
CAUTION: IT IS IMPORTANT ON THIS FINAL STROKE TO HOLD THE TOOL AS STEADY AND PERPENDICULAR TO THE CABLE AS POSSIBLE WHILE ENSURING THAT A FULL STROKE IS USED TO MAINTAIN A CONSISTENT TENSIONING OF THE CABLE. (8) After crimping and cutting, release the tool handle and slide the tool off the crimped ferrule. Pull the excess cable from the tool.
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STANDARD PRACTICES MANUAL AS907-1-1A (9) Visually inspect safety cable for kinks, frayed wires, or improper crimps. Remove and replace safety cable if a problem exists.
(10) Remove and discard the unused safety cable from the bottom of the crimping tool. (11) Push against aSafety cable with light finger pressure halfway between the safety cabled parts. If cable feels loose, do dimensional check to make sure safety cable is serviceable as follows: See Figure . (a) Measure the distance between the safety cabled parts. Write this measurement down as Dimension A. If three parts are safety cabled together, measure the distance between each of the parts and add the two measurements together to get Dimension A. Push against the safety cable with light finger pressure halfway between two safety cabled parts. Measure the distance the safety cable moves laterally. Write this measurement down as Dimension C. Compare the dimensions that were written down to th limits given Figure .
(b)
(c)
CAUTION: DO NOT TRY TO BREAK THE SAFETY CABLE. IF THE SAFETY CABLE MUST BE REMOVED, CUT THE SAFETY CABLE TO AVOID DAMAGE TO THE HOLES IN THE PARTS. (12) If the safety cable is not in the limits given in Figure 7, Page 14, cut the safety cable with wire cutters C10-149 and remove the safety cable. Install new safety cable.
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Safety Cable Patterns (Method 3) Figure 5
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Safety Cable Patterns (Method 3) Figure 6
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Safety Cable Flex Limits (Method 3) Figure 7
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RIVETED JOINTS - RIVETED JOINTS TASK 70-13-00-390-001 1. Riveted Joints SUBTASK 70-13-00-99G-001 A. General. (1) Rivets are used primarily as shear fasteners in semi-permanent or permanently fastened assemblies. They are used when warpage of mating parts due to application of heat during heat treatment, welding or brazing is undesirable or where light-weight, low-profile and low-cost shear fasteners are desired. Sheet metal joints secured by rivets must be made in such a way that neither the metal nor the rivets are deformed beyond accepted or dimensional limits. Rivets must be set with the manufactured head snugly against the material surface, and the adjacent surfaces of the material in firm contact with each other before the driven head is formed. Burrs created when the installation hole is being drilled shall be removed prior to insertion of the rivet. ACETONE C04-003 AND ISOPROPYL ALCOHOL C04-035 ARE FLAMMABLE. DO NOT USE NEAR WELDING AREAS, NEAR OPEN FLAMES OR ON VERY HOT SURFACES. USE ONLY WITH ADEQUATE VENTILATION. AVOID PROLONGED OR REPEATED CONTACT WITH SKIN. STORE IN APPROVED SAFETY CONTAINER.
(2)
WARNING:
(3)
All aluminum fasteners or steel fasteners in aluminum material will be installed with wet zinc chromate primer C03-001 or epoxy resin primer C03-002 or C03-005. If contaminate is present in the hole it shall be cleaned with Acetone C04-003 or Isopropyl Alcohol C04-035 and dried.
SUBTASK 70-13-00-390-011 B. Rivet Types. (1) Rivets used on engines are generally classified into the following categories: (a) (b) (c) Formed rivets. Hi-Shear rivets. Blind rivets.
SUBTASK 70-13-00-390-012 C. Rivet Removal. (1) Use care in disassembly, particularly with rivet removal, to avoid damage to base structure. Unless otherwise specified in the repair procedure, rivets must be drilled out, but care must be exercised with each rivet removed. Select drill size
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RIVETED JOINTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A consistent with rivet diameter. Use caution to avoid oversize of the rivet hole. Rivet should be center-punched for start of drilling.
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RIVETED JOINTS Page 2 Dec 01/03
ACCEPTABILITY LIMITS - ACCEPTABILITY LIMITS FOR FORMED RIVETS TASK 70-13-01-390-002 1. Acceptability Limits for Formed Rivets SUBTASK 70-13-01-99G-002 A. General. (1) Formed rivets are available in both aluminum and steel. Unless otherwise indicated, the limits specified are applicable to both kinds. Except for flush-head rivets, the manufactured head may be placed on either side of the material unless otherwise specified.
SUBTASK 70-13-01-390-021 B. Heading Methods. (1) (2) Do not hand-peen rivets made of materials that are susceptible to rapid workhardening. Gaps under the manufactured head or between sheets shall not be closed by restriking the rivet. The resulting flash can weaken the rivet and crack the joint. Replace the rivet. Cold upsetting can be accomplished by squeeze driving, gun driving or automatic equipment. The squeeze driven rivet is recommended because they provide more accurate control of driving pressures, give better centering of formed heads, results in more consistent rivet strength and minimizes damage to the sheet by over driving.
(3)
SUBTASK 70-13-01-390-022 C. Head Dimensions. (1) (2) Dimensions of driven heads shall conform to the requirements illustrated in Figure 1, Page 2. Countersunk steel rivets (flush-head) should fill the countersink or dimpled hole so that the manufactured head is flush to 0.015 inch (0.38 mm) below the surrounding surface. When flush riveting is required on both sides of the work, both heads should be flush to 0.015 inch (0.38 mm) below the surface. See Detail A, Figure 2, Page 3. Riveting is to be accomplished with a mandrel on the manufactured head side equal to or slightly smaller than the head diameter. When shaving of countersunk head is required, the head shall not extend above the surrounding surface more than the distance shown in Figure 2, Page 3. After shaving, the rivet head shall be flush with the surface.
(3)
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70-13-01
ACCEPTABILITY LIMITS FOR FORMED RIVETS Page 1 Dec 01/03
Driven Head Limits Figure 1
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Flush Formed Rivet Dimensions Figure 2
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-13-01-390-023 D. Length. (1) When the length of a steel rivet is specified in repair or other instruction, the length may vary by one increment, depending upon whether the parts to be joined are on the high side or the low side of the tolerance. In any case, the rivet must be long enough to form the driven head to minimum requirements. (General Rule: 1.5 x diameter protruding through work piece for steel rivets.) NOTE: If rivets (excluding aluminum rivets) are cut to obtain proper length, annealing is required to eliminate work hardening. SUBTASK 70-13-01-390-024 E. Material Defects. (1) See Figure 3, Page 6. Rivets with open breaks or splits in either head are not acceptable. Superficial heading splits or hairline cracks that cannot be felt with a 0.030 inch (0.76 mm) scriber are acceptable if they do not extend into a circle 1.1 times the shank diameter concentric with the shank (see A, Figure 3, Page 6), and conform to the following requirements. (a) (b) (c) (d) The cracks shall be approximately radial. Cracks shall not intersect each other. There shall be no more than 4 cracks per rivet head. The length (L) of cracks, as shown in A, Figure 3, Page 6, shall be within the limits shown in table 1, Page 4. Table 1. Formed Rivet Heading Crack Limits Rivet Diameter (d) inch (mm) 0.062 (1.58) 0.094 (2.39) 0.125 (3.18) 0.156 (3.96) 0.188 (4.78) 0.250 (6.35) 0.312 (7.93) 0.375 (9.53) (2) (3) Maximum Length (L) of Superficial Splits and Cracks inch (mm) 0.015 (0.38) 0.023 (0.58) 0.030 (0.76) 0.040 (1.02) 0.050 (1.27) 0.060 (1.52) 0.080 (2.03) 0.090 (2.29) Cut heads are acceptable if the maximum depth of the cut is not more than onequarter of the normal height of the head. (See Detail B, Figure 3, Page 6.) Rivets that have misformed heads are acceptable provided:
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STANDARD PRACTICES MANUAL AS907-1-1A (a) (b) (4) (5) (6) (7) (8) (9) Heads meet the minimum requirements as given in Detail C, Figure 3, Page 6. Contour of step is not sharp (see Detail D, Figure 3, Page 6).
Cocked or beveled heads are acceptable if the head is within the limits shown in Detail E, Figure 3, Page 6. Bulbed heads are acceptable, but heads that do not contact the stock on all sides shall be rejected. (See Detail F, Figure 3, Page 6.) Punch rings made with automatic riveting machines which are above or below the surface flat are acceptable within limits specified in Detail G, Figure 3, Page 6. Offset heads are acceptable if the edge of the hole is not visible at any point (see Detail H, Figure 3, Page 6). Cuts or sharp tool marks around a rivet head due to excessive pressure of rivet gun or tooling. See Detail I, Figure 3, Page 6 for limits. Deformation of sheet due to pressure on the rivet is acceptable within the limits shown in Detail J, Figure 3, Page 6.
(10) If a washer is used under the driven head, it shall be in firm contact with the sheet and within the limits shown in Detail K, Figure 3, Page 6. (11) Superficial pitting, stretch marks, folds, stringers (material defect) and slag inclusions are acceptable. Stringers and inclusions shall be no longer than twice the length shown in table 1, Page 4 in paragraph E.(1)(d). (12) Hanging chips or flakes at the edge of the driven head, and feathered edges that result in loose material at the extremity of the head are not acceptable.
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Formed Rivet Heading Defect Limits Figure 3
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-13-01-390-025 F. Oversized Rivets. (1) Rivets from 0.062 (1.58 mm) through 0.156 (3.96 mm) may be replaced with rivets 0.015 (0.38 mm) oversize or 0.032 (0.81 mm) larger for repair or rework. Do not use oversize rivets in more than 5 adjacent holes. Hole size and edge distance must conform to the requirements of Figure 4, Page 8.
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Driven Head Limits Figure 4
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-13-01-390-026 G. Countersunk Holes. (1) Countersunk holes shall have a nominal included angle of 100 degrees and be of sufficient diameter to meet applicable flushness requirements. A shoulder countersink to accommodate the land on a fastener is not acceptable. In nonstructural applications where the countersink extends through more than one sheet, a countersink deep enough to provide a proper bearing for the fastener shall be produced as shown in Figure 5, Page 10. Subcountersinking is used for mating a coin-dimpled surface sheet with its corresponding substructure. The nominal countersunk angle shall be 100 degrees. The diameter shall be large enough to ensure a fit with the underside of the dimple. When a subcountersink is used with a conventional or large radius dimple, the top edge of the countersink shall be chamfered to provide clearance for a proper fit. (a) When a countersink is used with a conventional dimpled surface, the edge of the countersink cone shall be chamfered to provide a clearance for proper nesting. See Figure 6, Page 11. Gaps between dimpled sheets and a countersunk sheet shall not exceed the limits shown in Figure 7, Page 12.
(2)
(b) (3)
Figure 8, Page 13 presents data on recommended rivet length selection for aluminum rivets, only.
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Countersunk Holes Figure 5
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Subcountersunk Assembly Figure 6
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Dimpled and Countersunk Sheet Gaps Figure 7
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Grip Ranges for Rivet Lengths and Diameters Figure 8
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ACCEPTABILITY LIMITS - ACCEPTABILITY LIMITS FOR HI-SHEAR RIVETS TASK 70-13-02-390-003 1. Acceptability Limits for Hi-Shear Rivets SUBTASK 70-13-02-99G-003 A. General. (1) Hi-shear rivets consist of two parts: the collar, and the rivet proper. When set, the collar forms the driven head by flowing under pressure, into a circumferential groove in the shank end of the rivet.
SUBTASK 70-13-02-390-031 B. Acceptability Requirements. (1) Hi-shear rivet assemblies shall not be loose, misaligned, improperly filled, or overdriven, and shall be free from defects that would impair their holding action. (a) (b) Loose rivets, or gaps between the sheets joined by rivets shall not exceed 0.002 inch (0.05 mm). (See Detail A, Figure 1, Page 2.) An open head or tilted rivet is acceptable if no more than a 0.002 inch (0.05 mm) gap can be measured beneath the manufactured head or the collar at any one place including not more than 120 degrees of the circumference. (See Detail B, Figure 1, Page 2.) A collar which is not driven sufficiently to fill the pin-groove properly is not acceptable. (See Detail C, Figure 1, Page 2.) Collars that have been overdriven are acceptable if the shoulder at the top of the collar, or the flange formed at the base of the collar, do not exceed 0.030 inch (0.76 mm) inch. (See Detail D, Figure 1, Page 2.) Ragged or broken edges at the top of the collar, after driving, are acceptable. Cracks are cause for rejection. (See Detail E, Figure 1, Page 2.) Pins too short or too long for the stock being riveted may indicate that the parts being assembled are not in accordance with the drawing. (See Detail F, Figure 1, Page 2.) Parts that do not assemble properly are not acceptable.
(c) (d)
(e) (f)
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70-13-02
ACCEPTABILITY LIMITS FOR HI-SHEAR RIVETS Page 1 Dec 01/03
Hi-Shear Rivet Defects Figure 1
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ACCEPTABILITY LIMITS FOR HI-SHEAR RIVETS Page 2 Dec 01/03
HEAT TREATMENT - HEAT-TREATMENT AND HANDLING OF 2024 ALUMINUM ALLOY RIVETS TASK 70-13-03-370-001 1. Heat-Treatment and Handling of 2024 Aluminum Alloy Rivets SUBTASK 70-13-03-99G-001 A. General. (1) Aluminum alloy 2024 rivets require special heat-treatment and handling. Aluminum rivets harden at room temperature.
SUBTASK 70-13-03-370-011 B. Heat-Treatment and Quench. (1) (2) (3) Soak rivets for 40 to 60 minutes at 9208F, plus or minus 108F, (4938C, plus or minus 68C) in air or in a suitable molten salt bath. Rivets heat-treated in an air furnace shall be held in a wire mesh or perforated container so that air circulates freely. Rivets heat-treated in salt solution shall be held in a type of container that will allow direct contact between the molten salt bath and the rivets, and will drain quickly upon removal from the molten salt bath. Quench in a large volume of circulating water. Water temperature at completion of quench shall not exceed 408F (4.48C). Rivets are now in the "W" (as quenched) temper. NOTE: Rivets shall not be quenched in the containers used during the solution heat-treatment soak either in an air furnace or molten salt bath, but shall be transferred to other containers in the quench tank by emptying the rivets from the heat-treat container into the quench water containing a catch basket. Rivets shall be quenched within 7 seconds after removal from the furnace or molten salt tank. Immersion time shall be a minimum of one minute. (5) Rivets shall be transferred to a tank containing alcohol, ethylene glycol or a Freonalcohol mixture at 408F (4.48C), maximum temperature to remove all traces of water. Rivets heat-treated in a molten salt bath shall be water spray rinsed before immersion in the alcohol rinse tank. Transfer rivets to a refrigerated storage box held at a temperature not exceeding minus 58F (minus 20.68C) within 5 minutes after removal from heat-treatment.
(4)
(6)
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70-13-03
HEAT-TREATMENT AND HANDLING OF 2024 ALUMINUM ALLOY RIVETS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-13-03-370-012 C. STORAGE AND HANDLING. (1) (2) (3) Rivets shall be stored in refrigerated boxes at minus 58F (minus 20.68C) maximum. Storage shall not exceed 30 days after which remaining rivets shall be discarded. Refrigerated rivets shall be driven within 20 minutes after removed from refrigerator. Rivets remaining after 30 minutes shall be discarded. Reheat-treatment of discarded rivets is acceptable. If reheat-treatment is utilized, reinspection is recommended.
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70-13-03
HEAT-TREATMENT AND HANDLING OF 2024 ALUMINUM ALLOY RIVETS Page 2 Dec 01/03
ACCEPTABILITY LIMITS - ACCEPTABILITY LIMITS FOR BLIND RIVETS TASK 70-13-04-390-004 1. Acceptability Limits for Blind Rivets SUBTASK 70-13-004-99G-004 A. General. (1) The blind rivet, which can be completely installed from one side of the work, is used primarily when it is impossible or uneconomical to drive the normal solid rivet requiring access to both sides of the work.
SUBTASK 70-13-04-390-041 B. Blind Rivets. (1) Of the several types of mechanically-expanded rivets used on engines, the most common are the self-plugging type. As shown in Figure 1, Page 2 and Figure 2, Page 3, the hollow rivet shank is expanded by an internal driver stem. Figure 1, Page 2 shows a rivet which must be sheared off after the stem is drawn into the rivet. After the stem is sheared, the pin is held in place by a spin burr produced by a circular cutting shaving tool. Figure 2, Page 3 shows a rivet which depends on a collar locked in place after the stem is set. Installation for blind rivets shall be selected to suit rivet diameter and head style. Stems of self-plugging rivets may be trimmed with a rotary tool at a slow speed (1800 rpm) to produce a spun burr in the chamfered recess of the rivet head in order to meet flushness requirements. In those areas where it is impossible for skin trimming, flat ground nippers may be used. Stems shall be checked by a hand pressure pushout test, approximately 10 pounds (4.5 kg), with a suitable small tool to insure that they are securely installed. Missing stems are not acceptable. Head gapping on the visible side shall be checked with a 0.002 inch (0.05 mm) feeler gage for countersunk and protruding head rivets. Rivets with 0.002 inch (0.05 mm) gap on more than 40 degree of the head circumference shall be replaced. When possible, the blind side of the work shall be inspected for proper rivet upset. See Figure 3, Page 4. NAS1398 and NAS 1399 blind lock rivet collar and pin position shall meet the limits of Figure 4, Page 5. Splits or cracks in the expanded sleeve are not acceptable and the rivet shall be replaced.
(2) (3)
(4)
(5)
(6)
(7)
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70-13-04
ACCEPTABILITY LIMITS FOR BLIND RIVETS Page 1 Dec 01/03
Blind Rivet Figure 1
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Blind Rivet (Locked Collar) Figure 2
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Blind Rivet Acceptability Figure 3
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Blind Rivet Locking Collars and Stems Figure 4
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VISU-LOK - VISU-LOK BLIND BOLT RIVET ASSEMBLIES TASK 70-13-06-390-006 1. Visu-Lok Blind Bolt Rivet Assemblies SUBTASK 70-13-06-99G-006 A. General. (1) The Visu-Lok is a three piece blind bolt rivet consisting of a threaded nut and screw and an expandable sleeve. It is available in a variety of head styles and materials, in sizes from 5/32 in. (3.969 mm) diameter through 3/8 in. (9.525 mm) diameter, and in grip length increments of 1/16 in. (1.588 mm). During installation, the screw is turned as the nut is held stationary by a nose piece. The sleeve is compressed between the screw head and the conical end of the nut, and is drawn over the tapered nose portion of the nut. The sleeve is expanded, subsequently forming a head against the mating surface being joined. As driving is completed, the slabbed portion of the screw is snapped off and ejected.
(2)
SUBTASK 70-13-06-390-051 B. Equipment. (1) Visu-Lok blind bolt rivets can be installed either with a manual or a pneumatic tool fitted with a nose adapter, depending on the bolt head style and diameter. NOTE: Refer to the manufacturers documentation for tool identification. (2) (3) The pneumatic tool can be fitted with a straight or right angle adapter, depending on the part shape and the required bolt positions. Tools for bolt removal or inspection. (a) The special tools for removal or inspection of the bolt (such as a removal kit or gun and gages, or torque adapters for inspections) can be obtained from the bolt manufacturers: Monogram/Aerospace Fasteners. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. EUREP Industries. Refer to the List of Suppliers in Step D. of Subtask 70-8000-800-003.
(b) (c)
SUBTASK 70-13-06-390-052 C. Material. (1) None Required.
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VISU-LOK BLIND BOLT RIVET ASSEMBLIES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-13-06-390-053 D. Procedure. (1) Bolt Holes. (a) Unless otherwise specified in the applicable manual, drill holes for the various type as shown in Figure 1, Page 5. The dimensions of drill holes are shown in Figure 8, Page 12, table 1. Drill holes perpendicular to head seating surface (90 degrees 30 minutes). When possible, drill the holes with the sheets clamped together to avoid offset holes.
(b) (c) (2)
Countersinks and Dimpling. (a) Unless otherwise specified in the applicable manual, perform countersinks for the various type as shown in Figure 1, Page 5. The dimensions for the countersinks are shown in table 2. Unless otherwise specified in the applicable manual, perform dimpling for the various type as is called out for the countersink in Figure 1, Page 5 and table 2. NOTE: It is recommended that dimpling be performed with undersize pilot holes and the holes redrilled or reamed to the size specified in table 1.
(b)
(3)
Deburring. (a) After drilling, deburr the sheets to be assembled as follows: 1 If sheets are drilled separately or disassembled before rivet installation, perform deburring as shown in Figure 2, Page 6, detail A and C or detail B and C. If sheets are drilled when they are assembled and they are not disassembled before the bolt is installed, only deburr the external (head side) faces. See Figure 2, Page 6, detail A and B. NOTE: Make sure the sheets are thoroughly squeezed together to prevent introduction of chips or debris in the interface. 3 When the assemblys blind part is not accessible (inside a box type structure for instance) holes can be deburred with a small tool similar to the tool illustrated in Figure 3, Page 7.
(4)
Selection of Bolts. (a) Identification. 1 (b) Refer to table 3 for explanation of markings on blind bolt rivets.
Bolts Used.
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STANDARD PRACTICES MANUAL AS907-1-1A 1 Use bolts specified in the applicable manual. However, it is necessary to make sure the thickness of the sheet assembly is appropriate for the rivet grip length. Use the gage illustrated in Figure 4 to measure the thickness of the assembled sheets as shown in Figure 5. The gage may be purchased from the bolt manufacturer. NOTE: To measure the sheet assembly thickness, be sure the sheets are thoroughly squeezed together. 3 In those application where a tapered sheet condition exists on the blind side, the grip length must be the depth at the maximum point of taper at the hole. In no case should this taper exceed 8 degrees in order to ensure proper performance of the fastener.
(5)
Installation of Visu-Lok Bolts. CAUTION: DEFECTIVE BOLTS MUST NOT BE RELUBRICATED AND USED. (a) Bolts are lubricated by manufacturer with a special lubricant. Check for presence of the lubrication before installation. NOTE: Excessive heat, degreasing agents and cleaning products will damage the lubricant. (b) Check Visu-Lok bolt condition as follows: 1 Unacceptable defects: a b 2 Cracks in any direction or location. Discontinuities and inclusions on the head to shank fillet.
Acceptable defects: a Discontinuities except in zones specified in paragraph A. and the following limits: 0.004 in. (0.1 mm) on the nut. 0.002 in. (0.05 mm) on the screw.
(c) (d)
Thoroughly squeeze the sheets together before and during riveting. Install bolt as shown in Figure 7, Page 11. NOTE: Where special driving tools are used wrenching speed shall not exceed 700 RPM.
(6)
Shaving of Bolts. NOTE: Bolt shaving is only done on millable head Visu-Loks (PLT130 Series) and only when specified in the applicable manual.
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STANDARD PRACTICES MANUAL AS907-1-1A (a) Shave the bolt head flush with the sheet surface using a standard rivet shaver equipped with a carbide cutter, turning at a speed of approximately 10,000 RPM. NOTE: A stop-controlled drill may be used to remove the portion of the core screw which is above flush prior to the milling operation. CAUTION: CAREFUL SETTING OF THE DRILL IS REQUIRED TO ENSURE THAT NO PORTION OF THE STEM IS DRILLED BELOW FLUSH. (7) Replacement of Visu-Lok Bolts. (a) Remove bolts. 1 Visu-Lok bolts should be removed by drilling of the core screw as described in Figure 8, Page 12. In the drilling operation, a drill motor set at a speed not over 700 RPM is recommended. NOTE: When possible, retrieve bolts that have fallen in box-type structures. (b) Bolt hole inspection. 1 Perform a visual and dimension check of bolt holes: a b 2 3 Check for no visual defects such as cracks, unradiused sharp edges, ovalization, etc. are allowed. Dimensions of the holes must be within the tolerances specified in table 1.
When bolt holes are within the above requirements, install original fit bolts. When bolt holes are not within the above requirements, install oversize bolts. NOTE: The applicable manual specifies the specific oversize bolt to use for each particular case.
(c)
Special recommendations. 1 If countersinks have to be enlarged, check this to ensure this operation is appropriate to the thickness of the sheets.
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Bolt Hole Dimensions Figure 1
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Sheet Deburring Figure 2
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Deburring Tool for Inaccessible (Blind Faces) Figure 3
EFFECTIVITY: ALL
70-13-06
Thickness Measurement Gage Figure 4
EFFECTIVITY: ALL
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Thickness Measurement of Assembled Sheet Figure 5
EFFECTIVITY: ALL
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Bolt Grip Length for Clamping Capacity Figure 6
EFFECTIVITY: ALL
70-13-06
Bolt Installation Figure 7
EFFECTIVITY: ALL
70-13-06
Bolt Removal Figure 8
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-13-06-390-054 E. Quality Control. (1) Inspection of the Bolt Stem Break-off. (a) Two procedures are possible to check the stem break-off limits: Gaging and manual measurements. 1 Gage Checking. See Figure 9, Page 16. a Use round gages for flush head bolts as follows: Place the gage on the installed bolt, when checking high break-off, as shown in Figure 9, Page 16, detail A. The gate prongs must straddle both sides of the screw. If the gage rocks, the break-off is too high. Place the gage on the installed bolt, when checking low break-off, as shown in Figure 9, Page 16, detail B. If gage does not rock, the break off is too low. b Use leaf gages for protruding head as follows: Place the gage on the installed bolt, when checking high break-off, as shown in Figure 9, Page 16, detail C. The gage prongs must straddle both sides of the screw. If the gage rocks, the break-off is too high. Place the gage on the installed bolt, when checking low break-off, as shown in Figure 9, Page 16, detail D. If the gage does not rock, the break-off is too low. NOTE: The gage kind and size depend on the bolt head style and diameter. Refer to manufacturers documentation for references and selection. 2 (b) (2) Manual measurement.
Check dimensions as specified in Figure 10, Page 17 and table 1, Page 14.
Inspection of Bolt Assembly. (a) (b) Inspect bolt assembly as shown in Figure 11, Page 18. Inspect the bolt for looseness. 1 This can be done by holding the nose installation piece with your hand and applying a light torque in the counterclockwise direction on the head of the bolt. NOTE: The nose installation piece may be adapted to a torque wrench. Apply the torque values specified in table 1, Page 14 to determine looseness.
EFFECTIVITY: ALL
70-13-06
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: CAUTION SHOULD BE EXERCISED NOT TO OVERTORQUE THE INSTALLED BOLT WHEN USING A TORQUE WRENCH TO CHECK FOR LOOSENESS. (c) Check the rivet head seating, as shown in Figure 12, Page 19 and Figure 13, Page 20 Table 1. Bolt Stem Break-off Limits For Manual Check
NOTE: Dimensions are in inches with millimeters in parentheses. Plus (+) in front of a dimension indicates the s Minus (-) in front of a dimension indicates the screw end projection is below the plane of reference. *A BREAK-OFF LIMITS FLUSH PROTRUDING +0.20 -0.068 +0.015 -0.073 +0.010 -0.078 +0.010 -0.083 +0.010 -0.093 +0.082 -0.006 +0.072 -0.016 +0.072 -0.026 +0.072 -0.031 +0.072 -0.031 +0.000 +0.088 +0.010 +0.98 +0.010 -0.098 (0.5) (1.73) (0.38) (1.85) (0.25) (1.98) (0.25) (2.1) (0.25) (2.36) (2.08) (0.15) (1.83) (0.4) (1.83) (0.66) (1.83) (0.7) (1.83) (0.78) (0) (2.23) (0.38) (2.49) (0.25) (2.49)
FASTENER SIZE CLASS 1 5 6 8 10 12 CLASS 2 5 6 8 10 12 CLASS 3 5 6 8
TORQUE VALUES INCH LBS (N.m) 4 6 10 20 30 (0.452) (0.678) (1.13) (2.26) (3.39)
4 6 10 20 30
(0.452) (0.678) (1.13) (2.26) (3.39)
4 6 10
(0.452) (0.678) (1.13)
A slight gap between the rivet head and the seating surface is acceptable under the following conditions.
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STANDARD PRACTICES MANUAL AS907-1-1A a b c d e Maximum value of the gap does not exceed 0.0039 in. (0.099 mm) protruding heads. A 0.0039 in. (0.099 mm) feeler gage, placed under countersunk head, does not reach rivet shank. The rivet head is in contact with at least 60 percent of the circumference. No more than 10 percent of the rivets in a row may be affected by this defect. No two consecutive rivets may be defective.
EFFECTIVITY: ALL
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Gage Check for Bolt Stem Break-off Limits Figure 9
EFFECTIVITY: ALL
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Manual Check of Bolt Stem Break-off Limits Figure 10
EFFECTIVITY: ALL
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Bolt Assembly Inspection Figure 11
EFFECTIVITY: ALL
70-13-06
Check Countersunk Heads for Flushness Figure 12
EFFECTIVITY: ALL
70-13-06
Check Blind Bolt Rivet Head for Seating Figure 13
EFFECTIVITY: ALL
70-13-06
HANDLING BEARINGS - HANDLING OF BEARINGS TASK 70-14-00-620-003 1. Handling of Bearings SUBTASK 70-14-00-99G-003 A. General. (1) Ball and roller bearings are precision components that are required to support heavy loads at high speed. Special care must be exercised throughout the entire bearing processing procedure, and a special area should be set aside exclusively for the handling of bearings. This area should conform to typical clean-room standards: completely closed off from other shop areas, filtered air supplied at slightly higher pressure than that outside the room; hard, smooth walls, floors, and work surfaces, lint-free clothes, gloves, etc., supplied. Personnel working on bearings should be experienced and trained in the proper methods of handling bearings.
SUBTASK 70-14-00-620-031 B. Handling Procedures. (1) Bearings and their components should be handled gently. All handling should be kept to the minimum, and fingerprint neutralizer C02-054 used at any time the bearings are touched with the bare hands. Observe the following precautions. (a) Personnel handling bearings must wear either synthetic rubber or Nylonmesh gloves with polyethylene palms and fingers. Lint-free cotton gloves are acceptable if they are discarded before they become contaminated with skin oils and salts, which are corrosive to bearing surfaces. Protective hand creams are also acceptable. Heated rings may be handled with clean fire resistant gloves. Be certain to keep all parts of separable bearings together as a set (same serial numbers) throughout all processing operations. Be extremely careful to avoid mixing parts of one bearing with those of another. Place each bearing (all components of matched bearings) in individual containers during transportation, processing and storage. To protect the parts from becoming magnetized by induction, do not transport bearings on electrically motorized vehicles unless the bearings/components are given appropriate protection. Avoid striking assembled bearings or the components of disassembled bearings on work surfaces, cleaning baskets or other rigid surfaces.
(b)
(c)
(d)
EFFECTIVITY: ALL
70-14-00
HANDLING OF BEARINGS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: DO NOT USE COMPRESSED AIR TO BLOW EXCESS SOLVENTS OR LUBRICANTS FROM ASSEMBLED BEARINGS AS SPINNING CAN DAMAGE THE BEARING. (e) Do not spin bearings rapidly to listen for roughness at any time. Slow rotation is permissible only after the bearing has been cleaned, reassembled if necessary, and properly lubricated. Never use tools of steel or other hard metals in direct contact with bearings when using hammers or mallets to aid in installing or removing them. Exercise particular care to prevent damage to the bearing cage, which is frequently made of bronze. Cage deformation can cause seizure of the rollers or balls; nicks or dents can result in failure during operation. Be sure that no slivers from soft plastic or metallic bars lodge in the bearing. When a bearing is retained by a shrink fit, the source of heat or cold used for assembly/disassembly must never touch the bearing directly. Observe the following. 1 When necessary to use Dry Ice to chill the bearing, apply preservative oil MIL-L-6085 C02-050 to the bearing, and place it in a plastic bag. Bearing should not touch the Dry Ice directly. Immediately after installing or removing a chilled bearing, use a heat gun to restore the bearing and any adjacent cold source to room temperature so that condensation is minimized. Check carefully for evidence of moisture, and continue heating until the bearing is completely dry. Apply preservative oil MIL-L-6085 C02-050 at once to the bearing after complete drying. When heat is required to relieve shrink fits of bearings, use heat guns, ovens, or induction heating per TASK 70-10-01-370-001, Induction Heating for Shrink Fit Assembly of Bearings and Seals. Do not use direct-heat sources to apply the heat, and do not heat the bearings to a temperature higher than 3508F (1758C). Apply preservative oil MIL-L6085 C02-050 to the bearing before heating and after it has cooled to room temperature.
(f)
(g)
CAUTION: DO NOT USE UNAUTHORIZED PETROLEUM-BASE OILS ON BEARINGS TO BE PLACED IN ENGINES THAT USE SYNTHETIC OILS. SOME MIXTURES CAN CAUSE SLUDGING. (h) Refer to TASK 70-22-01-110-013, Special Cleaning Procedure No. 1 Cleaning of Bearings, for special cleaning procedures for bearings. Refer to TASK 70-33-00-999-001, Special Inspection Procedures, for special inspection methods and criteria. Refer to TASK 70-60-01-620-002, Preservation of Antifriction Bearings, for preservation data.
EFFECTIVITY: ALL
70-14-00
HANDLING OF BEARINGS Page 2 Dec 01/03
TRI-WING FASTENERS - TRI-WING FASTENERS TASK 70-15-00-400-003 1. Tri-Wing Fasteners SUBTASK 70-15-00-99G-003 A. General. (1) Tri-Wing recessed-head fasteners are available in a wide range of sizes, and each size requires the use of a matched driver. See Figure 3, Page 5. When properly used, the Tri-Wing design permits a higher ratio of torque to end-pressure than is possible with slotted-head or cross-head designs; hence, burring and mutilation are minimized, and both tool- and part-reusability are increased. If the fastener should become seized because of corrosion or other conditions, the head design forms a built-in center which permits drilling out without risking damage to surrounding surfaces.
SUBTASK 70-15-00-400-031 B. Equipment. (1) A complete selection of drivers is recommended, to provide maximum adaptability to the Tri-Wing fastener system. In addition to straight drivers, offset and universaljoint drivers and hand screwdrivers with screwholders are available.
SUBTASK 70-15-00-400-032 C. Driver Selection. CAUTION: BE SURE THAT AXIS OF DRIVER IS ALIGNED WITH AXIS OF FASTENER WHEN INSTALLING OR REMOVING FASTENER. (1) Select the correct driver. The driver number should match the recess number of the fastener head as shown in Figure 3, Page 5. Figure 4, Page 6 lists a range of standard fastener sizes with their corresponding Tri-Wing recess identification numbers. If the head of the fastener has been coated with paint or other material, use a driver one size smaller than that indicated, to compensate for the thickness of material on the walls of the recess.
(2)
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70-15-00
TRI-WING FASTENERS Page 1 Dec 01/03
Tri-Wing Fastener and Drive Configuration Figure 1
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Tri-Wing Recess Number Table Figure 2
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-15-00-400-033 D. Extraction. (1) There is no slope to the walls of mating surfaces of either fastener or driver, so that the tendency of the driver to "cam out" of the recess is minimized; therefore, normal extraction by applying counterclockwise torque is usually successful. If corrosion or other factors have caused the fastener to seize so that failure of the recess occurs, select the proper drill and screw extractor for the size of fastener involved. The bottom of the fastener recess is shaped so that the drill centers itself naturally, and no special drilling procedure is required. Drill into the fastener deep enough to provide sufficient working depth for the screw extractor. Tap the extractor to seat it firmly, then apply counterclockwise torque to remove the fastener.
(2)
EFFECTIVITY: ALL
70-15-00
Tri-Wing Fastener and Drive Configuration Figure 3
EFFECTIVITY: ALL
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Tri-Wing Recess Number Table Figure 4
EFFECTIVITY: ALL
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MARKING PRACTICES - MARKING PRACTICES TASK 70-16-00-350-001 1. Marking Practices SUBTASK 70-16-00-99G-001 A. General. (1) Identification of parts, assemblies, subassemblies, modules and/or engines is achieved by marking at the time of manufacture. The type and location of marking is determined by the size, shape, material, environment, function, etc., of the part. There are two categories of marking: permanent and temporary. (a) Permanent marking normally will imprint the part with the required information and is intended to remain legible through engine operation and maintenance procedures. Temporary marking is accomplished by applying or adding some material to the surface of the part. Temporary marking is not intended to withstand engine operation and is normally removed during or following maintenance procedures.
(2)
(b)
(3)
Many engine parts are exposed to high temperature environments during use or maintenance. Improper marking may be obliterated by high temperature and the part identification lost. Chemical attack from marking materials exposed to high temperature may corrode the part and lead to possible part failure. Some marking methods require deep impressions in the part, causing local stresses. The use of these marking methods must be carefully considered relative to the tolerance of the part to these stresses. These marking methods are the most permanent, however, and are frequently utilized.
(4)
SUBTASK 70-16-00-350-011 B. Permanent Marking. (1) Permanent marking of part is often required when parts are modified during maintenance and the part identification is changed. Permanent marking may also be used to monitor part life or history. The method and location of permanent marking must be selected so as not to cause damage to the part. Application: Typical uses for permanent marking are: (a) (b) Part number identification change following a modification of the part. Indicate compliance to service bulletins.
(2) (3)
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70-16-00
MARKING PRACTICES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (c) (d) (e) (f) (4) Indicate repairs completed. Indicate the number of heat treat cycles on part. Indicate the accumulated hours or cycles on part. Indicate position marking for aid in assembly.
Marking Methods: Whenever permanent marking is required, the method and location are usually specified in the applicable manual. When marking instructions are not specified or the method and/or location is not available, the following recommendations should be followed. (a) (b) Mark in low-stress areas. Do not mark on any surface which contacts another surface during assembly or operation such as flange mating surfaces or other areas subject to possible contact or wear. Do not mark on surfaces exposed to the primary gas flow of the engine. Do not remove or totally obliterate existing markings, but line-out or mark through existing marking such that it remains legible. Make new marking adjacent to, or in the same area as existing marking. Make new marking on the same surface as existing marking. Make new marking by the same method and same size characters as the existing marking. Do not use impression type marking which could cause deformation of part or reduced wall thickness on thin walled parts. Do not use impression type marking on parts made from titanium alloy.
(c) (d) (e) (f) (g) (h) (i)
SUBTASK 70-16-00-350-012 C. Temporary Marking. (1) Temporary marking is used for temporary identification purposes. This is accomplished by the attachment of tags or adhesive labels or marking directly on the part. Temporary marking is usually removed prior to assembly or operation of the engine. The materials selected, however, should be chosen so that failure to remove the marking will not cause damage or failure of the parts so marked. (a) Application: Typical uses for temporary marking are: 1 2 3 Indicating location of defects during inspection. Indicating relative position of parts in an assembly by sequential numbering or matchmarks. Identifying the subassembly, module, or engine the part may be assigned to or removed from.
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STANDARD PRACTICES MANUAL AS907-1-1A 4 (b) Identify shop operations or inspections performed or to be performed.
Marking Methods: Whenever temporary marking is required, the method and location are usually specified in the applicabl manual. When marking instructions are not specified or the method and/or location not available, the following recommendations should be followed: 1 2 3 Metal tags must be made from stainless steel and held to part with stainless steel wire. Adhesive on tape or labels must be approved by suitability tests to ensure against corrosion to parts when subjected to high temperature. Marking ink, pencils, paints, etc., must be approved by suitability test to ensure against corrosion to parts when subjected to high temperature.
EFFECTIVITY: ALL
70-16-00
EFFECTIVITY: ALL
70-16-00
TIME/CYCLE - TIME/CYCLE MARKING OF PARTS TASK 70-16-01-350-016 1. Time/Cycle Marking of Parts SUBTASK 70-16-01-99G-016 A. General. (1) (2) (3) (4) Certain engine parts, which require special monitoring and/or have life limitations, may need to be marked with engine operation hours/cycles. The parts that must be marked with their operating time/ cycles are indicated in the applicable manual. The time/cycle marking code described herein is based on SAE Standard AS1105. The time/cycle code shall be added to the nameplate of the part if space is provided. If no space is provided, the time/cycle code shall be placed as close as possible to (preferably above) the part identification number unless otherwise specified by the applicable manual. Unless otherwise specified, the marking method used for the time/cycle code shall not be more severe (leave a deeper impression) than the method used in marking the part identification number.
(5)
SUBTASK 70-16-01-350-161 B. Time/Cycle Coding. (1) (2) A code indicating the operating time/cycle may be placed on parts removed for shop maintenance or other reasons. Only parts removed from the engine during disassembly will be marked with the operating time/cycle code. A part shall not be removed from an engine with the sole aim of marking the code indicating the operating time/cycle. The following codes will be used to supplement, and not to replace the part history, which is itself recorded in a more detailed manner elsewhere. (a) (b) (c) (4) U: Operating time/cycle which cannot be evaluated. Y: Used part installed during shop maintenance. C: Operating cycles.
(3)
Operation hours or cycles are represented by either the letter A, denoting 50 or less, or by a code number. A code number indicates the hour/cycle value in 100s with a tolerance of -49 to +50 added. When adding codes to determine total operating time, assign mean value to codes, i.e., A = 25, 1 = 100, 2 = 200, etc.
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70-16-01
TIME/CYCLE MARKING OF PARTS Page 1 Dec 01/03
Code Mark A 1 2 3 10 99 990
Hours 1-50 51-150 151-250 251-350 951-1050 9851-9950 98951-99050
Code Mark CA C1 C2 C3 C10 C99 C990
Cycles 1-50 51-150 151-250 251-350 951-1050 9851-9950 98951-99050
SUBTASK 70-16-01-350-162 C. Procedure. (1) (2) (3) (4) Mark used parts which do not have an operation history with the letter U. Mark parts which have an operation history with the appropriate code. Mark parts so that the sum of the operating times gives the total operating time. Determine the total operating time of used, uncoded parts from the appropriate records. For later code updating, use the appropriate records and log book.
SUBTASK 70-16-01-350-163 D. Code Interpretation. (1) (2) (3) (4) Part marked: A/5/10. Interpretation: Part has a total operating time of 25 + 500 + 1000 = 1525 hours since installation. Part marked: U/7/9/8. Interpretation: Part was used for an undetermined amount of time prior to time coding then was marked with total operating time of 700 + 900 + 800 = 2400 hours. Part marked: 8/Y/10. Interpretation: Part operated for 800 hours prior to being installed as a used part during shop maintenance and then undergoing 1000 hours of additional operation. Total time on part is 1800 hours. Part marked: C3/C7.
(5) (6)
(7)
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STANDARD PRACTICES MANUAL AS907-1-1A (8) Interpretation: Part operated for 300 cycles then for 700 cycles more giving a total of 1000 cycles.
SUBTASK 70-16-01-350-164 E. Quality Assurance. (1) Check marking for legibility.
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EFFECTIVITY: ALL
70-16-01
TEMPORARY - TEMPORARY MARKING TASK 70-16-02-350-017 1. Temporary Marking SUBTASK 70-16-02-99G-017 A. General. CAUTION: AVOID CONTAMINATION OF PARTS. ALL MARKING MATERIALS MUST PASS SUITABILITY TESTS. (SEE TASK 70-16-80-700-009, SUITABILITY TEST OF TEMPORARY MARKING PRODUCTS.) ELEMENTS IN SOME MARKING MATERIALS WILL CAUSE INTERGRANULAR CORROSION WHEN THE PART IS SUBJECTED TO HIGH TEMPERATURE. (1) (2) Temporary marking is used to identify and/or indicate condition, position, and/or status of engine parts being disassembled or processed. Temporary markings are normally removed prior to engine operation. The materials selected, however, should be chosen so that failure to remove the marking/label will not cause damage or failure of parts. Temporary marking can be accomplished in 2 ways. (a) (b) Labels and markers of various materials can be attached to the part by means of wires, ties, adhesives, etc. Ink mark can be made on the surface of the part.
(3)
SUBTASK 70-16-02-350-171 B. Equipment. (1) Not applicable.
SUBTASK 70-16-02-350-172 C. Materials. (1) The following materials are required for the application of this process: (a) (b) (c) (d) (e) Felt-tip pen Quick-drying ink Non-metallic pencils Pressure sensitive adhesive labels Cardboard labels (tags)
EFFECTIVITY: ALL
70-16-02
TEMPORARY MARKING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (f) Metal labels (tags).
SUBTASK 70-16-02-350-173 D. Procedure. CAUTION: DO NOT APPLY MARKING MATERIALS TO FACES OF MATING PARTS, ASSEMBLY, OR CONNECTOR SURFACES. DEPOSITS OF MARKING MATERIALS MAY ADVERSELY AFFECT THE CLEARANCES AND CONCENTRICITY OF PARTS. (1) Attach label or mark parts as required.
SUBTASK 70-16-02-350-174 E. Quality Assurance. (1) Ensure that markings are legible and that labels are secure. Ensure that marking products have been tested.
SUBTASK 70-16-02-350-175 F. Temporary Marking Materials. (1) The following commercially available products are satisfactory for marking parts for inspection and repair.
Product Identification Empire Berol Verithin 753 Silver Pencil Dykem Steel Blue (DX 100) Marco S-1141 (black) Dykem Hi-Spot Blue (No. 107) Gear Marking Compound No. 10 (yellow) Dykem Remover and Thinner, No. 138 Aircraft Marker LN9051 Red or Blue Action Marker Nuclear Grade (Black or White) No. 33, 44, or 55 tips Sharpie T.E.C. Marker Chalk, Marking White (extruded)
Application General parts marking General parts marking General parts marking Contact marking mating parts Gear contact-pattern marking Cleaning/removal of marking inks General parts marking General parts marking
Consumable No. C05-003 C05-002 C05-004 C05-020 C05-001 C05-021 C05-003 Previously C05-102 C05-003 (Previously C05-104 C05-003 C05-111
General parts marking General parts marking
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70-16-02
TEMPORARY MARKING Page 2 Dec 01/03
ELECTROCHEMICAL - ELECTROCHEMICAL ETCH MARKING TASK 70-16-03-350-018 1. Electrochemical Etch Marking SUBTASK 70-16-03-99G-018 A. General. CAUTION: THE USE OF ELECTROCHEMICAL ETCH MARKING ON THE FOLLOWING TYPES OF CRITICAL ENGINE HARDWARE MUST BE PERFORMED WITH EXTREME CARE: LIFE LIMITED PARTS (SUCH AS DISKS, BLISKS, SPOOLS, SHAFTS), COUPLING NUTS, CASINGS, COMPRESSOR REAR FRAMES, COMBUSTION/DIFFUSER CASINGS. PROPER CONTROL OF MARKING DEPTH, ELECTROLYTE SELECTION, NEUTRALIZATION, AND INSPECTION FOR ANY STRAY ELECTRICAL ARCING TO THE PART ARE CRITICAL TO THE PROCESS. (1) Electrochemical etch marking is a method for permanently marking parts by causing an electrically induced chemical reaction in the part surface. An electrical current is passed through an electrolyte-saturated wick pad and through a stencil resting on the surface of the part. The charged electrolyte reacts with the part surface at the stencil openings to make an impression that you can read. Surfaces to be marked must be electrically conductive. Surfaces covered with paint, lacquer, or varnish, etc., cannot be electrochemically etched.
(2)
CAUTION: DO NOT USE ELECTROCHEMICAL ETCH MARKING ON ANODIZED SURFACES. THE CHEMICAL REACTION CAN CAUSE CORROSION. (3) Electrochemical etch marking can make impressions that are either clear or dark, and shallow or deep. The different impressions are a result of the base metal that is being marked, the type (AC or DC) and intensity of the current, the length of dwell time, and the electrolyte that is used. (a) Alternating current (AC) results in dark marks and direct current (DC) results in clear or light marks; however, aluminum can be dark-marked with DC and light marks can be made on black oxide coatings with AC. Shallow marking of approximately 0.0003 inch (0.008 mm) results from applying AC of low intensity for a short duration. Deep marking of approximately 0.002 inch (0.05 mm) results from applying DC of high intensity.
(b) (c)
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70-16-03
ELECTROCHEMICAL ETCH MARKING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-16-03-350-181 B. Equipment. (1) The equipment required for the application of this process can be obtained from: Lectroetch Co. or Monode Marking Products Inc. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. Prepare the stencil with a typewriter (an electric typewriter is best) or with a printer that hits the stencil and makes an impression (such as a dot matrix printer).
(2)
SUBTASK 70-16-03-350-182 C. Materials. (1) (2) The materials required for the application of each process can be obtained from the equipment vendor. Typical materials and accessories needed are: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) Hand markers Bench fixtures Flat pads Rocker pads Saddle markers Cartridge hand pads Cartridge markers Stencil paper Electrolyte Scotch Brite pad
SUBTASK 70-16-03-350-183 D. Procedure. ELECTROCHEMICAL ETCH MATERIALS ARE TOXIC. USE PERSONAL PROTECTION EQUIPMENT.
WARNING: (1)
Prepare the stencil as follows: (a) Select the proper stencil for the application. 1 2 Brown stencils are adequate for 1-2 markings. (These stencils are no longer recommended.) Blue stencils are available for several hundred markings.
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STANDARD PRACTICES MANUAL AS907-1-1A (b) (c) Cut the stencil to a size so that the wick pad of the marker does not extend beyond the edges of the stencil. Place the stencil in the typewriter/printer with the white backing paper against the roller. Use an electric typewriter, if possible. 1 2 Set the typewriter/printer for stencil cutting, or remove the ribbon. Type the marking information in the center of the stencil with typewriter/printer set on medium pressure. If a manual typewriter is used, apply even pressure for all characters. Remove the stencil from the typewriter/printer, remove the backing paper from the stencil, and hold the stencil up to a light. The typed information should show completely through the stencil openings.
CAUTION: TO AVOID INFERIOR MARKINGS WHEN USING A NEW STENCIL, MARK ON SAMPLE OR SCRAP PARTS FIRST. (2) Make sure that the part is clean and free from all grease, oil, or film prior to marking. Lightly burnish the area to be marked with the Scotch Brite pad C10-010. NOTE: The surface to be marked must be electrically conductive. Surfaces covered with paints, lacquers, or enamels cannot be electrochemically etched. CAUTION: EXCESS ELECTROLYTE ON THE WICK PAD MAY CAUSE THE MARKING TO BLUR. INSUFFICIENT ELECTROLYTE MAY CAUSE A VERY LIGHT MARK, OR NO MARK. (3) Apply a sufficient amount of the correct electrolyte to the wick pad of the marker. NOTE: Different base metal and marking systems require different electrolytes for correct electroetch marking. (4) Place the stencil on the surface to be marked. The marking location for the part you are marking is indicated in applicable manual.
CAUTION: USE THE SMALLEST AMOUNT OF CURRENT AND THE SHORTEST DWELL TIME THAT WILL GIVE A SATISFACTORY MARK. LARGE AMOUNTS OF CURRENT AND LONG DWELL TIMES WILL DECREASE THE STENCIL LIFE. (5) (6) Set up and adjust the power unit for the necessary shade, type, and depth of mark. Place the marker over the stencil as follows: (a) (b) (c) Make sure that the typed marking information is covered. Make sure that the wick pad does not extend off of the stencil edges. Apply firm, but not excessive, pressure on the marker for the required dwell time.
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STANDARD PRACTICES MANUAL AS907-1-1A (7) (8) Remove the marker and stencil from the part. If the mark is too light, turn the power setting higher or increase the dwell time. Clean the marked part as follows: CAUTION: USE CLEAN CLOTHS, PAPER TOWELS, ETC., FOR EACH CLEANING. CHANGE CLOTHS, ETC. FREQUENTLY TO PREVENT CONTAMINATION. (a) (b) Wipe the electrolyte from the part with a clean cloth, paper towel, etc. Clean the part with the correct cleaner. Clean the marked area carefully plus any other area where the electrolyte wetted the part. NOTE: Different base metals and marking systems may require various cleaners. (c) (d) (e) (9) Wipe the part dry. Rub marked area lightly with the Scotch Brite pad C10-010. Apply protective coating if specified.
Clean the equipment after use as follows: (a) (b) Rinse the marker wick pad in water to remove all of the electrolyte. Rinse the stencils in water and dab-dry them with a clean, dry cloth.
SUBTASK 70-16-03-350-184 E. Quality Assurance. (1) (2) Inspect the marks to make sure you can read them after rubbing them with the Scotch Brite pad C10-010. Visually inspect all areas of the part near where the marking was performed and where the part was grounded (grounding clamp or sitting on a grounding plate) to make sure there are no signs of electrical arcing. Evidence of arcing will cause the part to be placed on hold for engineering disposition.
SUBTASK 70-16-03-350-185 F. Electrochemical Etch Marking Materials. (1) The following commercially available products are satisfactory for marking.
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Table 1. Product Identification Lectroetch 250A Nuclear Grade Compound Monode MSC-1 Compound Application Electrolyte for permanent marking titanium, iron, nickel, and cobalt-base alloys Electrolyte for permanent marking all materials except titanium and titanium alloys Electrolyte for permanent marking titanium and titanium alloys Cleaning and neutralizing electrochemical etch for iron, nickel, cobalt, titanium, and titanium alloys Cleaning and neutralizing electrochemical etch (all materials) Die impression stencils Consumable Reference C05-014
C05-015
Monode T10-NC Electrolyte (Nuclear Grade) Lectroetch Cleaner No. 3 (Nuclear Grade)
C05-108
C05-017
Monode APC Neutralizer
C05-109
Stencils Blue (Long life)
C05-019
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EFFECTIVITY: ALL
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VIBRO-PEEN - VIBRO-PEEN MARKING TASK 70-16-04-350-019 1. Vibro-Peen Marking SUBTASK 70-16-04-99G-019 A. General. (1) Vibro-peen marking employs a sharp, conically pointed, tungsten carbide tool which is vibrated, either electrically or pneumatically, against the surface to be marked while guided by the operators hand, much like a pen. The point, vibrating at several thousand strokes per minute, peens or imprints the surface to be marked with depressions.
SUBTASK 70-16-04-350-191 B. Equipment. (1) Either of the following types of equipment may be used for the application of this process. (a) (b) Pneumatic Marker. Electromagnetic Marker.
SUBTASK 70-16-04-350-192 C. Procedure. (1) (2) (3) (4) (5) Ensure that area to be marked is clean and unobstructed. Activate marking tool and adjust stroke if necessary. Guide tool by hand to "write" marking information. Markings from 0.001-0.006 inch (0.03-0.15 mm) are acceptable. Carefully remove all projections produced on the surface by the displaced metal.
SUBTASK 70-16-04-350-193 D. Quality Assurance. (1) Inspect mark for uniformity and legibility.
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70-16-04
VIBRO-PEEN MARKING Page 1 Dec 01/03
EFFECTIVITY: ALL
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VIBRO-PEEN MARKING Page 2 Dec 01/03
METAL STAMP - METAL STAMP MARKING TASK 70-16-05-350-020 1. Metal Stamp Marking SUBTASK 70-16-05-99G-020 A. General. (1) (2) Metal stamp marking employs the technique of forcing the metal stamp into the surface of the part to be marked thereby displacing parent material. The force applied to the stamp may be instantaneous, as by percussion, or without impact, as by mechanical, or pneumatic or hydraulic press or roller.
SUBTASK 70-16-05-350-201 B. Equipment. (1) The following equipment is required for the application of this process. (a) (b) (c) Metal stamps. Press (mechanical, hydraulic or pneumatic). Roller.
SUBTASK 70-16-05-350-202 C. Procedure. (1) Prepare part for marking as follows: (a) (b) (2) (3) Ensure area to be marked is clean and free from debris. Provide backing support at the location where stamp mark is to be made to prevent any distortion of part.
Place metal stamp on the desired area to be marked and apply force. Ensure that proper size-to-depth ratio is maintained. (a) (b) Characters 0.03-0.08 inch (0.8-2.0 mm) in height require an impression depth of 0.002-0.006 inch (0.05-0.15 mm). Characters 0.10-0.16 inch (2.5-4.0 mm) in height require an impression depth of 0.006-0.01 inch (0.15-0.3 mm).
(4)
Carefully remove any surface irregularities caused by the displaced metal.
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70-16-05
METAL STAMP MARKING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-16-05-350-203 D. Quality Assurance. (1) Inspect mark for legibility and high metal.
EFFECTIVITY: ALL
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METAL STAMP MARKING Page 2 Dec 01/03
LASER - LASER MARKING TASK 70-16-06-350-022 1. Laser Marking SUBTASK 70-16-06-99G-022 A. General. (1) Laser marking is a marking process which employs the use of a low or medium power ND:YAG or CO laser to produce controlled depth dot matrix or engrave patterns in coatings or base metal. Typical systems use either a fixed-beam and mask or a moving-beam and computer-controlled galvanometers. This specification will control the laser process by depth of penetration and by type of laser method used (continuous wave or pulsed energy laser modes). It is important to follow the appropriate manual for detailed instructions on location and size of the mark and the method used. Some applications on rotating hardware may require post mark surface conditioning (shotpeening).
(2) (3)
SUBTASK 70-16-06-350-221 B. Equipment. (1) Laser marking equipment typically requires the use of the following: (a) A low to medium power laser (5 to 50 watts power typical) with appropriate control accessories such as flat field lenses, automatic shutter controls, computer-controlled galvanometers for a moving-beam system, or appropriate masks for a fixed-beam system, and appropriate fixturing to insure proper part positioning. A working enclosure that adequately shields the surrounding area from laser energy emissions. View ports will have adequate filter lenses, and all openings should be interlocked with the laser power supply to prevent laser operation while the safety enclosure is open. It is recommended that machine operators wear filtered goggles or glasses supplied by the laser equipment manufacturer. Test pieces and measuring devices that will ensure that the marking system is operating properly and that the part fixturing system provides correct alignment.
(b)
(c)
SUBTASK 70-16-06-350-222 C. Marking Parameters. (1) The type of marking method and the depth of penetration shall be as follows:
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LASER MARKING Page 1 Dec 01/03
Table 1. Marking Method and Depth Marking Method Inch minimum Dot Matrix Mode Shallow Intermediate Deep Engrave Mode Shallow Intermediate Deep (2) 0.0001 0.0007 0.004 0.0006 0.004 0.010 0.003 0.018 0.10 0.015 0.10 0.25 0.0001 0.0004 0.001 0.0003 0.001 0.003 0.003 0.010 0.03 0.008 0.03 0.08 Depth Inch maximum MM minimum MM maximum
The marking methods shall be identified per the following: METHOD 1A TYPE Dot matrix, shallow penetration Dot matrix, intermediate penetration Dot matrix, deep penetration Engrave, shallow penetration Engrave, intermediate penetration Engrave, deep penetration
1B
1C 2A 2B
2C
(3)
The character size will be controlled by the requirements as specified in the appropriate manual. If no character size limits are given, a size shall be chosen which will insure legibility and allow the marking to remain within the defined marking boundaries.
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-16-06-350-223 D. Procedure. (1) Marking parameter determination: (a) Pre-establish and store the part marking procedures into the machine memory or on floppy disk or cassette. Mark the trial pieces used for program build and parameter verification. Record the depth of penetration by methods such as cross section or ellipsometric comparison. Ensure that the material used for parameter evaluation is in the same material family as the pieces to be marked. If a program does not currently exist for a piece part, make sample markings on scrap material and determine the depth.
(b) (2)
Verify fixturing and part/beam location. (a) Before pieces are marked, verify that part location and beam location are aligned so that part marking will be in the location required. Typical alignment techniques are to use a HeNe laser beam to monitor the marking beam path (by running the actual program with the marking laser unpowered), or to use the marking beam at low power setting on a piece of white paper that is covered with black toner (i.e., from a copying machine). Adjust fixturing or beam location to insure proper mark location.
(3)
Prepare part(s) to be marked as follows: (a) (b) (c) (d) Ensure area to be marked is clean and free from any surface debris. Warm up the laser system and ensure that the part/beam orientation is correct. Set the laser power setting and verify as correct for the depth of penetration desired. Correctly load the characters to be marked on the part into the machine working memory or configure the mask with the appropriate stencil and correctly load it. DIRECT OR REFLECTED LASER RADIATION CAN CAUSE EYE DAMAGE. IT IS STRONGLY RECOMMENDED THAT PERSONNEL WORKING WITH THE LASER MARKING MACHINE WEAR APPROPRIATE SAFETY GLASSES OR GOGGLES AS RECOMMENDED BY THE LASER EQUIPMENT MANUFACTURER.
WARNING:
(4)
Mark parts. (a) (b) (c) Load the first part onto the fixture and close the safety enclosure. Verify that information to be marked on the part is correct. If information is incorrect, adjust characters as needed. Cycle machine.
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STANDARD PRACTICES MANUAL AS907-1-1A (d) (e) Remove part from machine and inspect for proper mark location. Verify that alpha and numeric characters are correct. Reload the machine with another part to be marked. If a different marking is required (serial number change), adjust the marking information. Cycle the machine for the remaining parts.
SUBTASK 70-16-06-350-224 E. Quality Assurance. (1) (2) Inspect marked parts for proper marked information and location. Parts with improper marking can be re-marked in an alternate area with prior approval of Honeywell. A series of lower case "x"s will be marked over the incorrect mark. Parts with marks in an improper location must be reviewed through Honeywell to determine usability.
(3)
EFFECTIVITY: ALL
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GRIT BLAST - GRIT BLAST MARKING TASK 70-16-07-350-023 1. Grit Blast Marking SUBTASK 70-16-07-99G-023 A. General. (1) Grit blast marking is a method for permanently marking parts by using an abrasive material confined to an area of characters by a stencil or by other masking.
SUBTASK 70-16-07-350-231 B. Equipment. (1) The following equipment, or equivalent equipment, is required for the application of this process: (a) Grit blast booth and nozzle equipment, Model MH-2636P, R manufactured by: Empire Abrasive Equipment Corp. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. (b) Stencil machine, 0.125 in. (3.18 mm) inch letters, manufactured by: Ideal Stencil Machine Co. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. (c) Portable grit blast marking kit, "Air Eraser Kit" No. 045003, manufactured by: Paasche Airbush Co. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. (d) Vacuum cleaner, shop type.
SUBTASK 70-16-07-350-232 C. Materials. (1) The following materials are required for the application of this process: (a) (b) (c) (d) Stencil material (Rubber or Plastic Stock) Tape C10-021 Plastic bag/Plastic wrap - local purchase 180 aluminum oxide grit - local purchase
EFFECTIVITY: ALL
70-16-07
GRIT BLAST MARKING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-16-07-350-233 D. Procedure. (1) Prepare stencil as follows: (a) (b) (c) Select proper stencil for application. Using a stencil machine, 0.125 in. (3.18 mm) inch letters, type marking information for specific part. Cut stencil to size for specific location. NOTE: Refer to appropriate applicable manual or Service Bulletin to identify surface location for marking. (2) (3) Place stencil on surface to be marked and secure, using tape C10-021. Place part in a large, clean plastic bag, leaving the stencil exposed. Secure plastic bag tightly around stencil, using tape C10-021. WHEN HANDLING ALUMINUM OXIDE IN AIR-EXHAUSTED, ENCLOSED CABINET, BE SURE THAT VENTILATION IS IN OPERATION AND THAT DOORS ARE PROPERLY SEALED. WHEN HANDLING MATERIAL IN A PARTIALLY ENCLOSED, AIREXHAUSTED CABINET, OR IN OPEN WORK AREA, WEAR APPROVED RESPIRATOR, GLOVES, GOGGLES, AND LONGSLEEVED CLOTHING. SPILLED MATERIAL SHOULD NOT BE DRYSWEPT. WET DOWN SPILLAGE AND PLACE IT IN A SEALED CONTAINER.
WARNING:
(4) (5) (6)
Using 180 aluminum oxide grit at 30 psi (207 kPa) air pressure, shallow grit blast stencil area. Depth of marking to be 0.0005 in (0.013 mm) max. Brush away or vacuum grit blast material from stencil area. Remove plastic bag and tape from part. Using applicable manual, clean part using approved method for specific part.
SUBTASK 70-16-07-350-234 E. Quality Assurance. (1) Inspect markings for legibility.
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GRIT BLAST MARKING Page 2 Dec 01/03
DOT PEEN - DOT PEEN MARKING FOR OPTICAL CHARACTER RECOGNITION TASK 70-16-08-350-001 1. Dot Peen Marking For Optical Character Recognition SUBTASK 70-16-08-99G-024 A. General. (1) Dot peen marking is a permanent marking process where characters are formed by a series of indentations or dots. The spacing between dots and characters are controlled by a microprocessor. This is a sub-set of metal stamp identification but under a carefully controlled process. The identification string which is required for dot peening will be indicated in the repair procedure. Location for identification should also be specified in the repair procedure.
(2) (3)
SUBTASK 70-16-08-350-001 B. Equipment. (1) (2) PyroMark V 2068, manufactured by Dapra Corporation. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. Technifor CN210Sm with Electromagnetic Stylus (table mounted or portable model), manufactured by Technifor SA. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. Telesis TMP4100/400 or TMP1700/400 manufactured by Telesis Technologies, Inc. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003.
(3)
SUBTASK 70-16-08-350-002 C. Materials. (1) Scotch Pad C10-010.
SUBTASK 70-16-08-350-003 D. Reference Publications. (1) (2) (3) (4) TASK 70-16-00-350-001, Marking Practices AS 478, Identification Marking Methods ANSI x 3.93M, Character positioning for optical character recognition (OCR) ANSI x 3.17, Character set for optical recognition (OCR-A)
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DOT PEEN MARKING FOR OPTICAL CHARACTER RECOGNITION Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-16-08-350-004 E. Definitions. (1) (2) Font - A style of alphanumeric and symbolic characters with unique type and face (for example, Gothic, Roman, OCR-A, 5 x 7 Dot Matrix). Optical Character Recognition (OCR) - An automatic data-entry system that utilizes predefined human-readable shaped alphanumeric character fonts which can be read by automatic scanning equipment. 5 x 7 Dot Matrix Marking - An alphanumeric and symbol character set where each character is formed by a series of individual dots arranged on a 5 x 7 (width x height) matrix. The dots are concave shaped depressions formed in the marked surface by a tool. OCR-A - A specific set of alphanumeric characters and symbols containing 96 graphic shapes and the character space, for use in OCR systems.
(3)
(4)
SUBTASK 70-16-08-350-005 F. Requirements. (1) Dot-Peen marking must be defined by the parameters specified in Table 1, Page 2, Table 2, Page 3 and Table 3, Page 3 Specific requirements will be listed in the appropriate part repair document. Dot-Peening Requirements. When Dot-Peening marking is used on parts that have the Life Limits specified in the Time Limits section of the applicable manual the following requirements shall apply: (a) (b) The marking pins cone angle ( Figure 1, Page 8) shall be 32 degrees maximum. The marking pins tip radius ( Figure 1, Page 8) shall be 0.010 inch (0.25 mm) minimum. Table 1. Dot Peen Marking Dot Peen May Be Used as Alternative Method for Standard Practice Requirements Below TASK 70-16-04-350-019 TASK 70-16-03-350-018, TASK 70-16-04-350-019, TASK 70-1606-350-022 Method 1C or 2B TASK 70-16-04-350-019, TASK 70-16-05-350-020, TASK 70-1606-350-022 Method 2C
(2)
Method Number/Description 1 Shallow 2 Intermediate
Depth Limits (a*) - 0.002 in. (a*) - (0.05 mm) 0.001 - 0.004 in. (0.03 - 0.10 mm) 0.002 - 0.006 in. (0.05 - 0.15 mm)
3 Deep
(a*) Depth sufficient to provide marking that is can be seen without magnification.
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Table 2. OCR Requirements for 5x7 Dot Matrix Marking OCR Font Designator DM1 Character Height (a*) 0.047 0.004 in. (1.19 0.10 mm) 0.059 0.005 in. (1.50 0.12 mm) 0.083 0.007 in. (2.11 0.17 mm) 0.094 0.008 in. (2.39 0.19 mm) 0.126 0.010 in. (3.20 0.26 mm) 0.150 0.012 in. (3.81 0.30 mm) Character Width (b*) 0.031 0.004 in. (0.80 0.10 mm) 0.039 0.005 in. (1.00 0.12 mm) 0.055 0.007 in. (1.41 0.17 mm) 0.063 0.008 in. (1.59 0.19 mm) 0.084 0.010 in. (2.13 0.26 mm) 0.100 0.012 in. (2.54 0.30 mm) Character Spacing (c*) 0.047 0.004 in. (1.19 0.10 mm) 0.059 0.005 in. (1.50 0.12 mm) 0.083 0.007 in. (2.11 0.17 mm) 0.094 0.008 in. (2.39 0.19 mm) 0.126 0.010 in. (3.20 0.26 mm) 0.150 0.012 in. (3.81 0.30 mm) Max. Deviation (d*)(e*) 0.008 in. (0.20 mm) 0.024 in. (0.60 mm) 0.010 in. (0.25 mm) 0.030 in. (0.75 mm) 0.014 in. (0.35 mm) 0.042 in. (1.05 mm) 0.016 in. (0.40 mm) 0.047 in. (1.19 mm) 0.021 in. (0.53 mm) 0.063 in. (1.60 mm) 0.025 in. (0.64 mm) 0.075 in. (1.91 mm) Min. Line Separation (d*) 0.024 in. (0.60 mm)
DM2
0.030 in. (0.75 mm)
DM3
0.042 in. (1.05 mm)
DM4
0.047 in. (1.19 mm)
DM5
0.063 in. (1.60 mm)
DM6
0.075 in. (1.91 mm)
NOTE: (a*) Character height is measured from the centers of the characters highest and lowest positioned dots except on the hyphen and space characters. NOTE: (b*) Character width is measured from the centers of the characters furthermost left and right positioned dots except for number one and space character. NOTE: (c*) Character spacing is the horizontal distance between two adjacent characters vertical center lines. NOTE: (d*) Character skew must be less than 3.0 degrees. For terms and definitions of the characters positional control requirements refer to ANSI X3.93M except that skewness shall be measured from the average baseline of a line of characters rather than from a reference document edge. NOTE: (e*) Maximum deviation is from the average baseline.
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Table 3. OCR-A Marking OCR Font Designator A1 Character Height (a*) 0.030 0.004 in. (0.76 0.09 mm) 0.040 0.005 in. (1.02 0.12 mm) 0.094 0.008 in. (2.39 0.19 mm) 0.126 0.010 in. (3.20 0.26 mm) 0.150 0.012 in. (3.81 0.30 mm) 0.060 0.005 in. (1.52 0.12 mm) 0.083 0.007 in. (2.11 0.17 mm) Character Width (a*) 0.015 0.004 in. (0.38 0.09 mm) 0.020 0.005 in. (0.51 0.12 mm) 0.055 0.008 in. (1.40 0.19 mm) 0.060 0.010 in. (1.52 0.26 mm) 0.080 0.012 in. (2.03 0.30 mm) 0.030 0.005 in. (0.76 0.12 mm) 0.042 0.007 in. (1.07 0.17 mm) Character Spacing (b*) 0.025 0.004 in. (0.63 0.09 mm) 0.033 0.005 in. (0.84 0.12 mm) 0.100 0.008 in. (2.53 0.19 mm) 0.134 0.010 in. (3.39 0.26 mm) 0.159 0.012 in. (4.04 0.30 mm) 0.048 0.005 in. (1.22 0.12 mm) 0.068 0.007 in. (1.73 0.17 mm) Max. Deviation (c*)(d*) 0.005 in. (0.13 mm) Min. Line Separation (c*) 0.015 in. (0.38 mm)
A2
0.007 in. (0.17 mm)
0.020 in. (0.51 mm)
A3
0.016 in. (0.40 mm)
0.047 in. (1.19 mm)
A4
0.021 in. (0.53 mm)
0.063 in. (1.60 mm)
A5
0.025 in. (0.64 mm)
0.075 in. (1.91 mm)
A6
0.010 in. (0.25 mm)
0.030 in. (0.76 mm)
A7
0.014 in. (0.36 mm)
0.042 in. (1.07 mm)
NOTE: (a*) Character height and width measurements are referenced from the center of the characters scribe line. NOTE: (b*) Character spacing is the horizontal distance between two adjacent characters vertical center lines. NOTE: (c*) Character skew must be less than 3.0 degrees. For terms and definitions of the characters positional control requirements refer to ANSI X3.93M, except that skewness shall be measured from the average baseline of a line of characters rather than from a reference document edge. NOTE: (d*) Maximum deviation is from the average baseline.
(c) (d)
The pin stroke (the distance the pin travels prior to contacting the part being marked) and pressure shall be adjusted to obtain proper marking depth. Method 2 shall be used unless otherwise specified in the repair document.
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STANDARD PRACTICES MANUAL AS907-1-1A (3) Legibility. Characters shall be legible without magnification. (a) Type of Lettering. 1 2 The marking shall be block-form capital letters and Arabic numerals without serifs (for example, Gothic or Futura). When manual marking methods are used (that is, when the tool is guided by hand in contrast to being mechanically guided) the form of numeric characters shall be as shown in Figure 2, Page 9. The number 1 must be made exactly as shown in Figure 2, Page 9, not just a straight vertical line. The number 0 must have a slanted line through it as shown in Figure 2, Page 9, not just an open circle. The number 7 must be as shown in Figure 2, Page 9, without a horizontal bar.
3 4 5 (b)
Depth 1 2 Depth will vary with the alloy being marked. Qualification tests must be performed for each alloy type and marking depth combination. Depth will be specified in the repair and may vary from shallow 0.002 to 0.006 inch (0.015 to 0.15 mm) deep as shown in Table 1, Page 2.
(c)
Character size 1 Optical Character Recognition (OCR). When optically recognized character marking is required, the designator OCR and the applicable OCR font designator shall be specified in the repair document following the marking method number. For example, if the applicable manual specifies: MARK PER METHOD X OCR-DM3 The X specifies the Marking Method Number (see the left column in Table 1, Page 2) The OCR specifies that OCR characters must be used. The DM-3 specifies the Font Designator (see the left column in Table 2, Page 3 and Table 3, Page 3). 2 5 x 7 Dot Matrix Marking. The 5 x 7 matrix is a set of points defined by the intersection of seven horizontal (height) and five vertical (width) lines, all of which are equally spaced. The center of the individual dots shall be marked at the designated intersection on the matrix ( Figure 2, Page 9). The marking characters height, width, spacing requirements and positional controls are specified in Table 2, Page 3.
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STANDARD PRACTICES MANUAL AS907-1-1A a The height of each character can vary from 0.048-0.150 inch (1.213.81 mm). Measure from the center of the characters highest and lowest positioned dots for all characters but the hyphen and space characters. The width of each character can vary from 0.048-0.100 inch (0.362.54 mm). Measure from the center of the characters furthermost left and right positioned dots for all characters but the number one and space characters. The character spacing can vary from 0.076-0.150 inch (1.94-3.81 mm). This is the horizontal distance between two adjacent characters vertical center lines. Character skew is less than 3.0 degrees. The maximum deviation from the average base line can vary from 0.008-0.025 inch (0.20-0.64 mm). The minimum line separation can vary from 0.025-0.075 inch (0.60-1.91 mm).
d e f 3
OCR-A Marking. Requirements for the standard OCR-A character set are specified in ANSI x 3.17. The OCR-A marking characters height, width, spacing and positional requirements are specified in table 3, Page 3. a The height of each character can vary from 0.030 (0.76 mm) to 0.083 inch (2.11 mm). Character height measurements are referenced from the center of the characters scribe line. The width of each character can vary from 0.015 inch (0.38 mm) to 0.042 inch (1.07 mm). Character height measurements are referenced from the center of the characters scribe line. The character spacing can vary from 0.025 inch (0.63 mm) to 0.068 inch (1.73 mm). This is the horizontal distance between two adjacent characters vertical center lines. Character skew is less than 3.0 degrees. The maximum deviation from the average baseline can vary from 0.005 inch (0.13 mm) to 0.014 inch (0.36 mm). The minimum line separation can vary from 0.015 inch (0.38 mm) to 0.042 inch (1.07 mm).
d e f (4)
Marking Location. Unless specifically defined in the repair procedure, the specified marking shall be allowed anywhere on the surface indicated on the engineering part drawing within the following limitation. (a) Edge Clearance. Permanent markings shall not be nearer than 0.031 inch (0.78 mm) to any corner, fillet, radius, edge, or break-edge unless specifically designated. Where the designated marking location does not provide enough
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STANDARD PRACTICES MANUAL AS907-1-1A area for the 0.031 edge clearance, the markings shall be centered upon the area without breaking over a corner, edge, break-edge, or a tangent point of a fillet or radius ( Figure 3, Page 10). (b) Bolts, Studs, Screws, and Nuts. When identification marking is required on bolts, screws, studs, or nuts, the item shall be marked in accordance with this specification, but due to the limitations of available marking area, the following exceptions apply. 1 Unless otherwise specified in the repair document, the marking may be located on any non-wrenching or non-bearing surface, except that bolts, screws, or studs shall not be marked on the reduced shank area. Reference paragraph F.(4) (marking location). Edge distance requirements of paragraph F.(4)(a) do apply. The term edge as applied to hexagon head bolts is defined as the intersection of the hexagon flats with the top of the head; on double hexagon head bolts the edge is the intersection of the root of two adjacent flats with the top of the head. The marked character sizes shall be in accordance with AS 478.
3 (5)
Arrangement. The arrangement for identification and traceability mark shall be in accordance with the applicable manual. If instructions are not specified, follow TASK 70-16-00-350-001, Marking Practices, for permanent marking.
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Cone Angle Figure 1
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Character Shapes - Standard 5 x 7 Dot Matrix Characters Figure 2
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Marking Location Figure 3
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-16-08-350-006 G. Procedure. (1) (2) (3) Prepare the system by programming the appropriate identification string in the unit. Make sure that the part is clean and free from all grease, oil, or film prior to marking. Lightly burnish the area to be marked with the Scotch Brite Pad C10-010. Carefully remove all projections produced on the surface by the displaced metal.
SUBTASK 70-16-08-350-007 H. Quality Requirements. (1) (2) Process qualification for depth of marking should involve metallographic cross sections to determine stamp penetration. The samples used for qualification must meet the parameters below to be representative of actual part processing: Same Alloy Same heat treat condition Same surface treatment (if applicable) Same surface finish Minimum 0.030 inch (0.76 mm) thickness (3) (4) Qualification will be required for each alloy/depth combination used during part marking. Maintain the tip radius as calibrated tooling under calibration control. See Step F.(2)(b) in Subtask 70-16-08-350-005, Requirements.
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SUITABILITY TEST - SUITABILITY TEST OF TEMPORARY MARKING PRODUCTS TASK 70-16-80-700-009 1. Suitability Test of Temporary Marking Products SUBTASK 70-16-80-99G-009 A. General. (1) (2) (3) Marking control tests should be performed on all products used for temporary marking. The control tests will identify temporary marking products likely to deteriorate engine parts during engine operation or shop maintenance. Specific control tests may also be appropriate when temporary marking products are applied to nonmetallic materials. The markers appropriate for nonmetals must be established on a case-by-case basis. Removal of temporary marking products must be performed using a method (thinners, solvents, abrasives, etc.) that does not deteriorate the base material of the engine part. The ink used in temporary markers should be lot controlled. The analysis and testing defined in this section may be used for determining the acceptability of certain products that are used and subsequently left on engine hardware. An example of such a product would be penetrating oil used during disassembly.
(4)
(5) (6)
SUBTASK 70-16-80-700-091 B. Requirements. (1) Temporary marking materials shall be tested for either composition or temperature resistance and shall meet the requirements of the performed test. (a) Composition. 1 Purpose: To evaluate the marking material compatibility on jet engine components in the area of potential contamination from residual elements. Procedure: Testing should be done per ASTM methods for elemental analysis.
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SUITABILITY TEST OF TEMPORARY MARKING PRODUCTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A a Obtain samples of the materials to be tested for the following elements: NOTE: Levels of elements are controlled by a maximum concentration per element as well as a total maximum for the group (I., II., and III.). Table 1. Element Lead Cadmium Antimony Bismuth Mercury Zinc Tin Selenium Silver Thallium Copper Total not to exceed 100 ppm II. Element Sulfur Sodium Potassium III. Element Fluorine Chlorine Bromine Iodine Total not to exceed 100 ppm b Metals (group I. of the elements) do not need to be individually analyzed if the ash content on 25 ml of the sample is less than or equal to 0.0025 wt percent. The sample can be dried at a low temperature then ashed by firing at 6508F (3438C) in a porcelain or platinum crucible to constant weight. The product shall pass the elemental analysis requirements above for the material to be approved for use on engine components. Composition (Maximum concentration) 100 ppm 100 ppm 100 ppm Composition (Maximum concentration) 50 ppm 50 ppm 50 ppm 50 ppm Composition (Maximum concentration) 25 ppm 25 ppm 25 ppm 25 ppm 25 ppm 25 ppm 25 ppm 25 ppm 25 ppm 25 ppm 25 ppm
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-16-80-700-092 C. Hot Corrosion Test for Metals. (1) Test Equipment. (a) Test part. The temporary marking product is applied to the test parts and subjected to a heat test for at least 2 hours. For the test parts, use raw material (metal sheet, tubes) of the same metal of parts to be marked, or a specimen taken from a large part or rod. (b) (c) Test materials. None required. Equipment. The convection ovens, used for the hot corrosion tests, shall have an electrical heating system capable of being regulated and programmed, and of maintaining the test parts at specified temperatures. The regulation shall function throughout the full temperature range. (2) Method of Test. (a) Heat the test part for 8 hours 30 minutes at the temperature appropriate for the metal being tested, as indicated below: Temperature 8F(+ 258F) 700 700 1700 1700 2000 900 Test Validation. (a) Visually check the test part for absence of corrosion, contamination, and intergranular attack in the marking zone, then repeat check on micrographic section examined under 400X magnification. Visual check of the sample should show no evidence of corrosion, contamination, or intergranular attack. Maximum allowable intergranular attack when examined under 400X magnification is 0.0002 in. (0.005 mm). Temperature 8C(158C) 371 371 927 927 1093 482 Test Panel Material AMS 4375 AMS 4037 AMS 5510 AMS 5596 AMS 5608 AMS 4911
Metal Magnesium alloys Aluminum alloy Steel Nickel alloys Cobalt alloys Titanium alloys (3)
(b)
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CLEANING - CLEANING ENGINE PARTS TASK 70-20-00-100-001 1. Cleaning Engine Parts SUBTASK 70-20-00-99G-201 A. General. (1) Cleaning of engine parts is necessary to permit adequate detailed inspection and subsequent repair of material defects. The cleaner the parts, the more reliable will be the inspection. Completeness of weld repairing is directly dependent upon the degree of cleanliness attained before inspection; however, cleaning that is adequate for inspection may not be adequate to permit satisfactory weld repairing. Chemical solutions must be limited to use on parts that will not be subject to surface corrosion, intergranular attack, or loss of dimension. Abrasive blasting, either wet or dry, must be used in such a way as to avoid loss of dimension or surface finish, masking or hiding of cracks and flaws in metal parts. Generally, the following points should be considered in the choice of an appropriate cleaning method. (a) (b) (c) (d) (e) (f) Type of contaminants to be removed. Type of material (s) composing the part. Surface finish and surface coating requirements. Degree of cleanliness required. Type and availability of cleaning materials and equipment. Complexity of the part (geometric complications). NOTE: The processes described in various cleaning methods are based upon compounds supplied by a particular vendor. Materials available from other vendors may be equally satisfactory. The procedure for obtaining approval from Honeywell for the use of other products or parameters will be supplied upon request. SUBTASK 70-20-00-100-011 B. Water Supply and Waste Disposal. (1) Ordinary tap water is satisfactory for use in formulating most cleaning solutions described in this section. When natural or artificial inclusions of chemicals will affect the process adversely, such as chlorides or fluorides which attack titanium, the fact will be noted in the specific cleaning method. Disposal of chemical wastes is a problem of growing importance because of increasing stream pollution. The disposal problem should be investigated before a particular process is installed, so that facilities for neutralization, filtration or other treatment can be incorporated.
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CLEANING ENGINE PARTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-20-00-100-012 C. Safety. (1) Hot solutions of strong acids and caustic ingredients are serious personnel hazards; therefore, good housekeeping, safety precautions, adequate ventilation and protective equipment, and emergency procedures to be followed in the event of accident are of paramount importance to minimize hazards and to promote safe and efficient operation.
SUBTASK 70-20-00-100-013 D. Corrosion Prevention. (1) The cleaning of parts leaves them susceptible to corrosion. After cleaning, parts must be protected during the inspection, repair, and reassembly process. For specific instructions, refer to TASK 70-60-00-620-001, Preservation of Engine Parts.
SUBTASK 70-20-00-100-014 E. Plastic Parts. (1) Plastic parts must be handled separately. Plastic parts are not to be submerged in cleaners or solvents unless specifically called for. Generally, plastic parts should be cleaned in accordance with TASK 70-21-03-160-001, Cleaning Method No. 3 Steam Cleaning.
SUBTASK 70-20-00-100-015 F. Acid and Alkaline Solutions. (1) Cleaning methods that utilize acid and alkaline solutions shall not be used where the possibility of entrapment exists so that the acid and alkaline solution might not be completely removed by subsequent neutralizing/rinsing process.
SUBTASK 70-20-00-100-016 G. Use of Ultrasonic Cleaning and Rinsing Methods.
CAUTION: ULTRASONIC CLEANING AND RINSING SHOULD NOT BE APPLIED TO SOFT METAL SUCH AS ALUMINUM AND MAGNESIUM WITHOUT SPECIFIC APPROVAL IN THE PROCESS DOCUMENT. SPECIAL TESTING MAY BE REQUIRED FOR THESE MATERIALS. (1) The use of ultrasonic cleaning and rinsing methods greatly enhances the speed and effectiveness of cleaning many difficult parts. It also substantially minimizes the possibility of entrapment of acid and alkaline materials. With ultrasonic cleaning, it is CRITICAL to prevent direct mechanical contact between the parts and the tank sidewall. If this occurs, excessive vibration may result and mechanical damage or cracking can occur in the engine parts. Control of equipment and fixtures is critical. (a) The following equipment is required for the application of this process:
(2)
(3)
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STANDARD PRACTICES MANUAL AS907-1-1A 1 Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products, and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. NOTE: The ultrasonic cleaning energy will heat the cleaning solution due to its own energy. This needs to be taken into consideration in any application that requires strict temperature control. CAUTION: ULTRASONIC ENERGY WILL TEND TO INCREASE THE TEMPERATURE OF THE WORKING BATH, SO COOLING AS WELL AS HEATING CAPABILITY MAY BE NECESSARY. THE BATH OPERATING TEMPERATURE RANGES MUST BE CAREFULLY MONITORED. 4 Processing tank with temperature control. a The tank should be made of stainless steel and be equipped with either a heat exchanger or heating coil capable of controlling the working solution in the temperature range of 708-2008F (218938C). The tank must be clearly labeled with the power density, frequency of the unit, and rated capacity in gallons (or liters). This label shall be fixed to the outside of the face of the tank in full view of the operator.
2 3
Generator Requirements: a b c The generator must be a fixed power rating and not be adjustable by the operator. 20 kHz minimum, 6-10 watts/square inch (0.93-1.55 watts/square cm) of tank bottom. Recommended watts per gallon (watts per liter) for tank sizes are as follows: Less than 30 gallons (114 liters): 30-40 watts per gallon (7.9-10.6 watts per liter) 31-100 gallons (115-379 liters): 20-30 watts per gallon (5.3-7.9 watts per liter) 101-250 gallons (380-946 liters): 15-25 watts per gallon (4.0-6.6 watts per liter). d Piezoelectric type transducers should be equipped with High Sweep Modulation capability for optimum cleaning efficiency.
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STANDARD PRACTICES MANUAL AS907-1-1A The sweep range should be 2 to 3 kHz. This requirement is not necessary for magnetostrictive type transducers. 6 Fixture Requirements: CAUTION: IT IS CRITICAL THAT THERE BE NO DIRECT MECHANICAL CONTACT BETWEEN THE ENGINE COMPONENT AND THE ULTRASONIC TRANSDUCER. IF CONTACT DOES OCCUR, HOLD THE PARTS AND CONSULT YOUR HONEYWELL, REPRESENTATIVE FOR DISPOSITION. a b c The parts must be suspended in the tank completely independent of the tank sidewalls, tank bottom, or transducer surface. Parts are not to be hung from the side of the tank without a rack to insulate it from mechanical vibration. Parts must be fully submerged in the solution. If the part has holes and/or cavities the fixture/part must be rotated to assure that they are filled with cleaning solution and all air is removed. If more than one part is cleaned at a time, they must not touch each other.
d (4)
A demonstration of the procedure is necessary for each new application and each model type of ultrasonic equipment to achieve internal approval to clean hardware using an ultrasonic system. Unless special requirements are stated in the process document, the internal approval package must include the following data as a minimum: (a) Identification of following process parameters involved in the cleaning procedure:
1 2 3 4 5 6 7 8 9
Description of tank including rated capacity and actual gallons (liters) used. Description of generator and frequency used. Watts/square inch (watts/square cm). Watts/gallon (watts/liter). Description of High End Modulation (sweep frequency) range. Process time in tank (range) permitted per procedure. Fixture identification number and description of how supported. Solution concentration and temperature. Description of temperature control (heat exchanger).
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STANDARD PRACTICES MANUAL AS907-1-1A (b) A demonstration of the cleaning procedure is necessary on the application in question. This demonstration must involve a 24 hour exposure of the component using the processing parameters developed for that application. However, the solution used for this test should be water in place of the alkaline cleaning fluids. This evaluation is to test exposure to the ultrasonic equipment and not the solution. A fluorescent penetrant inspection per the procedure and sensitivity defined on the process documents is to be performed before and after this exposure test to document that no cracks were initiated and that the conditions are appropriate for the given application. A demonstration of the cleaning procedure is necessary on a stock loss coupon of the alloy in question. This demonstration must use 2x (two times) the maximum permitted time developed for the application. Stock loss testing to be performed per ARP 1755.
(c)
SUBTASK 70-20-00-100-017 H. Control of Rinse Water. NOTE: As a general guideline, this is one way to control the quality of the rinse water used in chemical processes to assure the proper rinsing of parts. (1) Use of a conductivity meter. (a) (b) (c) Incoming water should be 500 micro-Siemens maximum. Set the control on the tank at 1,000 micro-Siemens to automatically turn on additional rinse water for dilution. Set the maximum limit at 2,000 micro-Siemens. Set the alarm to sound so that the operator can dump or drain down the rinse tank. Additional water can then be added to let the rinse bath decrease to less than 1,000 microSiemens.
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CHEMICAL CLEANING - CHEMICAL CLEANING TASK 70-21-00-110-051 1. Chemical Cleaning SUBTASK 70-21-00-99G-051 A. General. (1) Chemical cleaning is a process used for removing surface contaminants such as oil, grease, carbon deposits, oxidizing agents and corrosion. It is employed to clean surfaces prior to visual inspection, prior to crack detection using fluorescentpenetrant or magnetic-particle inspection methods, and prior to making repairs.
SUBTASK 70-21-00-110-511 B. Choice of Cleaning Method. (1) The choice of cleaning method is dictated by the type of contaminant to be removed and by the metal(s) in the part being cleaned. Oil and grease are removed by cleaning methods using chlorinated solvents in liquid or vapor phase. Rust and carbon deposits are eliminated by the use of acid and alkaline baths that are continually maintained and monitored.
SUBTASK 70-21-00-110-512 C. Presentation. (1) The information is presented as Processes, Products, and Solutions. (a) Processes - Mentioned under this heading are the baths or solutions to be employed; these are fully described in the instructions and in the solution sheets beginning with TASK 70-00-99-800-303, Solution Sheets. Products - Used either on their own or in solution, are covered in the Consumable Products List Chapter TASK 70-80-00-800-011. Solutions - These (as well as the products) are each identified by a No. It is preceded by: 1 2 (2) SXXXX for solutions. CXX-XXX for products (consumable products).
(b) (c)
The chemical cleaning processes are to be used in conjunction with the applicable manual, which should cover the operations or special handling of parts that precede and follow the application of the particular process. Many of the chemical cleaning solutions and products can be dangerous to human skin and clothes. It is essential that personnel involved in the cleaning of parts take effective precautions against any direct contact by wearing protective equipment
(3)
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CHEMICAL CLEANING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A and clothing, when the operation is preceded by a WARNING note similar to the following examples. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. HYDROFLUORIC ACID SOLUTIONS ARE VERY DANGEROUS AND POISONOUS. PREVENT CONTACT WITH SKIN, EYES, AND CLOTHING. PREVENT INHALATION OF VAPORS. IF INCIDENT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER AND OBTAIN IMMEDIATE MEDICAL ASSISTANCE. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. SOLVENT IS FLAMMABLE. TAKE PRECAUTIONS AGAINST FIRE. AVOID CONTINUED OR REPEATED INHALATION OF VAPORS. OPERATOR SHOULD USE ONLY IN WELL VENTILATED AREAS. SOLVENT IS TOXIC. AVOID INHALATION OF VAPORS. AVOID PROLONGED CONTACT WITH EYES, SKIN, OR CLOTHING. OPERATOR SHOULD USE ONLY IN WELL VENTILATED AREA.
WARNING: WARNING:
WARNING: WARNING:
WARNING: WARNING:
WARNING:
(4)
Be sure you read, understand, and obey all WARNINGS in this manual.
SUBTASK 70-21-00-110-513 D. Special Recommendations. (1) (2) Parts made entirely or partially out of titanium must not be degreased with chlorinated solvents. Blasting or thermal treatment is to be used, as specified in the applicable maintenance manual, for parts that cannot easily be degreased or otherwise cleaned. To ensure parts are thoroughly cleaned, the instructions of the cleaning process below must be strictly followed. (a) Parts of intricate shape or made from honeycomb and having blind holes difficult to rinse must not be cleaned in acid baths. These parts should be cleaned using a spray of a water/additive mix.
(3)
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STANDARD PRACTICES MANUAL AS907-1-1A (b) Intermediate rinsing has a great influence on the final result. Correct rinsing requires immersion of the part in water and agitation of the part or the water. This procedure avoids contaminating the next bath by removing all traces of the products used in the bath before rinsing. Components with recessed pockets or blind holes should be rinsed with a pressure jet (air-water nozzle). In addition, the use of a 2000 psi water pressure lance is permitted to assist in the removal of conditioned oxide scale following chemical cleaning steps. Maximum cleaning effectiveness is obtained by using both chemical and intermediate pressure assisted rinsing processes. The water required is defined in TASK 70-00-05-800-006, Water Types. Agitate the cleaning solution to improve the cleaning action. 1 2 The preferred method to agitate cleaning solutions is the mechanical method. Air Agitation has several disadvantages. a b c (d) Carbonic gas in the air of hot alkaline solutions causes the formation of carbonates. Foaming increases when surfactants are incorporated in the cleaner. Air agitation cools down the solution temperature and makes solution temperature difficult to control.
(c)
After the pressure water rinse and immersion in agitated cold water, the parts should be rinsed in a hot water bath of 150 to 2008F (66 to 938C). Keep the part submerged until the part temperature reaches the water temperature. Remove the part from the tank and drain the excess water. Use repositioning, suction, blotting with a clean, absorbent material, or by blowing off with an oil and water filtered shop air gun to remove excess water. Proper flash drying is indicated by seeing the water on the surface of a part start to flash or whisk off as the part is being removed from the hot water tank. Proper drying of the part is necessary for subsequent inspection operations such as fluorescent- penetrant inspection.
(4)
In many of the following cleaning procedures we recommend stainless steel tanks. In general these should be made from 316 stainless steel. Sometimes optional polypropylene liners are required to give additional protection to the stainless steel. Certain acids (such as hydrochloric acid) can cause pitting of stainless steel tanks. Other solutions can become aggressive and damage stainless steel if the chloride levels from make-up water get too high. Follow the advice of your chemical supplier and tank manufacturer.
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CLEANING METHOD NO. 1 - CLEANING METHOD NO.1 SOLVENT DEGREASING TASK 70-21-01-110-001 1. Cleaning Method No. 1 Solvent Degreasing NOTE: It is recommended that cold soak tanks of 1,1,1 trichloroethane or any other chlorinated hydrocarbon or chlorinated fluorocarbon be removed and replaced with alternate materials. If there is uncertainty on proper replacement for this tank process, contact Manager, Materials and Processes, Product Support Engineering for help to choose proper material. SUBTASK 70-21-01-99G-001 A. General. CAUTION: DO NOT APPLY THIS PROCESS TO CLEAN TITANIUM OR TITANIUM ALLOY PARTS WHEN USING 1,1,1 TRICHLOROETHANE OR ANY OTHER CHLORINATED HYDROCARBON. DAMAGE TO PARTS MAY RESULT. THE OTHER MATERIALS LISTED CAN BE USED FOR TITANIUM PARTS CLEANING. (1) This process is used to clean parts contaminated with oil, grease, or various slightly adherent deposits by a reduction in viscosity and/or dissolution in the solvent. Immersion is generally accompanied by a mechanical stirring of the bath, brushing or ultrasonic action.
(2)
CAUTION: SOME PLASTIC AND RUBBER-BASED MATERIALS ARE ATTACKED BY HYDROCARBON SOLVENTS. DO NOT CLEAN PARTS MADE FROM THESE MATERIALS OR PARTS CONTAINING COMPONENTS MADE FROM THESE MATERIALS WITH HYDROCARBON SOLVENTS. (3) Plastic or rubber-based materials which are attacked by hydrocarbon solvents are best cleaned using steam cleaning. For materials other than titanium use trichloroethane. See TASK 70-00-99-801-039, Solution S1039.
SUBTASK 70-21-01-110-011 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors.
(b) (c)
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CLEANING METHOD NO.1 SOLVENT DEGREASING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (d) A solvent degreasing tank made of stainless steel.
SUBTASK 70-21-01-110-012 C. Materials.
Solvent Solutions - Table 1 Solution Stoddard solvent Degreasol 99R Ardrox 552 Turco IND 79 SUBTASK 70-21-01-110-013 D. Procedure. WARNING: SOLVENTS ARE TOXIC. AVOID INHALATION OF VAPORS. AVOID PROLONGED CONTACT WITH EYES, SKIN, OR CLOTHING. OPERATOR SHOULD USE ONLY IN WELL VENTILATED AREA. STODDARD SOLVENT AND DEGREASOL 99R ARE FLAMMABLE. TAKE PRECAUTIONS AGAINST FIRE IN ACCORDANCE WITH LOCAL REGULATIONS. No. S1040 S1147 C04-224 C04-225 Operating Temperature Ambient Ambient Ambient Ambient
WARNING:
(1)
Immerse the parts slowly into the tank containing one of the solvent solutions listed in Subtask 70-21-01-110-012, Materials. OPERATOR SHOULD WEAR GLOVES AND A RUBBER APRON IF BRUSHING IS BEING DONE.
WARNING: (2) (3) (4)
Stir the solution through mechanical or ultrasonic action or brush by hand. Remove the part and allow it to drip over the tank. Dry use clean, dry air.
SUBTASK 70-21-01-110-014 E. Quality Assurance. (1) Visually check for the removal of all initial contamination and make sure that no local build-up of contaminants was produced on the part during dripping and drying.
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CLEANING METHOD NO.1 SOLVENT DEGREASING Page 2 Dec 01/03
CLEANING METHOD NO. 2 - CLEANING METHOD NO. 2 VAPOR DEGREASING TASK 70-21-02-110-002 1. Cleaning Method No. 2 Vapor Degreasing NOTE: Method 22, Light Duty Alkaline Cleaning may be used as an alternate to reduce solvent use prior to other cleaning methods. It may also be used prior to NDT inspections. SUBTASK 70-21-02-99G-002 A. General. CAUTION: DO NOT APPLY THE PROCESS TO TITANIUM ALLOY PARTS, TO BALL BEARINGS, OR TO RUBBER OR PLASTIC PARTS. THESE MATERIALS REACT TO CHLORINATED HYDROCARBONS OR ARE DESTROYED BY THE TEMPERATURE OF VAPORS. CAUTION: DO NOT INTRODUCE MOIST PARTS IN THE SOLVENT FUMES. THE PRESENCE OF WATER IN THE BATH REDUCES ITS EFFICIENCY AND CAUSES THE ACIDIFICATION OF THE PRODUCT. (1) Vapor degreasing is used to remove greasy substances. The continuous distillation means the parts are only in contact with clean solvent, thereby improving the degreasing efficiency and speed. The condensation of the solvent vapor on the parts during the initial phase also promotes the dissolution of greases and oils. After condensation, a spray of cold solvent may be used. The spray bar must operate below the vapor level and avoid excessive turbulence which may cause vapor in the tank to escape. This procedure utilizes the material 1,1,1, Trichloroethane (inhibited). Perchlorethylene and Trichloroethylene are recognized as alternate materials in certain regions of the world. If these alternate materials are used, the operating procedures used must reflect the boiling points of the material used and the process control concerns stated in this procedure.
(2)
(3)
SUBTASK 70-21-02-110-021 B. Equipment. (1) The following equipment is required for application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions.
(b)
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CLEANING METHOD NO. 2 VAPOR DEGREASING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (c) (d) Efficient ventilation system for extraction and neutralizing vapors. The vapor degreasing station shall include: 1 2 3 A solvent tank, whose accessories in contact with the solvent must be made from stainless steel. A heating coil in tank capable of heating the solution to 2008F (938C). Water must be supplied in sufficient amount to provide for efficient cooling of vapor in the condensation zone. A hinged and balanced cover must be provided to enable the tank to be closed.
SUBTASK 70-21-02-110-022 C. Materials. Operating 8F Temperature 8C
Solution A. Degreasing solution (1) Trichloroethane 11-1
No.
S1039
162-172
72-78
SUBTASK 70-21-02-110-023 D. Procedure. WARNING: SOLVENT IS TOXIC. AVOID INHALATION OF VAPORS. AVOID PROLONGED CONTACT WITH EYES, SKIN, OR CLOTHING. OPERATOR SHOULD USE ONLY IN WELL VENTILATED AREA.
(1)
Slowly immerse the parts in the tank until they are below the condensation level of vapors. The tank must be maintained at the specified temperature and contain one of the degreasing solutions listed in Subtask 70-21-02-110-022, Materials. Hold the parts in this position at least until the condensation stops. Spray the parts with a jet (atomized or not) of cold solvent. Raise the parts slowly above the condensation level to permit drying and evaporation of the solvent. Drain any liquid solvent entrapped in cavities. Operations A., B., C., and D. above may be repeated with the part in various positions, particularly for parts having intricate shapes.
(2) (3) (4) (5)
CAUTION: WEAR CLEAN GLOVES TO HANDLE DEGREASED PARTS. THIS AVOIDS SUBSEQUENT OXIDATION. (6) (7) Remove the parts from the degreasing tank. Dry the parts using clean, dry air.
EFFECTIVITY: ALL
70-21-02
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-02-110-024 E. Quality Assurance. (1) (2) Verify that all of the initial contamination has been eliminated and that no local build-up of contaminants has occurred during drainage and drying. Ensure that periodic checks are made of acidity and oil content of solution per the solution sheet.
EFFECTIVITY: ALL
70-21-02
EFFECTIVITY: ALL
70-21-02
CLEANING METHOD NO. 3 - CLEANING METHOD NO. 3 STEAM CLEANING TASK 70-21-03-160-001 1. Cleaning Method No. 3 Steam Cleaning SUBTASK 70-21-03-99G-001 A. General. (1) Steam cleaning combines the mechanical force of the spray jet with the chemical and physical action of the cleaning solution to remove oils, greases, and light soil from parts. This method is used when the part is too big for a soak tank or for component parts of different materials that cannot be put into acid or alkaline tanks. This process can be used on all materials except thermo-plastic materials.
(2)
SUBTASK 70-21-03-160-011 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. Two types of steam cleaning equipment are generally available: 1 Portable Equipment. a b c d Contains tanks for water. Contains tanks for detergent solutions. Contains heat source to generate steam. Contains controls for temperature, flow mixing, to supply steam at 90-100 psi (600-700 kPa) at a flow rate of 20-40 cu ft/hr (600-1200 1/hr.) Principle of operation of portable equipment requires only an external source of electric power to generate the steam from the water contained within the equipment. Separate tanks of detergent solution are mixed with the steam by metering valve controls. The detergent solution is premixed in the tank to the
(b) (c) (d)
EFFECTIVITY: ALL
70-21-03
CLEANING METHOD NO. 3 STEAM CLEANING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A desired concentration. The equipment produces either pure steam or a steam/solution mixture. 2 Fixed Equipment. a b c d Requires external supply of water at 20 psi (140 kPa) minimum. Requires external supply of steam at 40-150 psi (270-1040 kPa). Requires external supply of concentrated liquid detergent. Contains controls to mix the water, steam, and detergent in desired concentrations to regulate water temperature and cleaning action. Principle of operation of fixed equipment is to mix steam, cold water and detergent and deliver hot detergent solution combined with vapor under pressure through a spray gun to the surface to be cleaned. Impingement is directly related to steam pressure. The concentrated detergent is mixed with incoming water by means of an eductor and the concentration is controlled by orifice tips. Detergent supply line can be dosed for hot water rinse without stopping flow of water and steam.
SUBTASK 70-21-03-160-012 C. Materials. Table 1. Alkaline Cleaning Solution Solution Name Detergent solution No. S1025 Operating Temperature F (C) 160-220 (70-105)
NOTE: The solution operating temperature corresponds to the temperature of the spray exiting the gun.
SUBTASK 70-21-03-160-013 D. Procedure. WARNING: WHEN USING THE SPRAY GUN, WEAR GLOVES, A PROTECTOR MASK, A RUBBER APRON, AND APPROPRIATE PROTECTIVE FOOTWEAR. THE STEAM CAN BURN YOU.
(1)
Adjust the appropriate water/steam/solution/temperature control to the required setting to obtain a proper cleaning action. This will give a wet spray with sufficient impact to clean the surface. Hold spray gun approximately 10-12 inches (250-300 mm) from surface and inclined at about 45 degrees to the surface. Rinse the part with unheated water (optional).
(2) (3)
EFFECTIVITY: ALL
70-21-03
STANDARD PRACTICES MANUAL AS907-1-1A (4) Rinse the parts with hot water using the spray gun with the cleaning solution supply shut off. WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG (207 KPA). WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS.
WARNING:
(5)
Carefully dry using clean, dry air.
SUBTASK 70-21-03-160-014 E. Quality Assurance. (1) Visually check the cleanliness of the parts particularly for residues trapped in holes and recesses.
EFFECTIVITY: ALL
70-21-03
EFFECTIVITY: ALL
70-21-03
CLEANING METHOD NO. 4 - CLEANING METHOD NO.4 - DRY ABRASIVE BLAST CLEANING TASK 70-21-04-120-001 1. Cleaning Method No. 4 Dry Abrasive Blast Cleaning SUBTASK 70-21-04-99G-001 A. General. (1) Abrasive blast cleaning is a mechanical technique for removing scale, corrosion, oxidation and carbon deposits from all kinds of materials that could not be removed by chemical cleaning. It should only be used to supplement chemical cleaning, not as a replacement. Abrasive blast cleaning is often employed for surface preparation of steels that have a breaking strength greater than 210000 psi (1450 MPa) and which cannot be cleaned by chemical processes.
(2)
CAUTION: SUBSTITUTION OF A DIFFERENT METHOD FOR THE ONE RECOMMENDED IS DANGEROUS AND CAN DAMAGE PARTS. CAUTION: AVOID EXCESSIVE BLASTING. OPERATE THE EQUIPMENT SO THAT THE ABRASIVE JET IS NOT LOCALIZED ON THE SAME SPOT. DO NOT DWELL FOR MORE THAN 2 SECONDS. BLASTING IS DONE BY SWEEPING OBLIQUELY OVER THE ENTIRE SURFACE AND NOT NORMAL TO IT. (3) The applicable manual specifies the particular process to be used in each case. The choice depends upon: (a) (b) (c) (d) (4) The standard of cleanliness desired. The nature of the part. Part shape and degree of fragility. Surface finish to be obtained.
Approved dry abrasive blast methods are: (a) (b) (c) (d) (e) Method No. 4A - Alumina 220 (fine) mesh or Alumina 120 (medium) mesh. Method No. 4B - Shells and rice hulls. Method No. 4C - Alumina 500 (very fine) mesh. Method No. 4D - Fruit stones. Method No. 4E - Plastic Media
EFFECTIVITY: ALL
70-21-04
CLEANING METHOD NO.4 - DRY ABRASIVE BLAST CLEANING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-04-120-011 B. Equipment. (1) The following equipment is required for dry abrasive blasting. WARNING: THE DRY ABRASIVE EQUIPMENT USED FOR TITANIUM AND TITANIUM ALLOYS SHALL BE CLEANED REGULARLY TO PREVENT FIRE HAZARDS DUE TO THE ACCUMULATION OF METALLIC PARTICLES.
(a)
Dry abrasive blasting operations must be performed using installations specifically designed for that purpose (blasting booths) complete with safety devices such as air-extraction systems, soundproofing, exhaust mufflers, etc. Such installations must also be equipped with devices guaranteeing good quality processing including dust removers, catch-and select units for broken particles, internal lighting, air pressure adjustments, etc. To prevent contamination of parts being processed, a blasting booth should be reserved, whenever possible, for use with a given material (alloyed steel, aluminum alloy, or titanium parts, as applicable). To minimize fire hazards which could result from an accumulation of very fine particles of titanium (or its alloys), the blasting booths used for dry abrasive blasting of titanium parts shall be carefully cleaned at frequent intervals. A dry blasting booth lined with anti-abrasive material. Operators must use safety gear, gloves, breathing masks, and protective clothes.
(b)
(c) (d)
TASK 70-21-04-120-002 2. Dry Abrasive Blast Cleaning - Method No. 4A SUBTASK 70-21-04-99G-991 A. General - Method 4A - Alumina 220 (Fine) or 120 (Medium) Mesh. CAUTION: DRY ABRASIVE BLASTING MAY REDUCE THE FATIGUE STRENGTH ON TITANIUM OR TITANIUM ALLOYS. DO NOT USE ON TITANIUM OR TITANIUM ALLOYS WITHOUT SPECIFIC INSTRUCTIONS IN THE APPLICABLE MANUAL. BLASTING MUST BE ACCOMPLISHED IN ACCORDANCE WITH SPECIFICATIONS AND IN INSTALLATIONS RESERVED SOLELY FOR THE PURPOSE. (1) In most cases, using either medium or fine mesh ensures efficient cleaning. However, the surface finish achieved with the fine mesh is smoother than that obtained with the medium mesh.
SUBTASK 70-21-04-120-012 B. Equipment - 4A. (1) See Subtask 70-21-04-120-011, Equipment.
EFFECTIVITY: ALL
70-21-04
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-04-120-013 C. Materials - 4A. No. C04-113 C04-114
Consumable Product Alumina 220 mesh Alumina 120 mesh SUBTASK 70-21-04-120-014 D. Procedure - 4A. (1)
Cover all ports, pockets, cavities, or tube ends to prevent entry of abrasive which may be difficult to detect and remove after cleaning. Mask all surfaces, if required, as indicated in the applicable manual. The part must be free of oil and grease to prevent the quality of the abrasive from deteriorating. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING:
CAUTION: AVOID EXCESSIVE ABRASIVE BLASTING. OPERATE THE EQUIPMENT SO THAT THE ABRASIVE JET IS NOT LOCALIZED ON THE SAME SPOT. DO NOT DWELL FOR MORE THAN 2 SECONDS. BLASTING IS DONE BY SWEEPING OBLIQUELY OVER THE ENTIRE SURFACE AND NOT NORMAL TO IT. (2) Grit blast parts using one of the products listed in Subtask 70-21-04-120-013, Materials. Maintain air pressure at 25-90 psi (170-620 kPa) with the nozzle held at a distance of 6-8 inches (150-200 mm) from the part. The recommended angle to the surface being blasted is 60 10 degrees. Remove masking if applied. Blow out all residues from the abrasive cleaning operation with clean, dry air.
(3) (4)
SUBTASK 70-21-04-120-015 E. Quality Assurance - 4A. (1) Visually check that the part has been evenly cleaned and no blasting residues have accumulated.
EFFECTIVITY: ALL
70-21-04
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-21-04-120-003 3. Dry Abrasive Blast Cleaning - Method No. 4B SUBTASK 70-21-04-99G-992 A. General - Method 4B - Shells and Rice Hulls Shells and Rice Hulls. WARNING: THE DRY ABRASIVE EQUIPMENT USED FOR TITANIUM OR TITANIUM ALLOYS SHALL BE CLEANED REGULARLY TO PREVENT FIRE HAZARDS THROUGH ACCUMULATION OF METALLIC PARTICLES.
CAUTION: DRY ABRASIVE BLASTING MAY REDUCE THE FATIGUE STRENGTH OF TITANIUM OR TITANIUM ALLOYS. DO NOT USE ON TITANIUM OR TITANIUM ALLOYS WITHOUT SPECIFIC INSTRUCTIONS IN THE APPLICABLE REPAIR MANUAL. (1) This technique uses a mild abrasive (crushed shells and rice hulls) and is an effective method of cleaning light scale or carbon deposits, corrosion, and rust from parts where retarded cutting action is required. It can be used, without any detriment to the part treated, on components of high precision or of low mechanical strength. Its cleaning efficiency is limited to rather loosely adhering contaminations.
SUBTASK 70-21-04-120-016 B. Equipment - 4B. (1) See Subtask 70-21-04-120-011, Equipment.
SUBTASK 70-21-04-120-017 C. Materials - 4B. No. C04-115 C04-116
Consumable Product Walnut shells Rice hulls SUBTASK 70-21-04-120-018 D. Procedure - 4B. (1)
Cover all ports, pockets, cavities, or tube ends to prevent entry of abrasive which may be difficult to detect and remove after cleaning. Mask all surfaces, if required, as indicated in the applicable manual. The part must be free of oil and grease to prevent the quality of the abrasive from deteriorating.
EFFECTIVITY: ALL
70-21-04
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
CAUTION: AVOID EXCESSIVE ABRASIVE BLASTING. OPERATE THE EQUIPMENT SO THAT THE ABRASIVE JET IS NOT LOCALIZED ON THE SAME SPOT. DO NOT DWELL FOR MORE THAN 2 SECONDS. BLASTING IS DONE BY SWEEPING OBLIQUELY OVER THE ENTIRE SURFACE AND NOT NORMAL TO IT. (2) Grit blast parts using the products listed in Subtask 70-21-04-120-017, Materials. Use a 50 percent by volume of each. Maintain air pressure at 80-100 psi (550-690 kPa) with the nozzle held at a distance of 6-8 inches (150-200 mm) from the part. The recommended angle to the surface being blasted is 75 to 105 degrees. Remove masking if applied. Blow out all residues from the abrasive cleaning operation with clean, dry air.
(3) (4)
SUBTASK 70-21-04-120-019 E. Quality Assurance - 4B. (1) Visually check that the part has been evenly cleaned and no blasting residues have accumulated.
TASK 70-21-04-120-004 4. Dry Abrasive Blast Procedure - Method No. 4C SUBTASK 70-21-04-99G-993 A. General - Method 4C - Alumina 500 (Very Fine) Mesh. CAUTION: DO NOT USE ON TITANIUM OR TITANIUM ALLOYS WITHOUT SPECIFIC INSTRUCTIONS IN THE APPLICABLE MANUAL. BLASTING MUST BE ACCOMPLISHED IN ACCORDANCE WITH SPECIFICATIONS AND IN INSTALLATIONS RESERVED SOLELY FOR THE PURPOSE. (1) The surface finish achieved by this process is smoother than that obtained with the medium process. In most cases, the method will ensure efficient cleaning.
SUBTASK 70-21-04-120-020 B. Equipment - 4C. (1) See Subtask 70-21-04-120-011, Equipment.
EFFECTIVITY: ALL
70-21-04
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-04-120-021 C. Materials - 4C. No. C04-112
Consumable Product Alumina 500 mesh SUBTASK 70-21-04-120-022 D. Procedure - 4C. (1)
WARNING:
CAUTION: AVOID EXCESSIVE ABRASIVE BLASTING. OPERATE THE EQUIPMENT SO THAT THE ABRASIVE JET IS NOT LOCALIZED ON THE SAME SPOT. DO NOT DWELL FOR MORE THAN 2 SECONDS. BLASTING IS DONE BY SWEEPING OBLIQUELY OVER THE ENTIRE SURFACE AND NOT NORMAL TO IT. (2) Grit blast parts using product listed in Subtask 70-21-04-120-021, Materials. Maintain air pressure at 25-30 psi (172-207 kPa) for direct pressure equipment or 50-60 psi (345-414 kPa) for suction-type equipment. Hold the nozzle at a distance of 2-4 inches (50-100 mm) from the part. The recommended angle to the surface being blasted is 60 10 degrees. Remove masking if applied. Blow out all residues from the abrasive cleaning operation with clean, dry air.
(3) (4)
SUBTASK 70-21-04-120-023 E. Quality Assurance - 4C. (1) Visually check that the part has been evenly cleaned and no blasting residue have accumulated.
EFFECTIVITY: ALL
70-21-04
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-21-04-120-005 5. Dry Abrasive Blast Procedure - Method No. 4D SUBTASK 70-21-04-99G-994 A. General - Method 4C - Alumina 500 (Very Fine) Mesh. CAUTION: DO NOT USE ON TITANIUM OR TITANIUM ALLOYS WITHOUT SPECIFIC INSTRUCTIONS IN THE APPLICABLE MANUAL. BLASTING MUST BE ACCOMPLISHED IN ACCORDANCE WITH SPECIFICATIONS AND IN INSTALLATIONS RESERVED SOLELY FOR THE PURPOSE. (1) The surface finish achieved by this process is smoother than that obtained with the medium process. In most cases, the method will ensure efficient cleaning.
SUBTASK 70-21-04-120-024 B. Equipment - 4D. (1) See Subtask 70-21-04-120-011, Equipment.
SUBTASK 70-21-04-120-025 C. Materials - 4D. No. C04-117
Consumable Product Fruit stones (pits) SUBTASK 70-21-04-120-026 D. Procedure - 4D. (1)
WARNING:
CAUTION: AVOID EXCESSIVE ABRASIVE BLASTING. OPERATE THE EQUIPMENT SO THAT THE ABRASIVE JET IS NOT LOCALIZED ON THE SAME SPOT. DO NOT DWELL FOR MORE THAN 2 SECONDS. BLASTING IS DONE BY SWEEPING OBLIQUELY OVER THE ENTIRE SURFACE AND NOT NORMAL TO IT. (2) Grit blast parts using product listed in Subtask 70-21-04-120-025, Materials. Maintain air pressure at 22-72 psi (150-500 kPa) with the nozzle held at a distance of 6-8 inches (150-200 mm) from the part. The recommended angle to the surface being blasted is 75 to 105 degrees.
EFFECTIVITY: ALL
70-21-04
STANDARD PRACTICES MANUAL AS907-1-1A (3) (4) Remove masking if applied. Blow out all residues from the abrasive cleaning operation with clean, dry air.
SUBTASK 70-21-04-120-027 E. Quality Assurance - 4D. (1) Visually check that the part has been evenly cleaned and no blasting residue have accumulated.
TASK 70-21-04-120-006 6. Dry Abrasive Blast Procedure - Method No. 4E SUBTASK 70-21-04-99G-995 A. General - Method 4E - Plastic Media. (1) This technique uses a mild abrasive plastic media which is effective for parts cleaning as an alternate to chemical methods. Direct pressure or suction type machines may be used. Direct pressure machines are recommended to allow media flow rate control. This process is capable of dirt and light scale removal. It may be also used to remove RTV materials, dry film lubricants (spray on or resin bonded), epoxy/ polyurethane paint systems, and many other metal finish coatings.
(2)
SUBTASK 70-21-04-120-029 B. Equipment - 4E. CAUTION: DO NOT USE PLASTIC MEDIA IN MACHINES USED FOR OTHER ABRASIVE MEDIA OPERATIONS. MACHINES USED FOR ALUMINA OR SILICA BLAST OPERATIONS ARE CONTAMINATED WITH DENSE PARTICLES THAT WILL COMPROMISE THE PLASTIC MEDIA AND ITS MINIMAL EFFECT TO THE SURFACE BEING BLASTED. (1) See Subtask 70-21-04-120-011, Equipment. In addition, plastic media blasting equipment should have a suitable media filter and reclaim system to remove residues from the blast stream. Systems with no functioning reclaimer should be checked frequently per paragraph E. to monitor the media condition. Set up machine so that media flow rate is heavy. Back off media flow just slightly from a full choke condition.
(2)
EFFECTIVITY: ALL
70-21-04
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-04-120-030 C. Materials - 4E. No. C04-153
Consumable Product Plastic media SUBTASK 70-21-04-120-031 D. Procedure - 4E.
CAUTION: TAKE PRECAUTIONS TO ENSURE THAT ALL RESIDUES ARE MOVED FROM THE COMPONENT BEING BLASTED. NO MEDIA OR RESIDUES MAY BE ENTRAPPED. CAUTION: LIMIT DWELL TIMES AT LOCATIONS WHERE EXCESSIVE METAL REMOVAL MAY OCCUR. CAUTION: PROCESS PARTS WITH METAL THICKNESSES UNDER 0.035 INCHES (0.89 MM) WITH REDUCED PRESSURES TO PREVENT DISTORTION OR OTHER DAMAGE TO SIGNIFICANT SURFACES. CAUTION: GIVE ALUMINUM COMPONENTS EXTRA CARE. SHOTPEEN, IF REQUIRED, AFTER THE PLASTIC BLAST TO RESTORE THE SURFACE CONDITION. CAUTION: CHECK ANODIZED ALUMINUM COMPONENTS TO INSURE THAT THE COATING HAS NOT BEEN DEGRADED OR REMOVED. PRE- AND POSTPROCESSING CONDUCTIVITY CHECKS SHOULD BE COMPARABLE. (1) Cover all ports, pockets, cavities, or tube ends to prevent entry of abrasive which may be difficult to detect and remove after cleaning. Mask all surfaces, if required, as indicated in the applicable manual. The part must be free of oil and grease to prevent the quality of the abrasive from deteriorating. Set machine parameters. Set the air pressure for direct pressure machines to 2540 psi (170-270 kPa) and suction machines to 30-60 psi 207-414 kPa). Use minimum pressure setting required. Set nozzle at 4-8 inches (100-200 mm) at an angle to the surface of 30-80 degrees. The nozzle diameter shall be 0.3-0.5 inches (8-15 mm). OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. A RESPIRATOR IS RECOMMENDED.
(2)
WARNING:
CAUTION: AVOID EXCESSIVE BLASTING. OPERATE THE EQUIPMENT SO THAT THE ABRASIVE JET IS NOT LOCALIZED ON THE SAME SPOT. DO NOT DWELL FOR MORE THAN 2 SECONDS. BLASTING IS DONE BY SWEEPING OBLIQUELY OVER THE ENTIRE SURFACE AND NOT NORMAL TO IT. (3) (4) Blast parts using the parameters above. Remove any applied masking. Remove any residue or media using clean, dry air.
EFFECTIVITY: ALL
70-21-04
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-04-120-032 E. Quality Assurance - 4E. (1) (2) Visually check that the part(s) has been evenly cleaned and that all residues and residual media have been removed. Visually check media for wear at an interval that will prevent blasting with deteriorated media. Inspect using 10x to 20x magnification a media sample for rounded edges (loss of cutting edges) and under-size particles (broken-down media). Verify that residues removed from components are being removed by the reclaiming system. The media should be replaced when approximately 50% of the sample is rounded and/or undersize. Use a sample of new media for visual comparison if necessary.
EFFECTIVITY: ALL
70-21-04
CLEANING METHOD NO. 5 - CLEANING METHOD NO. 5 WET ABRASIVE BLAST CLEANING TASK 70-21-05-120-002 1. Cleaning Method No. 5 Wet Abrasive Blast Cleaning SUBTASK 70-21-05-99G-002 A. General. (1) (2) Abrasive blast cleaning is a mechanical technique for removing scale, corrosion, oxidation and carbon deposits from all kinds of materials. Abrasive blast cleaning is often employed for surface preparation of steels that have a breaking strength greater than 210000 psi (1450 MPa) and which cannot be cleaned by chemical processes.
CAUTION: SUBSTITUTION OF A DIFFERENT METHOD FOR THE ONE RECOMMENDED IS DANGEROUS AND CAN DAMAGE PARTS. (3) The applicable manual specifies the particular process to be used in each case. The choice depends upon: The standard of cleanliness desired. The nature of the part. Part shape and degree of fragility. Surface finish to be obtained. (4) Approved wet abrasive blast methods are: Method No. 5A - Fine. Method No. 5B - Medium. SUBTASK 70-21-05-120-021 B. Equipment. (1) The following equipment is required for the application of this process. CAUTION: IT IS ADVISABLE NOT TO CLEAN DIFFERENT MATERIALS (STEELS, ALUMINUM, TITANIUM) WITH THE SAME EQUIPMENT SO AS TO AVOID POSSIBLE CONTAMINATION. (a) Wet abrasive blasting operations must be performed using installations specifically designed for that purpose (blasting booths) complete with safety devices such as air-extraction systems, soundproofing, exhaust mufflers, etc. Such installations must also be equipped with devices guaranteeing good quality processing including dust removers, internal lighting, abrasive material recovery pumps, air pressure adjustments, etc.
EFFECTIVITY: ALL
70-21-05
CLEANING METHOD NO. 5 WET ABRASIVE BLAST CLEANING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (b) To prevent contamination of parts being processed, a blasting booth should be reserved, whenever possible, for use with a given material (alloyed steel, aluminum alloy, or titanium parts, as applicable). The abrasive blasting station shall consist of the following. 1 2 3 (d) (e) (f) A wet blasting booth lined with anti-abrasive material. A blower/suction unit. A water supply and evacuation system.
(c)
A water rinse tank made from stainless steel or a carbon steel tank with a polypropylene lining. A hot water rinse tank made from stainless steel with a heating coil in the tank that is capable of heating the solution to 1808F (808C). Operators must use safety gear, gloves, breathing masks, and protective clothes.
TASK 70-21-05-120-003 2. Wet Abrasive Blast Cleaning - Method No. 5A SUBTASK 70-21-05-99G-996 A. General - Method No. 5A - Fine. CAUTION: THIS PROCEDURE IS USED FOR THE PREPARATION OF SURFACES FOR PAINTING. IT MUST BE CARRIED OUT IN ACCORDANCE WITH SPECIFICATIONS AND IN INSTALLATIONS RESERVED SOLELY FOR THAT PURPOSE. CAUTION: IT IS ADVISABLE NOT TO CLEAN DIFFERENT MATERIALS (STEELS, ALUMINUM, TITANIUM) IN THE SAME INSTALLATION TO AVOID POSSIBLE CONTAMINATION. CAUTION: AVOID EXCESSIVE ABRASIVE BLASTING. OPERATE THE EQUIPMENT SO THAT THE ABRASIVE JET IS NOT LOCALIZED ON THE SAME SPOT. DO NOT DWELL FOR MORE THAN 2 SECONDS. BLASTING IS DONE BY SWEEPING OBLIQUELY OVER THE ENTIRE SURFACE AND NOT NORMAL TO IT. (1) (2) The surface finish achieved by this process is smoother than that obtained with the medium process. The blasting parameters are variable depending on the blasting material and the shape of the part. For thinner parts reduce the pressure.
EFFECTIVITY: ALL
70-21-05
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-05-120-022 B. Equipment - 5A. (1) See Subtask 70-21-05-120-021, Equipment.
SUBTASK 70-21-05-120-023 C. Materials - 5A. (1) Solution 1250 Novaculite SUBTASK 70-21-05-120-024 D. Procedure - 5A. (1) Cover all ports, pockets, cavities, or tube ends to prevent entry of abrasive which may be difficult to detect and remove after cleaning. Mask all surfaces, if required, as indicated in the applicable manual. The part must be free of oil and grease to prevent the quality of the abrasive from deteriorating. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. Materials. No. S1048 Operating Temperature 8F (C8) Ambient
WARNING:
CAUTION: AVOID EXCESSIVE ABRASIVE BLASTING. OPERATE THE EQUIPMENT SO THAT THE ABRASIVE JET IS NOT LOCALIZED ON THE SAME SPOT. DO NOT DWELL FOR MORE THAN 2 SECONDS. BLASTING IS DONE BY SWEEPING OBLIQUELY OVER THE ENTIRE SURFACE AND NOT NORMAL TO IT. (2) Wet blast parts using solution listed in Subtask 70-21-05-120-023, Materials. Maintain air pressure at 60-90 psi (415-620 kPa) with the nozzle held at a distance of 6-8 inches (150-200 mm) from the part. The recommended angle to the surface being blasted is 60 10 degrees. Rinse by immersion in water. Rinse by immersion in hot water at 1808F (808C). Remove masking if applied. Blow dry with clean, dry compressed air until all quartz grit is removed.
(3) (4) (5) (6)
SUBTASK 70-21-05-120-025 E. Quality Assurance - 5A. (1) Visually check that the part has been evenly cleaned and no blasting residues have accumulated.
EFFECTIVITY: ALL
70-21-05
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-21-05-120-004 3. Wet Abrasive Blast Cleaning - Method No. 5B SUBTASK 70-21-05-99G-997 A. General - Method No. 5A - Fine. CAUTION: THIS PROCEDURE IS USED FOR THE PREPARATION OF SURFACES FOR PAINTING. IT MUST BE CARRIED OUT IN ACCORDANCE WITH SPECIFICATIONS AND IN INSTALLATIONS RESERVED SOLELY FOR THAT PURPOSE. CAUTION: IT IS ADVISABLE NOT TO CLEAN DIFFERENT MATERIALS (STEELS, ALUMINUM, TITANIUM) IN THE SAME INSTALLATION TO AVOID POSSIBLE CONTAMINATION. CAUTION: AVOID EXCESSIVE ABRASIVE BLASTING. OPERATE THE EQUIPMENT SO THAT THE ABRASIVE JET IS NOT LOCALIZED ON THE SAME SPOT. DO NOT DWELL FOR MORE THAN 2 SECONDS. BLASTING IS DONE BY SWEEPING OBLIQUELY OVER THE ENTIRE SURFACE AND NOT NORMAL TO IT. (1) (2) The surface finish achieved by this process is smoother than that obtained with the medium process. The blasting parameters are variable depending on the blasting material and the shape of the part. For thinner parts reduce the pressure.
EFFECTIVITY: ALL
70-21-05
CLEANING METHOD NO. 6 - CLEANING METHOD NO. 6 - HEAVY-DUTY ALKALINE CLEANER (WITHOUT INHIBITED PHOSPHORIC ACID) TASK 70-21-06-110-004 1. Cleaning Method No. 6 SUBTASK 70-21-06-99G-004 A. General. CAUTION: DO NOT APPLY THIS PROCESS TO ALUMINUM OR TITANIUM ALLOYS. (1) This cleaning method is a hot-tank process which is effective for removing rust, stripping paint, and general cleaning of ferrous and high-temperature alloy jet engine parts.
SUBTASK 70-21-06-110-041 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline degreasing tank made of stainless steel with a heating coil capable of heating the solution to 2108F (998C). A water rinse tank made from stainless steel and a spray gun, used after the alkaline degreasing. A hot water rinse tank made from stainless steel (or a carbon steel tank with polypropylene lining) that can increase the temperature of the solution to 2008F (938C).
(b) (c) (d) (e) (f)
EFFECTIVITY: ALL
70-21-06
CLEANING METHOD NO. 6 - HEAVY-DUTY ALKALINE CLEANER (WITHOUT INHIBITED PHOSPHORIC ACID) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-06-110-042 C. Materials. Table 1. Alkaline Degreasing/Rust Removing Solution Solution Turco 4781-7 or Turco 4781-7L Ardrox 185 or Ardrox 185L Turco 4181 or Turco 4181-L Ferlon MagChem HDP-2888 Cee-Bee J84A or Cee-Bee 84AL MagChem HDL-202 Eldorado HTP-1150 Eldorado HTP-1150L Applied 5-840 SUBTASK 70-21-06-110-043 D. Procedure. (1) In case of excessive dirt, preclean part using a solvent or, if necessary, a vapor degreasing application as indicated in the applicable manual. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. No. S1005 S1024 S1006 S1027 S1017 S1026 S1150 S1161 S1162 S1176 Operating Temperature 8F (8C) 180-200 (82-93) 180-190 (82-88) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93)
WARNING:
WARNING: (2)
Immerse the part in a tank containing one of the alkaline degreasing/rust removing solutions and maintain at the specified temperature. The solutions are listed in Subtask 70-21-06-110-042, Materials. Duration: 15 to 60 minutes. Rinse by spraying with a water jet and by immersion in water at room temperature. Rinse by immersion in hot water at 150 to 2008F (66 to 938C). Keep the part submerged until the part temperature reaches the water temperature. If parts are still not clean, repeat Steps D.(2) through D.(4). Dry using clean, dry air.
(3) (4) (5) (6) (7)
EFFECTIVITY: ALL
70-21-06
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-06-110-044 E. Quality Assurance. (1) Visually check the part for cleanliness.
EFFECTIVITY: ALL
70-21-06
EFFECTIVITY: ALL
70-21-06
CLEANING METHOD NO. 7 - CLEANING METHOD NO. 7 - THREE-STEP HEAVY-DUTY ALKALINE DESCALING (WITHOUT INHIBITED PHOSPHORIC ACID) TASK 70-21-07-110-005 1. Cleaning Method No. 7 SUBTASK 70-21-07-99G-005 A. General. CAUTION: DO NOT APPLY THIS PROCESS ON ALUMINUM, TITANIUM, OR CHROMIUM-PLATED PARTS. (1) This cleaning method is a multiple hot-tank process that is effective in removing heat scale and oxide formations from high-temperature alloy jet engine parts.
SUBTASK 70-21-07-110-051 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline degreasing tank made from stainless steel with a heating coil that is capable of heating the solution to 2008F (938C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and a water spray gun, used after the degreasing bath. An alkaline stripping tank made from stainless steel with a heating coil that is capable of heating the solution to 2608F (1278C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and a water spray gun, used after the alkaline stripping. A permanganate cleaning tank made from stainless steel with a heating coil that is capable of heating the solution to at least 1808F (828C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and a water spray gun that are used after the alkaline permanganate bath.
(b) (c) (d) (e) (f) (g)
(h) (i)
EFFECTIVITY: ALL
70-21-07
CLEANING METHOD NO. 7 - THREE-STEP HEAVY-DUTY ALKALINE DESCALING (WITHOUT INHIBITED PHOSPHORIC ACID) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (j) A hot water rinse tank made from stainless steel (or a carbon steel tank with polypropylene lining) that can increase the temperature of the solution to 2008F (938C).
SUBTASK 70-21-07-110-052 C. Materials. Table 1. Alkaline Degreasing/Rust Removing Solution Solution Turco 4781-7 or Turco 4781-7L Ardrox 185 or Ardrox 185L Turco 4181 or Turco 4181-L Ferlon MagChem HDP-2888 Cee-Bee J84A or Cee-Bee J84AL MagChem HDL-202 Eldorado HTP-1150 Eldorado HTP-1150L Applied 5-840 No. S1005 S1024 S1006 S1027 S1017 S1026 S1150 S1161 S1162 S1176 Operating Temperature 8F (8C) 180-200 (82-93) 180-190 (82-88) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93)
Table 2. lkaline Stripping Solution for Stainless Steel and Heat-Resistant Alloys Solution Turco 4008 No. S1038 Operating Temperature 8F (8C) 270-280 (132-138)
Table 3. Alkaline Permanganate Solution Solution Turco 4338-C or Turco 4338-L Ardrox 188 or Ardrox 188RFU Alkaline permanganate MagChem HDP-2524 Cee-Bee J88, Cee-Bee J88A, or Cee-Bee J88L Eldorado HTP 1190 Eldorado HTP 1190L Applied 5-770 No. S1012 S1001 S1004 S1018 S1014 S1163 S1164 S1177 Operating Temperature 8F (8C) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 180-200 (82-93)
EFFECTIVITY: ALL
70-21-07
Table 3. Alkaline Permanganate Solution (Cont) Solution No. Operating Temperature 8F (8C)
NOTE: Operating the alkaline permanganate solution in the low end of the temperature range will extend the bath life but may decrease effectiveness. Conversely, operating the batch at the high end of the temperature range will improve cleaning ability at the risk of decreasing bath life and increasing the frequency of de-sludging.
SUBTASK 70-21-07-110-053 D. Procedure. CAUTION: IN CASE OF INSUFFICIENT DESCALING, DO NOT PROLONG THE IMMERSION BEYOND THE DURATION SPECIFIED, BUT REPEAT THE COMPLETE CYCLE. (1) In case of excessive dirt, preclean part using a solvent or if required a vapor degreasing application as indicated in the applicable manual. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING:
WARNING: (2)
Immerse the part in a tank containing one of the alkaline solutions listed in Table 1, Page 2 or Table 2, Page 2 and maintain the solution at the specified temperature. The alkaline solutions are listed in Subtask 70-21-07-110-052, Materials. Duration: 15 to 60 minutes. Rinse by spraying with a water jet and by immersion in water at room temperature. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
(3) (4)
WARNING:
WARNING: (5)
Immerse the part in a tank containing one of the alkaline permanganate solutions listed in Table 3, Page 2 and maintain the solution at the specified temperature. The alkaline permanganate solutions are listed in Subtask 70-21-07-110-052, Materials. Duration: 30 to 60 minutes. Rinse by spraying with a water jet and by immersion in water at room temperature.
(6) (7)
EFFECTIVITY: ALL
70-21-07
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (8)
Immerse the part in a tank containing one of the alkaline solutions listed in Table 1, Page 2 or Table 2, Page 2 and maintain the solutions at the specified temperature. The alkaline solutions are listed in Subtask 70-21-07-110-052, Materials. Duration: 30 to 60 minutes.
(9)
(10) Rinse by spraying with a water jet and by immersion in water at room temperature. (11) Rinse by immersion in hot water at 150 to 2008F (66 to 938C). Keep the part submerged until the part temperature reaches the water temperature. (12) If parts are still not clean, repeat Steps D.(4) through D.(8). (13) Dry using clean, dry air. SUBTASK 70-21-07-110-054 E. Quality Assurance. (1) Visually check for removal of all traces of oxide on the part.
EFFECTIVITY: ALL
70-21-07
CLEANING METHOD NO. 8 - CLEANING METHOD NO. 8 - CARBON REMOVAL FROM ALL MATERIALS TASK 70-21-08-110-006 1. Cleaning Method No. 8 - Carbon Removal From All Materials SUBTASK 70-21-08-99G-006 A. General. CAUTION: DO NOT USE THIS PROCESS TO CLEAN PARTS MADE FROM PLASTICS, RUBBER OR ALLOYS WITH A PROTECTIVE METAL COATING. (1) This cleaning process makes use of an organic solvent bath, active when hot, to dissolve carbon and rubber deposits. This process may also be used to remove most paints. The bath must be covered with an oil seal layer of 4-8 inches (102-203 mm) to reduce evaporation, loss of solvent and to improve safety.
SUBTASK 70-21-08-110-061 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline cleaning tank made from stainless steel with a heating coil that is capable of heating the solution to 2308F (1108C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and an air/water spray gun.
(b) (c) (d) (e)
EFFECTIVITY: ALL
70-21-08
CLEANING METHOD NO. 8 - CARBON REMOVAL FROM ALL MATERIALS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-08-110-062 C. Materials. Table 1. Solution for Removal of Carbon Deposits Solution Ardrox 2302 Turco 5668 MagChem Kemstrip-596 Cee-Bee A-477 SUBTASK 70-21-08-110-063 D. Procedure. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. No. S1187 S1171 S1155 S1160 Operating Temperatures 8F (8C) 176-230 (80-110) 160-180 (71-82) 176-230 (80-110) 160-212 (71-100)
WARNING:
CAUTION: PARTS MUST BE FREE OF MOISTURE BEFORE IMMERSION IN THE ALKALINE CARBON REMOVAL SOLUTION OR DAMAGE TO THE SUBSTRATE MAY RESULT. (1) Immerse the part in a tank containing one of the alkaline carbon removal solutions listed in paragraph 3. and maintain the solution at the specified temperature. The alkaline carbon removal solutions are listed in Subtask 70-21-08-110-062, Materials. Duration: 30 to 45 minutes. (a) (3) Ensure that the part is fully immersed into the lower layer and soak.
(2)
Drain the part over the stripping tank to allow the excess remover to drain back into the tank.
CAUTION: WATER RINSE MUST BE PERFORMED AWAY FROM THE STRIPPING TANK TO AVOID CONTAMINATION OF THE TANK WITH WATER. (4) Rinse the part by immersion in water, then drain and rinse using a pressurized water jet. Repeat operation if necessary.
CAUTION: IF A SECOND IMMERSION CYCLE IN THE BATH IS REQUIRED THE COMPONENTS MUST BE COMPLETELY DRY BEFORE IMMERSION. (5) Dry using clean, dry air.
EFFECTIVITY: ALL
70-21-08
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-08-110-064 E. Quality Assurance. (1) Visually check for the removal of all traces of carbon and rubber residues from the parts.
EFFECTIVITY: ALL
70-21-08
EFFECTIVITY: ALL
70-21-08
CLEANING METHOD NO. 9 - CLEANING METHOD NO. 9 LIGHT - DUTY ALKALINE CLEANING OF TITANIUM ALLOYS TASK 70-21-09-110-007 1. Cleaning Method No. 9 Light - Duty Alkaline Cleaning of Titanium Alloys SUBTASK 70-21-09-99G-007 A. General. CAUTION: RESTRICT TITANIUM CLEANING TANK TO TITANIUM PARTS ONLY. (1) (2) This process is used to clean titanium and titanium alloys using a weak alkaline aqueous solution. In the event of heavy contamination with grease, clean with appropriate solvents.
SUBTASK 70-21-09-110-071 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline degreasing tank made from stainless steel with a heating coil that is capable of heating the solution to 1908F (888C). A water rinse tank made from stainless steel, used after the alkaline degreasing bath. An air/hot water 150 to 2008F (66 to 938C) spray gun.
(b) (c) (d) (e) (f)
EFFECTIVITY: ALL
70-21-09
CLEANING METHOD NO. 9 LIGHT - DUTY ALKALINE CLEANING OF TITANIUM ALLOYS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-09-110-072 C. Materials. Table 1. Alkaline Degreasing Solution for Titanium Solution Turco 4181 or Turco 4181-L Turco 4181 or Turco 4181-L Turco Vitro-Klene Cee-Bee C46 Cee-Bee J84A or Cee-Bee J84AL Ardrox 185 or Ardrox 185L MagChem HDL-202 Eldorado HTP-1150 or 1150L Applied 5-840 SUBTASK 70-21-09-110-073 D. Procedure. (1) In case of excessive dirt, preclean part using a solvent as indicated in the applicable manual. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. No. S1003 S1003 S1010 S1030 S1139 S1140 S1151 S1168 S1175 Operating Temperature 8F (8C) 180-190 (82-88) 180-190 (82-88) 160-180 (71-82) 180-190 (82-88) 180-190 (82-88) 180-190 (82-88) 180-190 (82-88) 180-190 (82-88) 180-190 (82-88)
WARNING:
WARNING: (2)
Immerse the part in a tank containing one of the alkaline degreasing solutions listed in Table 1, Page 2 and maintain the solution at the specified temperature. The alkaline degreasing solutions are listed in Subtask 70-21-09-110-072, Materials. Duration: 10 to 20 minutes. Rinse by immersion in water. Spray rinse using an air/hot water spray at 150 to 2008F (66 to 938C). Rinse by immersion with deionized water (ambient). Dry using clean, dry air.
(3) (4) (5) (6) (7)
EFFECTIVITY: ALL
70-21-09
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-09-110-074 E. Quality Assurance. (1) Visually check the part for complete removal of oil and dirt.
EFFECTIVITY: ALL
70-21-09
EFFECTIVITY: ALL
70-21-09
CLEANING METHOD NO. 10 - CLEANING METHOD NO. 10 - FOUR-STEP ALKALINE CLEANING AND ACIDIC DESCALING (WITHOUT INHIBITED PHOSPHORIC ACID) TASK 70-21-10-110-008 1. Cleaning Method No. 10 SUBTASK 70-21-10-99G-008 A. General. CAUTION: DO NOT APPLY THIS PROCESS ON ALUMINUM, TITANIUM, AND THEIR ALLOYS, OR ON CHROMIUM-PLATED PARTS. (1) This cleaning method is a multiple hot-tank process that is effective in removing heat scale and oxide formation from hot-section parts of the engine. This method is only partially effective on oxidized nickel base alloys. NOTE: TASK 70-21-20-110-038 Cleaning Method No. 20 is permitted when Method 10 is specified. Method 20 cleans nickel base alloys better than Method 10.
SUBTASK 70-21-10-110-081 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline degreasing tank made from stainless steel with a heating coil that is capable of heating the solution to 2008F (938C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and a water spray gun, used after the degreasing bath. An acid stripping tank made from stainless steel with a heating coil that is capable of heating the solution to 1858F (858C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and a water spray gun, used after the acid stripping bath. A permanganate cleaning tank made from stainless steel with a heating coil that is capable of heating the solution to 1808F (828C).
(b) (c) (d) (e) (f) (g)
(h)
EFFECTIVITY: ALL
70-21-10
CLEANING METHOD NO. 10 - FOUR-STEP ALKALINE CLEANING AND ACIDIC DESCALING (WITHOUT INHIBITED PHOSPHORIC ACID) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (i) A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and a water spray gun, used after the alkaline permanganate bath. A hot water rinse tank made from stainless steel (or a carbon steel tank with polypropylene lining) that can increase the temperature of the solution to 2008F (938C).
(j)
SUBTASK 70-21-10-110-082 C. Materials. Table 1. Alkaline Degreasing/Rust Removing Solution Solution Turco 4781-7 or Turco 4781-7L Ardrox 185 or Ardrox 185L Turco 4181 or Turco 4181-L Ferlon MagChem HDP-2888 Cee-Bee J84A or Cee-Bee J84AL MagChem HDL-202 Eldorado HTP-1150 Eldorado HTP-1150L Applied 5-840 No. S1005 S1024 S1006 S1027 S1017 S1026 S1150 S1161 S1162 S1176 Operating Temperature 8F (8C) 180-200 (82-93) 180-190 (82-88) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93)
Table 2. Acid Stripping Solution Solution Ardrox 1871 Turco Scale Gon #5 Ardrox 1873 Cee-Bee J19 or Cee-Bee J19L MagChem AP-9186 MagChem AP-988 Eldorado AC-111 Ardrox 1873A Cee-Bee J3 Applied 2-751 No. S1023* S1159 S1021 S1103 S1157 S1152 S1165 S1184 S1183 S1179 Operating Temperature 8F (8C) 180-190 (82-88) 175-195 (80-90) 175-185 (80-85) 120-130 (49-54) 150-160 (65-71) 175-185 (80-85) 120-130 (49-54) 175-185 (80-85) 175-185 (80-85) 117-130 (47-54)
NOTE: * Do not use Ardrox 1871 to clean low alloy or high chrome steels. Ardrox 1873 or 1873A should be used for this purpose.
EFFECTIVITY: ALL
70-21-10
SUBTASK 70-21-10-110-083 D. Procedure. NOTE: You can do Steps D.(6) and D.(7) (alkaline permanganate) before you do Steps D.(4) and D.(5) (acid stripping). Some suppliers chemicals are formulated to work better if you do Steps D.(6) and D.(7) before Steps D.(4) and D.(5). (1) In case of excessive dirt, preclean part using a solvent or if necessary, a vapor degreasing application as indicated in the applicable manual. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING:
WARNING: (2)
Immerse the part in a tank containing one of the alkaline degreasing/rust removing solutions in table 1, Page 2 and maintain at the specified temperature. The solutions are listed in Subtask 70-21-10-110-082, Materials. Duration: 15 to 60 minutes. Rinse by spraying with a water jet and by immersion in water at room temperature.
(3) (4)
EFFECTIVITY: ALL
70-21-10
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING OF VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (5)
Immerse the part in a tank containing one of the acid stripping solutions in table 2, Page 2 and maintain at the specified temperature. The acid stripping solutions are listed in Subtask 70-21-10-110-082, Materials. Duration: 15 to 30 minutes. Rinse by spraying with a water jet and by immersion in water at room temperature. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
(6) (7)
WARNING:
WARNING: (8)
Immerse the part in a tank containing one of the alkaline permanganate solutions in table 3, Page 3 and maintain at the specified temperature. The solutions are listed in Subtask 70-21-10-110-082, Materials. Duration: 15 to 30 minutes.
(9)
(10) Rinse by spraying with a water jet and by immersion in water at room temperature. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING:
(11) Immerse the part in a tank containing one of the alkaline degreasing/rust removing solutions in table 1, Page 2 and maintain at the specified temperature. The solutions are listed in Subtask 70-21-10-110-082, Materials. (12) Duration: 15 to 60 minutes. (13) Rinse by spraying with a water jet and by immersion in water at room temperature. (14) Rinse by immersion in hot water at 150 to 2008F (66 to 938C). Keep the part submerged until the part temperature reaches the water temperature. (15) Dry using clean, dry air.
EFFECTIVITY: ALL
70-21-10
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-10-110-084 E. Quality Assurance. (1) Visually check for the removal of all traces of oxide on the part.
EFFECTIVITY: ALL
70-21-10
EFFECTIVITY: ALL
70-21-10
CLEANING METHOD NO. 12 - CLEANING METHOD NO. 12 HEAVY-DUTY ACIDIC CLEANING FOR ALUMINUM TASK 70-21-12-110-010 1. Cleaning Method No. 12 Heavy-Duty Acidic Cleaning For Aluminum SUBTASK 70-21-12-99G-010 A. General. (1) This cleaning method may be used to clean aluminum parts for removal of oxides which cannot be removed by milder cleaning methods.
SUBTASK 70-21-12-110-101 B. Equipment. (1) The following equipment is required for the application of this process: (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An acid stripping tank made from stainless steel with a polypropylene lining. A cold water rinse tank made from stainless steel with a polypropylene lining for use after the acid bath.
(b) (c) (d) (e)
SUBTASK 70-21-12-110-102 C. Solution Turco 4104 + HNO3 Ardrox 1635 + HNO3 Cee-Bee P-109B + HNO3 Ammonium bifluoride + HNO3 HF + HNO3 Materials. No. S1013 S1029 S1192 S1191 S1002 Operating Temperature 8F (8C) Ambient Ambient Ambient Ambient Ambient
NOTE: The use of Solution S1002 in Table 4 requires the handling of concentrated hydrofluoric acid C04-011. This material is unusually hazardous. The use of one of the alternative solutions listed in Table 4 in place of Solution S1002 is highly recommended.
EFFECTIVITY: ALL
70-21-12
CLEANING METHOD NO. 12 HEAVY-DUTY ACIDIC CLEANING FOR ALUMINUM Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-12-110-103 D. Procedure. (1) Vapor degrease parts per TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing. SOLUTION IS A STRONG ACID. ACID/FLUORIDE SOLUTIONS ARE VERY HAZARDOUS. USE IN A WELL VENTILATED AREA, TAKE ALL NECESSARY PRECAUTIONS TO AVOID SKIN AND EYE CONTACT. IF SOLUTION CONTACTS SKIN OR EYES, WASH THOROUGHLY WITH LARGE AMOUNTS OF CLEAR WATER AND OBTAIN MEDICAL ASSISTANCE IMMEDIATELY.
WARNING:
CAUTION: THE PARTS SHOULD BE CONTAINED IN A PLASTIC BASKET FOR IMMERSION. (2) (3) (4) (5) (6) Immerse the part in a tank containing the acid solution listed in Subtask 70-21-12110-102, Materials. Duration: 2 to 4 minutes. Water rinse part by immersing in cold water. Blow dry using clean, dry air. Restore protective coating to part as directed by the applicable manual.
SUBTASK 70-21-12-110-104 E. Quality Assurance. (1) Visually check the part for cleanliness.
EFFECTIVITY: ALL
70-21-12
CLEANING METHOD NO. 12 HEAVY-DUTY ACIDIC CLEANING FOR ALUMINUM Page 2 Dec 01/03
CLEANING METHOD NO. 13 - CLEANING METHOD NO. 13 - MOLTEN SALT BATH AND ACIDIC DESCALING TASK 70-21-13-110-011 1. Cleaning Method No. 13 Molten Salt Bath And Acidic Descaling
CAUTION: DO NOT CLEAN ALUMINUM, MAGNESIUM, TITANIUM OR COBALT BASE ALLOYS BY THIS PROCESS. SUBTASK 70-21-13-99G-011 A. General. (1) This cleaning method is a multiple hot-tank process that is effective in removing heat scale and oxide formation from hot-section parts of the engine. The following process cycle is recommended for Inconel 718 disks to prepare the surface for fluorescent-penetrant inspection.
SUBTASK 70-21-13-110-111 B. Equipment. (1) The following equipment is required for the application of this process: (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. A salt bath furnace that is capable of heating and maintaining molten salt solution up to 10008F (5388C). A water quench/rinse tank for use after the molten salt cleaning, and for quenching. A hold or shield enclosure which is movable, to protect personnel from splashing in the molten salt or quench operations. An acid stripping tank made of stainless steel with a heating coil that is capable of heating the solution to 1858F (858C). A water rinse tank made from stainless steel with a polypropylene lining and water spray gun, used after the acid stripping bath. An acid stripping tank made of stainless steel with a polypropylene lining.
(b) (c) (d) (e) (f) (g) (h) (i)
EFFECTIVITY: ALL
70-21-13
CLEANING METHOD NO. 13 - MOLTEN SALT BATH AND ACIDIC DESCALING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (j) (k) A hot water rinse tank made from stainless steel with an air/water spray gun, for removal of smut and final drying. Recommended source for the salt bath facility and auxiliary equipment is Kolene Corp. Refer to the List of Suppliers in Step D. of Subtask 70-80-00800-003.
SUBTASK 70-21-13-110-112 C. Solution Molten Salt (Virgo salt) Acid Descaling (Hydrochloric acid) Mixed Acid Solution (Turco 4104) Mixed Acid Solution (Ardrox 1635) Mixed Acid Solution (Cee-Bee P-109B) Mixed Acid Solution (Ammonium bifluoride + HNO3) SUBTASK 70-21-13-110-113 D. Procedure. (1) (2) (3) (4) (5) (6) (7) (8) Vapor degrease per TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, to remove oil, grease and other organic soils. Completely dry the part with towels or cloths, or bake the part prior to immersing it in the molten salt bath. Immerse the part in the molten salt solution indicated in Subtask 70-21-13-110-112, Materials. Duration: 20-25 minutes. Remove the part and quench it in cold running water. Immerse the part in the acid descaling solution using an 8 percent concentration by volume. The solution is listed in Subtask 70-21-13-110-112, Materials. Duration: 18-22 minutes. Remove the part and quench it in cold running water. Materials. No. C04-070 C04-071 S1013 S1029 S1192 S1191 Operating Temperature 8F (8C) 925-9758F (496-5248C) 150-1708F (65-778C) Ambient Ambient Ambient Ambient
EFFECTIVITY: ALL
70-21-13
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: SOLUTION IS A STRONG ACID. ACID/FLUORIDE SOLUTIONS ARE VERY HAZARDOUS. USE IN A WELL VENTILATED AREA, TAKE ALL NECESSARY PRECAUTIONS TO AVOID SKIN AND EYE CONTACT. IF SOLUTION CONTACTS SKIN OR EYES, WASH THOROUGHLY WITH LARGE AMOUNTS OF CLEAR WATER AND OBTAIN MEDICAL ASSISTANCE IMMEDIATELY.
(9)
Immerse the part in the mixed acid solution indicated in Subtask 70-21-13-110-112
(10) Duration: 1-2 minutes. (11) Remove the part and quench it in cold running water. (12) Air/water pressure-spray all surfaces to remove any residue (smut). (13) Hot water rinse the part for 1-3 minutes. (14) Dry the part using clean, dry air. SUBTASK 70-21-13-110-114 E. Quality Assurance. (1) Visually check the part for cleanliness.
EFFECTIVITY: ALL
70-21-13
EFFECTIVITY: ALL
70-21-13
CLEANING METHOD NO. 14 - CLEANING METHOD NO. 14 MANUALLY-ASSISTED DETERGENT CLEANING TASK 70-21-14-110-012 1. Cleaning Method No. 14 Manually-Assisted Detergent Cleaning SUBTASK 70-21-14-99G-012 A. General. (1) This cleaning method uses a liquid solution of detergent in combination with mechanical agitation to remove oil, grease, soot and various foreign deposits formed on cold-section parts of the engine. The following process is recommended to prepare the surface for fluorescent-penetrant inspection.
SUBTASK 70-21-14-110-121 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. Various types of fiber bristle brushes suitable for part configuration and abrasive polishing pads C10-010. Plastic or stainless steel containers for mixing and holding detergent solutions. A water rinse tank made from stainless steel and a water spray gun, for use after the detergent cleaning.
(b) (c) (d) (e) (f)
SUBTASK 70-21-14-110-122 C. Materials. No. C04-043 C04-045 C04-044 C04-152

CLEANING METHOD NO. 14 MANUALLY-ASSISTED DETERGENT CLEANING Page 1 Dec 01/03
Consumable Product Turco 5279-A Dubois C 1102 Cee-Bee Intex 8201 Turco 5948-R
EFFECTIVITY: ALL
70-21-14
Consumable Product Ardrox 6333 Ardrox 6333A MagChem DG-Kleen Turco 5948 DPM Super Bee 300LF Citrikleen HD Gas Path Cleaners SUBTASK 70-21-14-110-124 D. Quality Assurance. (1)
No. C04-163 C04-163 C04-184 C04-208 C04-221 C04-045 C04-140
Visually check the part for cleanliness.
EFFECTIVITY: ALL
70-21-14
CLEANING METHOD NO. 14 MANUALLY-ASSISTED DETERGENT CLEANING Page 2 Dec 01/03
CLEANING METHOD NO. 15 - CLEANING METHOD NO. 15 ULTRASONIC CLEANING TASK 70-21-15-130-001 1. Cleaning Method No. 15 Ultrasonic Cleaning SUBTASK 70-21-15-99G-001 A. General. (1) This cleaning process is applicable to fragile parts. It will remove contamination, oil deposits, organic material, without the risk of damaging the part (acoustic panels, for example).
SUBTASK 70-21-15-130-011 B. Equipment. (1) The following equipment is required for the application of this process: (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products, and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. NOTE: The ultrasonic cleaning energy will heat the cleaning solution due to its own energy. This needs to be taken into consideration in any application that requires strict temperature control. (d) Processing tank with temperature control. 1 The tank should be made of stainless steel and be equipped with either a heat exchanger or heating coil capable of controlling the working solution in the temperature range of 708-1708F (218-778C). The tank must be clearly labeled with the power density, frequency of the unit, and rated capacity in gallons (or liters). This label shall be fixed to the outside of the face of the tank in full view of the operator.
(b) (c)
(e)
Generator Requirements: 1 2 The generator must be a fixed power rating and not be adjustable by the operator. 20 kHz minimum, 6-10 watts/square inch (0.93-1.55 watts/square cm) of tank bottom.
EFFECTIVITY: ALL
70-21-15
CLEANING METHOD NO. 15 ULTRASONIC CLEANING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A 3 Recommended watts per gallon (watts per liter) for tank sizes are as follows: a b c 4 Less than 30 gallons (114 liters): 30-40 watts per gallon (7.9-10.6 watts per liter) 31-100 gallons (115-379 liters): 20-30 watts per gallon (5.3-7.9 watts per liter) 101-250 gallons (380-946 liters): 15-25 watts per gallon (4.0-6.6 watts per liter).
Piezoelectric type transducers should be equipped with High Sweep Modulation capability for optimum cleaning efficiency. The sweep range should be 2 to 3 kHz. This requirement is not necessary for magnetostrictive type transducers.
(f)
Fixture Requirements: CAUTION: IT IS CRITICAL THAT THERE BE NO DIRECT MECHANICAL CONTACT BETWEEN THE ENGINE COMPONENT AND THE ULTRASONIC TRANSDUCER. IF CONTACT DOES OCCUR, HOLD THE PARTS AND CONSULT YOUR HONEYWELL. REPRESENTATIVE FOR DISPOSITION. 1 2 3 The parts must be suspended in the tank completely independent of the tank sidewalls, tank bottom, or transducer surface. Parts are not to be hung from the side of the tank without a rack to insulate it from mechanical vibration. Parts must be fully submerged in the solution. If the part has holes and/ or cavities the fixture/part must be rotated to assure that they are filled with cleaning solution and all air is removed. If more than one part is cleaned at a time, they must not touch each other.
SUBTASK 70-21-15-130-012 C. Materials. Table 1. Solution for Ultrasonic Cleaning Solution Mild Alkaline Cleaner Alkaline solution No. S1046 S1047 Operating Temp 8F (8C) 120-150 (50-66) 120-150 (50-66)
EFFECTIVITY: ALL
70-21-15
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-15-130-015 D. Requirements. (1) A demonstration of the procedure is necessary for each new application and each model type of ultrasonic equipment to achieve internal approval to clean hardware using an ultrasonic system. Unless special requirements are stated in the process document, the internal approval package must include the following data as a minimum: (a) Identification of following process parameters involved in the cleaning procedure: 1 2 3 4 5 6 7 8 9 (b) Description of tank including rated capacity and actual gallons (liters) used. Description of generator and frequency used. Watts/square inch (watts/square cm). Watts/gallon (watts/liter). Description of High End Modulation (sweep frequency) range. Process time in tank (range) permitted per procedure. Fixture identification number and description of how supported. Solution concentration and temperature. Description of temperature control (heat exchanger).
A demonstration of the cleaning procedure is necessary on the application in question. This demonstration must involve a 24 hour exposure of the component using the processing parameters developed for that application. However, the solution used for this test should be water in place of the alkaline cleaning fluids. This evaluation is to test exposure to the ultrasonic equipment and not the solution. A fluorescent penetrant inspection per the procedure and sensitivity defined on the process documents is to be performed before and after this exposure test to document that no cracks were initiated and that the conditions are appropriate for the given application. A demonstration of the cleaning procedure is necessary on a stock loss coupon of the alloy in question. This demonstration must use 2x (two times) the maximum permitted time developed for the application. Stock loss testing to be performed per ARP 1755.
(c)
EFFECTIVITY: ALL
70-21-15
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-15-130-013 E. Procedure. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (1)
Fill tank with the cleaning solution specified for the application to the rated capacity of the tank. If the solution is to be heated, turn on the heater and monitor temperature. Degas the cleaning solution by running the ultrasonic generator for approximately 30 minutes to degas the solution. If the solution has been previously run, but the unit has been turned off for some time, run the unit for a minimum of 10 minutes to assure degassing is again complete. Position parts to be cleaned in required fixture. Turn off ultrasonic generator. NOTE: The ultrasonic generator should be "OFF" during loading and unloading of parts.
(2)
(3) (4)
CAUTION: THE PART OR FIXTURE MUST NOT COME INTO DIRECT CONTACT WITH THE TANK SIDEWALL, TANK BOTTOM, OR TRANSDUCER SURFACE DURING OPERATION OR MECHANICAL DAMAGE TO THE PART COULD OCCUR. (5) (6) Load the fixtured part(s) into the tank to appropriate depth. Turn on the ultrasonic generator and clean for amount of time specified for the specific application. If appropriate, confirm that the High Sweep Modulation accessory is in use. Turn off the generator and remove the fixtured part(s) from the ultrasonic tank. Drain solution from the part and rinse carefully under running water. Dry the part using clean, dry air.
(7) (8)
SUBTASK 70-21-15-130-014 F. Quality Assurance. (1) Visually check the part to see that all the dirt and contaminants have been removed.
EFFECTIVITY: ALL
70-21-15
CLEANING METHOD NO. 16 - CLEANING METHOD NO. 16 HEAVY-DUTY ALKALINE CLEANER (WITH INHIBITED PHOSPHORIC ACID) TASK 70-21-16-110-036 1. Cleaning Method No. 16 Heavy-Duty Alkaline Cleaner (With Inhibited Phosphoric Acid) SUBTASK 70-21-16-99G-036 A. General. CAUTION: DO NOT APPLY THIS PROCESS TO ALUMINUM OR TITANIUM ALLOYS. (1) This cleaning method is a hot-tank process which is effective for removing rust, stripping paint and general cleaning of ferrous and high-temperature alloy jet engine parts.
SUBTASK 70-21-16-110-361 B. Equipment. (1) The following equipment is required for the application of this process: (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline degreasing tank made of stainless steel (or a carbon steel tank with polypropylene lining) with a heating coil capable of heating the solution to 2108F (998C). A water rinse tank made from stainless steel (or a carbon steel tank with polypropylene lining) and water spray gun that are used after degreasing bath. A phosphoric acid tank made of stainless steel (or a carbon steel tank with polypropylene lining). A water rinse tank made from stainless steel (or a carbon steel tank with polypropylene lining) and a spray gun, used after the phosphoric acid bath. A hot water rinse tank made from stainless steel (or a carbon steel tank with polypropylene lining) that can increase the temperature of the solution to 2008F (938C).
(b) (c) (d)
(e)
(f) (g) (h)
70-21-16 EFFECTIVITY: ALL
CLEANING METHOD NO. 16 HEAVY-DUTY ALKALINE CLEANER (WITH INHIBITED PHOSPHORIC ACID) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-16-110-362 C. Materials. Table 1. Phosphoric Acid Solution with Inhibitor Solution Phos-it Ardrox 1218 Turco 4409 MagChem AP-954 Cee-Bee C-623 Eldorado AC-183 Applied 2-690 Corrosol 853 SUBTASK 70-21-16-110-363 D. Procedure. (1) In case of excessive dirt, preclean part using a solvent, or, if necessary, vapor degrease per TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. No. S1016 S1022 S1008 S1020 S1104 S1166 S1178 S1185 Operating Temperature 8F (8C) Ambient Ambient Ambient Ambient Ambient Ambient Ambient Ambient
WARNING:
WARNING: (2)
Immerse the part in a tank containing one of the alkaline degreasing/rust removing solutions in Table 1, Page 2 and maintain at the specified temperature. The alkaline/rust removing solutions are listed in Subtask 70-21-16-110-362, Materials. Duration: 15 to 60 minutes. Rinse by spraying with a water jet and by immersion in water at room temperature. ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
(3) (4)
WARNING:
WARNING: (5)
Immerse the part in a tank containing one of the phosphoric acid solutions with inhibitor in Table 1, Page 2. The solutions are listed in Subtask 70-21-16-110-362, Materials.
STANDARD PRACTICES MANUAL AS907-1-1A (6) (7) (8) (9) Duration: 15 to 30 minutes. Rinse by spraying and immersion in water at room temperature. Rinse by immersion in hot water at 150 to 2008F (66 to 938C). Keep the part submerged until the part temperature reaches the water temperature. Dry using clean, dry air.
SUBTASK 70-21-16-110-364 E. Quality Assurance. (1) Visually check the part for removal of all traces of oxide on the part.
CLEANING METHOD NO. 17 - CLEANING METHOD NO. 17 THREE-STEP HEAVY-DUTY ALKALINE DESCALING (WITH INHIBITED PHOSPHORIC ACID) TASK 70-21-17-110-037 1. Cleaning Method No. 17 Three-Step Heavy-Duty Alkaline Descaling (With Inhibited Phosphoric Acid) SUBTASK 70-21-17-99G-037 A. General. (1) This cleaning method is a multiple hot-tank process that is effective in removing heat scale and oxide formations from high-temperature alloy jet engine parts.
SUBTASK 70-21-17-110-371 B. Equipment.
CAUTION: DO NOT APPLY THIS PROCESS ON ALUMINUM, TITANIUM, OR CHROMIUMPLATED PARTS. (1) The following equipment is required for the application of this process: (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline degreasing tank made of stainless steel (or a carbon steel tank with a polypropylene liner) with a heating coil that is capable of heating the solution to 2008F (938C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene liner) and water spray gun, used after the degreasing bath. An alkaline stripping tank made of stainless steel (or a carbon steel tank with a polypropylene liner) with a heating coil that is capable of heating the solution to 2608F (1278C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene liner) and a water spray gun, used after the alkaline stripping. A permanganate cleaning tank made of stainless steel with a heating coil that is capable of heating the solution to 1808F (828C).
(b) (c) (d)
(e) (f)
(g) (h)
EFFECTIVITY: ALL
70-21-17
CLEANING METHOD NO. 17 THREE-STEP HEAVY-DUTY ALKALINE DESCALING (WITH INHIBITED PHOSPHORIC ACID) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (i) A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene liner) and a water spray gun, used after the alkaline permanganate bath. A phosphoric acid cleaning tank made of stainless steel (or a carbon steel tank with a polypropylene liner). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene liner) and water spray gun, used after the phosphoric acid bath. A hot water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene liner) that can increase the temperature of the solution to 2008F (938C).
(j) (k)
(l)
SUBTASK 70-21-17-110-372 C. Materials. Table 1. Alkaline Degreasing/Rust Removing Solution Solution Ardrox 185 or Ardrox 185L Turco 4181 or Turco 4181-L Ferlon MagChem HDP-2888 Cee-Bee J84A or Cee-Bee J84AL Turco 4781-7 or Turco 4781-7L MagChem HDL-202 Eldorado HTP-1150 Eldorado HTP-1150L Applied 5-840 No. S1024 S1006 S1027 S1017 S1026 S1005 S1150 S1161 S1162 S1176 Operating Temperature 8F (8C) 180-190 (82-88) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93)
Table 2. Alkaline Permanganate Solution Solution Turco 4338-C or Turco 4338-L Ardrox 188 or Ardrox 188RFU Alkaline permanganate MagChem HDP-2524 Cee-Bee J88, Cee-Bee J88A, or Cee-Bee J88L Eldorado HTP 1190 Eldorado HTP 1190L
EFFECTIVITY: ALL
No. S1012 S1001 S1004 S1018 S1014 S1163 S1164
Operating Temperature 8F (8C) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93)
70-21-17
Table 2. Alkaline Permanganate Solution (Cont) Solution Applied 5-770 No. S1177 Operating Temperature 8F (8C) 180-200 (82-93)
Table 3. Phosphoric Acid Solution with Inhibitor Solution Phos-it Ardrox 1218 Turco 4409 MagChem AP-954 Cee-Bee C-623 Eldorado AC-183 Applied 2-690 Corrosol 853 SUBTASK 70-21-17-110-373 D. Procedure. (1) In case of excessive dirt, preclean the part using a solvent or, if necessary, vapor degrease per TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. No. S1016 S1022 S1008 S1020 S1104 S1166 S1178 S1185 Operating Temperature 8F (8C) Ambient Ambient Ambient Ambient Ambient Ambient Ambient Ambient
WARNING:
WARNING: (2)
Immerse the part in a tank containing one of the alkaline degreasing/rust removing solutions and maintain the solution at the specified temperature. The alkaline degreasing/rust removing solutions are listed in Table 1, Page 2 in Subtask 70-2117-110-372, Materials. Duration: 15 to 60 minutes. Rinse by spraying with a water jet and by immersion in water at room temperature.
(3) (4)
EFFECTIVITY: ALL
70-21-17
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (5)
Immerse the part in a tank containing one of the alkaline permanganate solutions and maintain the solution at the specified temperature. The alkaline permanganate solutions are listed in Table 2, Page 2 in Subtask 70-21-17-110-372, Materials. Duration: 30 to 60 minutes. Rinse by spraying with a water jet and by immersion in water at room temperature. ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVEFOES.
(6) (7)
WARNING:
WARNING: (8) (9)
Immerse the part in a tank containing one of the phosphoric acid solutions with inhibitor listed in Table 3, Page 3 in Subtask 70-21-17-110-372, Materials. Duration: 15 to 30 minutes.
(10) Rinse by spraying and immersion in water at room temperature. (11) Rinse by immersion in hot water at 150 to 2008F (66 to 938C). Keep the part submerged until the part temperature reaches the water temperature. (12) Dry the part using clean, dry air. SUBTASK 70-21-17-110-374 E. Quality Assurance. (1) Visually check the part for removal of all traces of oxide on the part.
EFFECTIVITY: ALL
70-21-17
CLEANING METHOD NO. 20 - CLEANING METHOD NO. 20 FOUR-STEP ALKALINE CLEANING AND ACIDIC DESCALING (WITH INHIBITED PHOSPHORIC ACID) TASK 70-21-20-110-038 1. Cleaning Method No. 20 Four-Step Alkaline Cleaning And Acidic Descaling (With Inhibited Phosphoric Acid) SUBTASK 70-21-20-99G-038 A. General. CAUTION: DO NOT APPLY THIS PROCESS ON ALUMINUM, TITANIUM, AND THEIR ALLOYS, OR ON CHROMIUM-PLATED PARTS. (1) This cleaning method is a multiple hot-tank process that is effective in removing heat scale and oxide formation from hot-section parts of the engine. This method is only partially effective on oxidized nickel base alloys.
SUBTASK 70-21-20-110-381 B. Equipment. (1) The following equipment is required for the application of this process: (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline degreasing tank made of stainless steel with a heating coil that is capable of heating the solution to 2008F (938C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene liner) and a water spray gun, used after the degreasing bath. An acid stripping tank made of stainless steel with a heating coil that is capable of heating the solution to 1858F (858C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and water spray gun, used after the acid stripping bath. A permanganate cleaning tank made of stainless steel with a heating coil capable of heating the solution to 1808F (828C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and a water spray gun, used after the alkaline permanganate bath.
CLEANING METHOD NO. 20 FOUR-STEP ALKALINE CLEANING AND ACIDIC DESCALING (WITH INHIBITED PHOSPHORIC ACID) Page 1 Dec 01/03
(b) (c) (d) (e) (f) (g) (h) (i)
EFFECTIVITY: ALL
70-21-20
STANDARD PRACTICES MANUAL AS907-1-1A (j) (k) A phosphoric acid cleaning tank made of stainless steel (or a carbon steel tank with a polypropylene lining). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and water spray gun, used after the phosphoric acid bath. A hot water rinse tank made from stainless steel (or a carbon steel tank with polypropylene lining) that can increase the temperature of the solution to 2008F (938C).
(l)
SUBTASK 70-21-20-110-382 C. Materials. Table 1. Alkaline Degreasing/Rust Removing Solution Solution Ardrox 185 or Ardrox 185L Turco 4181 or Turco 4181-L Ferlon MagChem HDP-2888 Cee-Bee J84A or Cee-Bee J84AL Turco 4781-7 or Turco 4781-7L MagChem HDL-202 Eldorado HTP-1150 Eldorado HTP-1150L Applied 5-840 No. S1024 S1006 S1027 S1017 S1026 S1005 S1150 S1161 S1162 S1176 Operating Temperature 8F (8C) 180-190 (82-88) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93)
Table 2. Acid Stripping Solution Solution Ardrox 1871 Turco Scale Gon #5 Ardrox 1873 Cee-Bee J19 or Cee-Bee J19L MagChem AP-988 MagChem AP-9168 Eldorado AC-111 Ardrox 1873A Cee-Bee J3 Applied 2-751 No. S1023* S1159 S1021 S1103 S1152 S1157 S1165 S1184 S1183 S1179 Operating Temperature 8F (8C) 180-190 (82-88) 175-195 (80-90) 175-185 (80-85) 120-130 (49-54) 175-185 (80-85) 150-160 (65-71) 120-130 (49-54) 175-185 (80-85) 175-185 (80-85) 117-130 (47-54)
EFFECTIVITY: ALL
70-21-20
Table 2. Acid Stripping Solution (Cont) Solution No. Operating Temperature 8F (8C)
NOTE: * Do not use Ardrox 1871 to clean low alloy or high chrome steels. Ardrox 1873 or 1873A should be used for this purpose.
Table 4. Phosphoric Acid Solution with Inhibitor Solution Phos-it Ardrox 1218 Turco 4409 MagChem AP-954 Cee-Bee C-623 Eldorado AC-183 Applied 2-690 Corrosol 853 No. S1016 S1022 S1008 S1020 S1104 S1166 S1178 S1185 Operating Temperature 8F (8C) Ambient Ambient Ambient Ambient Ambient Ambient Ambient Ambient
EFFECTIVITY: ALL
70-21-20
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-20-110-383 D. Procedure. NOTE: You can do Steps D.(6) and D.(7) (alkaline permanganate) before you do Steps D.(4) and D.(5) (acid stripping). Some suppliers chemicals are formulated to work better if you do Steps D.(6) and D.(7) before Steps D.(4) and D.(5). (1) In case of excessive dirt, preclean part using a solvent, or, if necessary, vapor degrease per TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING:
WARNING: (2)
Immerse the part in a tank containing one of the alkaline degreasing/rust removing solutions and maintain the solution at the specified temperature. The alkaline degreasing/rust removing solutions are listed in Table 1, Page 2 in Subtask 70-2120-110-382, Materials. Duration: 15 to 60 minutes. Rinse by spraying with a water jet and by immersion in water at room temperature. ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
(3) (4)
WARNING:
WARNING: (5)
Immerse the part in a tank containing one of the acid stripping solutions and maintain the solution at the specified temperature. The acid stripping solutions are listed in Table 2, Page 2 in Subtask 70-21-20-110-382, Materials. Duration: 15 to 30 minutes. Rinse by spraying with a water jet and by immersion in water at room temperature.
(6) (7)
EFFECTIVITY: ALL
70-21-20
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (8)
Immerse the part in a tank containing one of the alkaline permanganate solutions and maintain the solution at the specified temperature. The alkaline permanganate solutions are listed in Table 3, Page 3 in Subtask 70-21-20-110-382, Materials. Duration: 15 to 30 minutes.
(9)
(10) Rinse by spraying with a water jet and immersion in water at room temperature. WARNING: ACID SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. AVOID BREATHING VAPORS. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING:
(11) Immerse the part in a tank containing one of the phosphoric acid solutions with inhibitor listed in Table 4, Page 3 in Subtask 70-21-20-110-382, Materials. (12) Duration: 15 to 30 minutes. (13) Rinse by spraying with a water jet and by immersion in water at room temperature. (14) Rinse by immersion in hot water at 150 to 2008F (66 to 938C). Keep the part submerged until the part temperature reaches the water temperature. (15) Dry the part using clean, dry air. SUBTASK 70-21-20-110-384 E. Quality Assurance. (1) Visually check the part and assure that all traces of oxide on the part have been removed.
EFFECTIVITY: ALL
70-21-20
EFFECTIVITY: ALL
70-21-20
CLEANING METHOD NO. 21 - CLEANING METHOD NO. 21 CARBON REMOVAL BY COLD TANK TWOPHASE REMOVER TASK 70-21-21-110-039 1. Cleaning Method No. 21 Carbon Removal by Cold Tank Two-Phase Remover SUBTASK 70-21-21-99G-039 A. General. (1) The carbon remover is a two-phase liquid solvent. The lower layer (solvent layer) consists of methylene chloride (dichloromethane) and cresols. The upper layer (aqueous layer) consists of a corrosion inhibited water seal. The solution is used for removing carbon deposits, fuel/oil residue and paint from engine parts fabricated from metal including aluminum, magnesium, carbon steel, stainless steel and all heat resistant alloys.
(2)
SUBTASK 70-21-21-110-391 B. Equipment. (1) The following equipment is required for the application of this process. (a) (b) (c) (d) Steel tank equipped with cover. Expanded mesh steel basket. Hot water dip tank. Stiff bristle and stainless wire brush.
SUBTASK 70-21-21-110-392 C. Materials. (1) Material Engine oil Lubricating oil Preservation oil Preservative Storage Preservative Inhibitor Stoddard Solvent Carbon-removing compound
EFFECTIVITY: ALL
The following materials are required for this process: Consumable No. C02-019 C02-021 C02-050 C02-054 C02-055 C02-056 C04-002 C04-076
70-21-21
CLEANING METHOD NO. 21 CARBON REMOVAL BY COLD TANK TWO-PHASE REMOVER Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-21-110-393 D. Procedure. WARNING: CARBON REMOVING COMPOUND IS HAZARDOUS, CAUSES SEVERE BURNS AND IS RAPIDLY ABSORBED THROUGH THE SKIN. USE PROTECTIVE CREAMS AND WEAR APPROVED GLOVES, APRON AND GOGGLES (OR FACE SHIELD) TO PROTECT THE SKIN FROM CONTACT. USE ONLY WITH ADEQUATE VENTILATION. AVOID BREATHING VAPORS BECAUSE THEY ARE HARMFUL. DO NOT TAKE INTERNALLY. IF SPILLED ON CLOTHING, REMOVE CLOTHES IMMEDIATELY.
(1) (2) (3)
Place parts in an expanded mesh basket, or suspend by a wire into the lower layer of carbon removing compound. Ensure that all parts are below the water seal. Close the lid of the tank and soak the parts until the carbon deposits are loosened (up to 4 hours, depending on the hardness and extent of the deposits to be removed). Raise the parts slowly and allow time for the parts to contact the upper layer. STODDARD SOLVENT (P-D-680) C04-002, IS FLAMMABLE. DO NOT USE NEAR WELDING AREAS, NEAR OPEN FLAMES OR ON HOT SURFACES. USE ONLY WITH ADEQUATE VENTILATION. AVOID PROLONGED OR REPEATED BREATHING OF VAPORS. DO NOT SMOKE WHEN USING IT. USE PROTECTIVE CREAMS. WEAR AN APRON AND WEAR GOGGLES (OR FACE SHIELD) TO PROTECT THE SKIN. STORE IN APPROVED METAL SAFETY CONTAINERS.
(4)
WARNING:
(5) (6)
Rinse with hot water or solvent C04-002. If necessary, scrub with a stiff, bristle brush (a wire brush may be used for steel, stainless steel, and all heat resistant alloys) under running hot water to remove localized deposits of loosened carbon. If necessary, rinse with pressure spray (clear water) at room temperature. COMPRESSED AIR IS HAZARDOUS. USE GOGGLES OR A FACE MASK WHEN USING COMPRESSED AIR FOR CLEANING, COOLING OR DRYING. DO NOT DIRECT AIRSTREAM TOWARDS YOURSELF OR TOWARDS ANOTHER PERSON. DO NOT USE AT A PRESSURE ABOVE 30 PSIG (207 KPA).
(7)
WARNING:
(8) (9)
Air-blast to dry and to remove remaining loose deposits. If necessary, treat steel parts to prevent corrosion per TASK 70-60-00-620-001, Preservation of Engine Parts.
EFFECTIVITY: ALL
70-21-21
CLEANING METHOD NO. 21 CARBON REMOVAL BY COLD TANK TWO-PHASE REMOVER Page 2 Dec 01/03
CLEANING METHOD NO. 22 - CLEANING METHOD NO. 22 LIGHT DUTY AQUEOUS CLEANING TASK 70-21-22-110-042 1. Cleaning Method No. 22 Light Duty Aqueous Cleaning - Method 1 SUBTASK 70-21-22-99G-042 A. General - Method 1. (1) Method 1: Light Duty Cleaning Using a Tank Dip (Immersion) Process. Unless specified differently, Method 2 ( TASK 70-21-22-110-050, Cleaning Method No. 22 Light Duty Aqueous Cleaning) is an equivalent alternative to Method 1. Light duty aqueous cleaning is a water-based cleaning method that is intended to offer an alternative to mineral oil and hydrocarbon-based solvent cleaners. Method 1 can be used as an alternate to TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, when used as a general cleaning method prior to visual, FPI, MPI, or electronic inspections. It may also be used as a precleaner process before the heavy duty cleaning methods like Method 6, 7, 9, 10, 16, 17, or 20. This is recommended to preserve the effective life of the deruster and descaler baths. This method can be safely used on all engine components, including titanium. Thorough post rinsing is emphasized for all parts, and especially for hollow hot section components. Non-metallic parts (or metal parts with non-metallic components or inserts) should only be cleaned by this method when specified in the applicable manual. This procedure can be accomplished by using a dip tank (immersion method) or by utilizing a spray wash cabinet for a spray wash process. The spray wash process is described in Method 2 of this procedure.
(2) (3)
(4)
(5)
SUBTASK 70-21-22-110-421 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant to neutralize waste and used solutions. Efficient ventilation system to remove and neutralize vapors. An alkaline degreasing tank made of stainless steel with a heating coil capable of heating the solution to 2108F (998C). This tank should have a good solution agitation system. Mechanical agitation is recommended.
(b) (c) (d)
EFFECTIVITY: ALL
70-21-22
CLEANING METHOD NO. 22 LIGHT DUTY AQUEOUS CLEANING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (e) (f) A water tank made from stainless steel and a spray gun that are used after alkaline degreasing. A hot water rinse tank made from stainless steel with heat coil in the tank capable of heating the solution to 1608F (718C) and a hot air water spray gun.
SUBTASK 70-21-22-110-422 C. Materials. Table 1. Light-Duty Tank Cleaners Solution Ardrox 6333 or Ardrox 6333A Blue Gold Industrial Cleaner Cee-Bee A7X7 Turco 5948-R Daraclean 282 or Daraclean 282GF Jettacin Soluwax Eldorado ED-306LF Super Bee 300LF Turco 5948 DPM Turco Liquid Sprayeze NP-LT Brulin 815 GD SUBTASK 70-21-22-110-423 D. Procedure. CAUTION: THIS METHOD SHOULD NOT BE USED ON PARTS COATED WITH UNSEALED ANODIZE. BASE METAL ATTACK WILL OCCUR. (1) Immerse the part(s) in a tank containing one of the materials listed in Subtask 7021-22-110-507, Materials. Maintain the solution at the recommended temperature. The best cleaning will occur only if the solution is properly agitated. (a) Dwell time in bath: 15 to 60 minutes. No. S1141 S1143 S1144 S1142 S1145 S1148 S1158 S1167 S1170 S1180 S1181 S1182 Operating Temp 8F (8C) 150-170 (66-77) 130-150 (54-66) 120-140(49-60) 160-180 (70-82) 120-180 (49-82) 140-160 (60-71) 140-170 (60-77) 120-160 (49-71) 140-160 (60-71) 150-175 (65-80) 90-190 (32-88) 140-180 (60-82)
CAUTION: DO NOT LET PARTS STAY IN THE CEE-BEE A7X7, TURCO 5948 DPM, OR TURCO LIQUID SPRAYEZE NP-LT SOLUTION FOR MORE THAN 30 MINUTES OR BASE METAL ATTACK COULD OCCUR. (b) Dwell time in bath for Cee-Bee A7X7, Turco 5948 DPM, and Turco Liquid Sprayeze NP-LT: 30 minutes maximum.
EFFECTIVITY: ALL
70-21-22
STANDARD PRACTICES MANUAL AS907-1-1A (2) (3) (4) Remove the part(s) from the cleaning tank and rinse by spraying with a water jet and by dipping in room temperature water. Rinse the part(s) by dipping in hot water and holding for at least five minutes. Rinse water temperature should be 1408F (608C) or higher. Process may be repeated if parts are not clean. Repeat paragraphs 4.A. through 4.C. WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG (206 KPA). WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS.
WARNING:
(5)
Alternate procedure available. After hot water rinse, parts will flash dry. If pools of water remain on the part you can use compressed air (clean and dry) to blow the part dry or a dry towel to pat the part dry. Alternate procedure. Place the part in an oven at 1408F (608C) minimum for a sufficient time for the part to get to oven temperature. Ensure all surface water is gone.
(6)
SUBTASK 70-21-22-110-424 E. Quality Assurance. (1) (2) (3) Do a visual inspection of the parts for cleanliness. Make sure the cleaning and hot water rinse tanks are operating at the recommended temperatures. Skim floating residue off of the surface of the cleaning tank at an interval to prevent surface scum from being redeposited on the cleaned parts as they are pulled out of the tank. Change the rinse waters frequently. If continuous flow tanks are not used to make sure surface of the part is properly rinsed. Do process control on cleaning tank as per the solution sheets, manufacturers recommendation, or as use requires. See the appropriate solution sheet.
(4) (5)
TASK 70-21-22-110-050 2. Cleaning Method No. 22 Light Duty Aqueous Cleaning - Method 2 SUBTASK 70-21-22-110-505 A. General. (1) Method 2: Light Duty Cleaning Using a Spray Wash Process. Unless specified differently, Method 1 ( TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning) is an equivalent alternative to Method 2.
EFFECTIVITY: ALL
70-21-22
STANDARD PRACTICES MANUAL AS907-1-1A (2) (3) Light duty aqueous cleaning is a water-based cleaning method that is intended to offer an alternative to mineral oil and hydrocarbon-based solvent cleaners. Method 2 can be used as an alternate to TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, Vapor degrease, when used as a general cleaning method prior to visual, FPI, MPI, or electronic inspections. It may also used as a precleaner process before the heavy duty cleaning methods like Method 6, 7, 10, 16, 17, or 20. This is recommended to preserve the effective life of the deruster and descaler baths. This method can be safely used on all engine components. Thorough post rinsing is emphasized for all parts, and especially for hollow hot section components. Nonmetallic parts (or metal parts with non-metallic components or inserts) should only be cleaned by this method when specified in the applicable manual. This procedure can be accomplished by using a dip tank (immersion method) or by utilizing a spray wash cabinet for a spray wash process. The immersion method process is described in Method 1 of this procedure.
(4)
(5)
SUBTASK 70-21-22-110-506 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant to neutralize waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An industrial spray wash machine, preferably made from stainless steel, with water jets and turbulators that will direct streams of cleaning solution and rinse water against the parts inside the wash area of the cabinet. Metering controls to allow correct amount of cleaning material to be metered into the water during the wash cycle. Suitable controls to allow for programmed washing cycles to include prerinse (optional), wash, post rinse and drying (optional) cycles.
(b) (c) (d)
(e) (f)
EFFECTIVITY: ALL
70-21-22
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-22-110-507 C. Materials. Table 2. Light-Duty Cleaners Material/Solution Turco 5948-R MagChem DG-Kleen Turco Liquid Sprayeze NP-LT Eldorado ED-306LF Super Bee 300LF Daraclean 282GF Turco 5948 DPM Ardrox 6333 Ardrox 6333A Consumable/Solution No. C04-152 (2.5% by volume) S1154 C04-193 (10% maximum) C04-218 (8-10% by volume) C04-221 (5-10% by volume) S1145 C04-208 (5-10% by volume) C04-163 (2-10% by volume) C04-163 (5-10% by volume) Operating Temperature 160-180 (71-82) 155-165 (68-74) 70-190 (77-88) 120-160 (49-71) 120-160 (49-71) 120-180 (49-82) 150-175 (65-80) 140-160 (60-71) 150-160 (65-71)
SUBTASK 70-21-22-110-508 D. Procedure. (1) Load parts onto cleaning rack for input into parts washer. Load parts so that adjacent parts will not cause masking of parts surfaces from the spray jets and resultant ineffective cleaning. Do not overload parts washer. Load basket into parts washer and start cycle. In general, industrial parts washer have programmable washing cycles incorporating pre rinse, wash (with detergent), post rinse, and possibly dry. The cycles will vary based on the machine used and the types and numbers of parts in the machine. A recommended cleaning cycle is as follows: (a) (b) Two minute prerinse (to wet the parts). A thirty to forty-five minute wash cycle (the wash cycle is where the soap is loaded into the machine and recirculated as the machines "cleans" the parts).
(2)
(3)
EFFECTIVITY: ALL
70-21-22
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: IT IS NOT RECOMMENDED TO USE A RUST INHIBITOR IN THIS CYCLE. IF OLD MACHINERY IS USED AND INHIBITORS ARE REQUIRED AS PART OF THE MACHINE MAINTENANCE, ADDITIONAL STEPS MUST BE TAKEN TO REMOVE THE INHIBITOR FROM THE PART SURFACES IF THE PARTS ARE ROUTED TO FPI AFTER THE SPRAY WASH CLEAN PROCESS. CAUTION: PARTS MUST BE THOROUGHLY DRY PRIOR TO FPI INSPECTION. WATER ON THE PARTS MAY DEGRADE THE SENSITIVITY OF THE PROCESS, ESPECIALLY FOR THE WATER WASHABLE PENETRANT PROCESS. (c) A post rinse cycle of 5 to 10 minutes (where the soap and dirt laden water is removed from the cabinet and the parts are rinsed with fresh water to remove soap and dirt residue). This rinse should be at least one-half cycle of hot water.
(4) (5) (6)
After cycle is complete, review parts for cleanliness. If parts are not clean, repeat cycle. Remove parts from washer and route to next process. If necessary, the parts can be dried in an oven with a minimum temperature of 1408F (608C).
SUBTASK 70-21-22-110-509 E. Process Control. (1) (2) (3) The detergent solution is fresh with each cycle, no solution maintenance is necessary. Make sure the solution metering valve is operating properly and supplying the correct amount of detergent per volume of water. If persistent water spotting is noticed on parts, a switch to demineralized or deionized water is recommended. Presence of water spots may cause undesirable fluorescent background in the penetrant inspection process.
SUBTASK 70-21-22-110-510 F. Quality Assurance. (1) (2) Visually check parts for cleanliness. Make sure the cleaning and hot water rinse steps are operating at the recommended temperatures.
EFFECTIVITY: ALL
70-21-22
CLEANING METHOD NO. 23 - CLEANING METHOD NO. 23 HAND-WIPE DEGREASING TASK 70-21-23-110-053 1. CLEANING METHOD NO. 23 HAND-WIPE DEGREASING SUBTASK 70-21-23-99G-053 A. General. (1) This procedure is for general hand-wipe cleaning of metallic parts, both titanium and non-titanium hardware. For hand-wipe cleaning of composite materials, refer to procedure TASK 70-46-01-350-030, Masking and Cleaning of Epoxy and Polyester Matrix Thermosetting Composite Materials. This procedure may be used as an alternate to TASK 70-21-01-110-001, Cleaning Method No. 1 - Solvent Degreasing, or TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning, whenever localized hand-wipe cleaning would be an effective alternative to cleaning the entire part by one of the other methods. Cleaners should be applied to the wipe cloths from dispensers that prevent contamination of the working fluid. Some cleaners will require post-rinsing with water and others are very slow to dry. These conditions must be considered when using these products before Fluorescent Penetrant Inspection (FPI). Process known defect standards or parts with the selected cleaner if used prior to FPI to ensure that the process capability is maintained.
(2)
(3) (4)
SUBTASK 70-21-23-110-531 B. Equipment. (1) Proper Personal Protection Equipment shall be used and shall include, but not be limited to, protective gloves and eye wear. Specific equipment for safe handling will be described in the manufacturers Material Safety Data Sheet for the specific cleaner. Hand-wipe cleaning shall be performed in an area with proper ventilation. Various types of bristle brushes for part configuration or cleaning pads C10-010 may be used in addition to the wiping cloths C10-182, clean, white, lint-free cotton cloths, or unsized cheesecloth.
(2) (3)
SUBTASK 70-21-23-110-532 C. Materials. NOTE: The following materials are required for the application of this process.
EFFECTIVITY: ALL
70-21-23
CLEANING METHOD NO. 23 HAND-WIPE DEGREASING Page 1 Dec 01/03
Table 1. Solvents for Wipe Procedure Consumable Product Methyl-Ethyl-Ketone Stoddard Acetone Isopropyl Alcohol 50/50 Toluene/Isopropyl Alcohol Ardrox 1064-K Methyl-Propyl-Ketone MagChem Teksol Positron Selig CE-SX-94, GB-SX-94, L-SX-94 Monsanto SkyKleen Turco 4460-BK Turco 6869 Bioact 105 Precision Cleaner Supersolve AS MagChem Skysol No. C04-001 C04-002 C04-003 C04-035 C04-036/C04-035 C04-160 C04-196 C04-197 C04-198 C04-199 C04-200 C04-201 C04-202 C04-251 C04-256 C04-260
Table 2. Aqueous Cleaners for Spray or Wipe Procedure Consumable Product Gas Path Cleaner Type IIA Gas Path Cleaner Type II Turco 6780 Ardrox Aviaclenz 6077 Window Cleaner Plus MagChem Evasol Nuvite Nu-Gear-Sc Bio-T-Max No. C04-140 C04-140 C04-203 C04-204 C04-205 C04-206 C04-207 Concentration As Received 20% Full Strength Full Strength Full Strength 20-25 v/v Full Strength Rinse Required? Yes Yes No No No Yes Yes
EFFECTIVITY: ALL
70-21-23
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-23-110-533 D. Procedure. (1) Wipe the part with cloth saturated with one of the cleaners identified in Table 1, Page 2. When using cleaners identified in Table 2, spray or wipe application may be used. NOTE: Various types of bristle brushes suitable for the part configuration or cleaner pads C10-010 may be used in addition to the wiping cloths to enhance the cleaning process. When using brushes or cleaning pads, a final wipe of the part surface should be performed with a cloth C10-182 saturated with the cleaner being used. (2) (3) (4) Flush the part completely with clean water when indicated in Table 2, Page 2. Dry the part with one of the cloths specified in Subtask 70-21-23-110-531, Equipment. Blow dry with clean, dry air.
SUBTASK 70-21-23-110-534 E. Quality Assurance. (1) (2) Visually check the part for cleanliness. Repeat the process if necessary.
EFFECTIVITY: ALL
70-21-23
EFFECTIVITY: ALL
70-21-23
CLEANING METHOD NO. 24 - CLEANING METHOD NO. 24 - EXTERIOR ENGINE CLEANING TASK 70-21-24-110-052 1. Cleaning Method No. 24 - Exterior Engine Cleaning SUBTASK 70-21-24-99G-052 A. General. (1) This procedure is for cleaning the exterior of gas turbine engines, including both titanium and non-titanium hardware. Products may be applied by spray, steam, foam, or gel application based on manufacturers recommendations. This procedure may be used as an alternate to TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning. When using this procedure prior to Fluorescent Penetrant Inspection (FPI), process known defect standards or parts with the selected cleaner prior to FPI to ensure process capability is maintained.
(2) (3)
SUBTASK 70-21-24-110-521 B. Equipment. (1) Proper personal protection equipment shall be used and shall include, but not be limited to, protective gloves, apron, and eye wear. Specific equipment for safe handling will be described in the manufacturers Material Safety Data Sheet for the specific cleaner. Exterior engine cleaning shall be performed in an area with proper ventilation. Various types of bristle brushes for part configuration or cleaning pads C10-010 may be used to assist the cleaning action of the chemicals.
(2) (3)
SUBTASK 70-21-24-110-522 C. Materials. NOTE: The following materials are required for the application of this process: Consumable Product Turco 5948 DPM Turco 5948 DPM Thick Ardrox Aviawash Green Gel Ardrox 6333 Ardrox 1900B MagChem DG-Kleen No. C04-208 C04-232 C04-209 C04-163 C04-210 C04-184 Concentration 20-30% by volume As Received As Received 15-20% by volume As Received 15-20% by volume
CLEANING METHOD NO. 24 - EXTERIOR ENGINE CLEANING Page 1 Dec 01/03
EFFECTIVITY: ALL
70-21-24
Consumable Product Nuvite Nu-Gear-SC Super Bee 262 Cee-Bee A-7X7 Gas Path Cleaner - Type IIA Gas Path Cleaner - Type II Super Bee 300LF SUBTASK 70-21-24-110-523 D. Procedure. (1)
No. C04-206 C04-211 C04-165 C04-140 C04-140 C04-221
Concentration 20-25% by volume As Received 15-25% by volume As Received 20% 5-10% by volume
Cover all openings to the interior of the engine with appropriate plugs, masks, or tape C10-021. This includes inlet and exhaust ducts and all tubes. Open electrical connectors should be sealed with foil and/or tape. Apply one of the cleaners using spray, wipe, foam, or gel application techniques recommended by the manufacturer. The cleaners are identified in Subtask 70-2124-110-522, Materials. NOTE: Various types of bristle brushes suitable for the part configuration or cleaning pads C10-010 may be used to enhance the cleaning process.
(2)
(3) (4) (5)
Allow the cleaner to dwell 5 to 20 minutes. Rinse the exterior of the engine fully with warm or hot water. Remove all coverings that were installed in step (1).
SUBTASK 70-21-24-110-524 E. Quality Assurance. (1) (2) Visually check the part for cleanliness. Repeat the process if necessary.
EFFECTIVITY: ALL
70-21-24
CLEANING METHOD NO. 24 - EXTERIOR ENGINE CLEANING Page 2 Dec 01/03
CLEANING METHOD NO. 25 - CLEANING METHOD NO. 25 - REMOVAL OF CARBON WITH ALKALINE GEL TASK 70-21-25-110-001 1. Cleaning Method No. 25 - Removal of Carbon with Alkaline Gel SUBTASK 70-21-25-99G-001 A. General. CAUTION: DO NOT USE ALKALINE GEL ON ALUMINUM, CARBON SEALS, OR ENGINE BEARINGS. DO NOT IMMERSE INSULATED PARTS. (1) This procedure is for removing carbon from gas turbine hardware, including both titanium and non-titanium metallic hardware. Products may be applied by spray or gel application based on manufacturers recommendations. It can be used for parts at module level and on insulation blankets. NOTE: This process is approved for use on steel, nickel, cobalt and titanium. SUBTASK 70-21-25-110-001 B. Equipment. (1) Proper personal protection equipment shall be used and shall include, but not be limited to, protective gloves, apron, and eye wear. Specific equipment for safe handling will be described in the manufacturers Material Safety Data Sheet for the specific cleaner. Part cleaning shall be performed in an area with proper ventilation. Various types of bristle brushes for part configuration or cleaning pads C10-010 may be used to assist the cleaning action of the chemicals.
(2) (3)
SUBTASK 70-21-25-110-002 C. Materials. No. C04-250 Concentration As Received
Consumable Product Cleaner, Carbon Removal Gel SUBTASK 70-21-25-110-003 D. Procedure. (1)
Cover all openings to the interior of the part with appropriate plugs, masks, or tape C10-021 as required. Open electrical connectors should be sealed with foil and/or tape. The inside of tubes may be cleaned by pumping the gel into the tubes.
EFFECTIVITY: ALL
70-21-25
CLEANING METHOD NO. 25 - REMOVAL OF CARBON WITH ALKALINE GEL Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: ON INSULATION BLANKETS AVOID APPLYING THE GEL SUCH THAT IT WILL ENTER THE VENTS. (2) Apply the cleaner C04-250 at ambient temperature using spray or gel application techniques recommended by the manufacturer. NOTE: Various types of bristle brushes suitable for the part configuration or cleaning pads C10-010 may be used to enhance the cleaning process. (3) (4) Allow the cleaner to dwell 10 minutes to 12 hours. Rinse the part fully with warm or hot water. Pressure spray may be used to assist the rinse operation.
CAUTION: ON INSULATION BLANKETS AVOID SPRAYING WATER INTO THE VENTS. DO NO IMMERSE THESE PARTS. (5) (6) Inspect the carbon removal. Do Steps D.(2) through D.(4) again if necessary. Maximum total soak time is 24 hours. Remove all the coverings that were installed in Step D.(1).
SUBTASK 70-21-25-110-004 E. Quality Assurance. (1) Visually check the part for cleanliness.
EFFECTIVITY: ALL
70-21-25
CLEANING METHOD NO. 25 - REMOVAL OF CARBON WITH ALKALINE GEL Page 2 Dec 01/03
CLEANING METHOD NO. 26 - CLEANING METHOD NO. 26 - ELECTRICAL WIRE HARNESS AND CONTACT CLEANING TASK 70-21-26-110-001 1. Cleaning Method No. 26 - Electrical Wire Harness and Contact Cleaning SUBTASK 70-21-26-99G-001 A. General. (1) This procedure is for cleaning electrical wiring harnesses and contacts.
SUBTASK 70-21-26-110-001 B. Equipment. (1) Proper personal protection equipment shall be used and shall include, but not be limited to, protective gloves, apron, and eye wear. Specific equipment for safe handling will be described in the manufacturers Material Safety Data Sheet for the specific cleaner. Part cleaning shall be performed in an area with proper ventilation.
(2)
SUBTASK 70-21-26-110-002 C. Materials. Table 1. Pre-Cleaners Consumable Product CaiKleen TNX No. C04-259
Table 2. Cleaners Consumable Product Positron Envirosolv 655 MagChem Teksol Selig CE-SX-94, GB-SX-94, and L-SX-94 Super Degreaser CRC Precision Cleaner Plus Isopropyl Alcohol Eco Spray ProGold GX100L or GX5L
EFFECTIVITY: ALL
No. C04-198 C04-252 C04-197 C04-199 C04-253 C04-254 C04-035 C04-257 C04-258
CLEANING METHOD NO. 26 - ELECTRICAL WIRE HARNESS AND CONTACT CLEANING Page 1 Dec 01/03
70-21-26
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-21-26-110-003 D. Procedure - Method 1. WARNING: DO NOT SPRAY FLAMMABLE CLEANERS AROUND POSSIBLE IGNITION SOURCES. MAKE SURE ALL ELECTRICAL POWER IS TURNED OFF, OR INJURY COULD RESULT. IF CLEANING OF THE CONNECTORS IS TO BE DONE DURING THE ENGINE TEST, FOLLOW ALL OF THE LOCAL PROCEDURES REGARDING COMBUSTIBLE MATERIAL HANDLING AND USE IN AND AROUND HOT ENGINE HARDWARE.
(1)
Spray the cleaner on the wiring harness and electrical contacts at ambient temperature, or at safe temperatures recommended by the manufacturer. The cleaners are identified in Table 2, Page 1. Wipe off the area to be cleaned with a clean cloth, non-metallic bristle brush, or equivalent to remove loosened dirt and excess cleaner. While area is wet with cleaner use a non-metallic bristle brush to clean around connector contacts, flushing with cleaner as required. USE EYE PROTECTION WHEN YOU USE COMPRESSED AIR TO CLEAN, COOL, OR DRY PARTS OR TOOLS. PARTICLES CAN CAUSE AN INJURY TO YOUR EYES. DO NOT USE MORE THAN 30 PSIG (200 KPA). DO NOT POINT COMPRESSOR AIR AT YOURSELF OR OTHER PERSONS.
(2)
WARNING:
(3) (4)
If necessary, blow dry with clean, filtered air at 30 psi (200 kPa) pressure maximum. Inspect for dirt removal. Do Steps D.(1) through D.(3) again, if necessary.
SUBTASK 70-21-26-110-013 E. Procedure - Method 2. NOTE: Method 2 uses a pre-cleaner and is recommended for electrical contacts that are more difficult to clean. The pre-cleaner is identified in Table 1, Page 1. (1) (2) Clean the metal surfaces of the contacts with a lint-free sponge swab or equivalent that has been wetted with CaiKleen TNX C04-259. Leave on for 15 to 20 seconds. Immediately following the cleaning, a triple flush is recommended using Isopropyl Alcohol C04-035. Pour the alcohol onto the contact area that was cleaned with CaiKleen TNX C04-259 and shake off the excess, preferably by holding the connector upside down to assist the removal of particles and residue. Repeat this flush three times.
EFFECTIVITY: ALL
70-21-26
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: USE EYE PROTECTION WHEN YOU USE COMPRESSED AIR TO CLEAN, COOL, OR DRY PARTS OR TOOLS. PARTICLES CAN CAUSE AN INJURY TO YOUR EYES. DO NOT USE MORE THAN 30 PSIG (200 KPA). DO NOT POINT COMPRESSOR AIR AT YOURSELF OR OTHER PERSONS.
(3)
Blow dry with clean, filtered air at 30 psi (200 kPa) pressure maximum. Coat the metal surfaces of the contacts with ProGold GX100L or GX5L C04-258, using short bursts from the spray container or a lint-free swab wetted with the liquid version. Allow to air dry for 10-15 seconds.
SUBTASK 70-21-26-110-004 F. Quality Assurance. (1) (2) Visually check the part for cleanliness. Make sure the connector contact area is completely dry before reconnecting.
EFFECTIVITY: ALL
70-21-26
EFFECTIVITY: ALL
70-21-26
CLEANING PRECAUTIONS - SPECIAL CLEANING PRECAUTIONS TASK 70-22-00-100-001 1. Special Cleaning Precautions SUBTASK 70-22-00-99G-001 A. General. (1) Some parts, because of the material from which they are made, (e.g., titanium) or because of their design (bearings), require special cleaning precautions. While some of the materials may be similar in many ways to those used for general cleaning, the precautions differ in important respects. In other cases, some cleaning materials cannot be used at all on specific parts without damaging them. For example, vapor degreasing cannot be used on titanium parts because the material used (1-1-1 tri-chloroethane or perchloroethylene) will cause stresscorrosion cracking at elevated temperatures. It cannot be used on bearings because, although the grease would be dissolved, it would carry particles of dirt into the bearing where they would be trapped, and also allows flash corrosion.
EFFECTIVITY: ALL
70-22-00
SPECIAL CLEANING PRECAUTIONS Page 1 Dec 01/03
EFFECTIVITY: ALL
70-22-00
SPECIAL CLEANING PRECAUTIONS Page 2 Dec 01/03
SPECIAL CLEANING NO. 1 - SPECIAL CLEANING PROCEDURE NO. 1 - CLEANING OF BEARINGS USING SOLVENT (METHOD 1) OR WATER-BASED SOLUTION (METHOD 2) TASK 70-22-01-110-013 1. Special Cleaning Procedure No. 1 - Cleaning Of Bearings Using Solvent Cleaning Materials (Method 1) SUBTASK 70-22-01-99G-013 A. General - Method 1. (1) This procedure has two different methods. Unless specified differently, all procedures that reference Method 1 can use Method 2 [ TASK 70-22-01-110-046, Special Cleaning Procedure No. 1 - Cleaning of Bearings Using a Water-Based Cleaning Solution (Method 2)] as an alternate. The difference between the two methods is that one is a solvent based cleaning process and the second method is a water based process. Bearings must be handled with clean gloves and plastic or plastic-coated equipment. Rooms in which bearings are cleaned must be equipped with a filtered air system, and supplied with lint-free cloths, gloves, etc. The rooms must be closed off from areas in which other maintenance operations are performed.
(2)
CAUTION: DO NOT USE COMPRESSED AIR TO BLOW EXCESS SOLVENTS OR LUBRICANTS FROM ASSEMBLED BEARINGS AS SPINNING CAN DAMAGE THE BEARING. (3) In this procedure, several different bearing types will be mentioned. They are nonseparable, semi-separable (semi-demountable), and fully separable (fully demountable). Non-separable means that the bearing cannot be disassembled. Semi-separable means that the bearing can be partially disassembled - where the inner or outer race can be removed but that the cage and rolling parts stay attached with the other race. Fully separable means that the bearing can be disassembled where the inner race, outer race, and cage/rolling parts are separate from each other as three distinct subassemblies. NOTE: Refer to TASK 70-14-00-620-003, Handling of Bearings, for handling techniques to prevent damage to bearings. SUBTASK 70-22-01-110-131 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and a means to neutralize acid or alkaline splashing. Processing plant for neutralizing waste and used solutions.
SPECIAL CLEANING PROCEDURE NO. 1 - CLEANING OF BEARINGS USING SOLVENT (Method 1) OR WATER-BASED SOLUTION (Method 2) Page 1 Dec 01/03
(b)
EFFECTIVITY: ALL
70-22-01
STANDARD PRACTICES MANUAL AS907-1-1A (c) (d) Efficient ventilation system for extracting and neutralizing vapors. Three alkaline cleaning tanks made of stainless steel. One tank must be capable of heating the solution to 1508 F (658 C) and be equipped with a recirculating pump and a 10-micron filtration supply. Another must have a recirculating pump and 10-micron filtration supply, and the third should have polypropylene lining. Demagnetization equipment and a Gaussmeter or magnetic compass to check for residual magnetism.
(e)
SUBTASK 70-22-01-110-132 C. Materials. Consumable Material No. C04-002 C04-076 C04-059 C02-054 C02-025 C02-063 C02-024 C10-009 C10-064 C02-023
Materials Stoddard solvent Turco Super Carb - Carbon Remover Turco 2538 - Carbon Remover Fingerprint neutralizer Preservative oil Preservative grease Grease proof paper Hand cream Engine oil SUBTASK 70-22-01-110-133 D. Procedure.
Operating Temp 8F (8C) As required Ambient Ambient Ambient Ambient Ambient N/A N/A N/A
CAUTION: HOLD THE INNER AND OUTER RACES OF NONSEPARABLE BEARINGS TOGETHER TIGHTLY TO PREVENT THE BALLS OR ROLLERS FROM VIBRATING. (1) Demagnetize nonseparable bearings as an assembly, but demagnetize the component parts of separable bearings individually. Be extremely careful to avoid mixing parts of one bearing with those of another. Pass the bearings or bearing components through the demagnetizer at a rate not exceeding 12 feet per minute. Remove the parts from the demagnetizing field before de-energizing the coil. After demagnetization, use a Gaussmeter or a magnetic compass to test the parts for residual magnetism. If the Gaussmeter indication exceeds 5 Gauss at any point, the demagnetization is incomplete and must be repeated until within limits. If a compass is used, place the bearing at the east or west points of the compass and
(2)
(3)
EFFECTIVITY: ALL
70-22-01
STANDARD PRACTICES MANUAL AS907-1-1A immediately adjacent to it. Slowly rotate the entire bearing or the parts 360 degrees while next to the compass. Deviation of the compass needle indicates incomplete demagnetization. CAUTION: NEVER SPIN ASSEMBLED BEARINGS BEFORE CLEANING. DO NOT PERMIT COMPONENTS OF BEARINGS TO STRIKE EACH OTHER SHARPLY DURING THE CLEANING PROCESS. DO NOT HANDLE BEARINGS OR COMPONENTS WITH BARE HANDS: USE EITHER CLEAN GLOVES OR PROTECTIVE HAND CREAM C10-064. (4) After demagnetization, pressure-flush each bearing or component thoroughly with a clean solvent-air spray C04-002. (a) Separable bearings should be disassembled for cleaning. All components of a bearing should be kept together during cleaning, and must not be permitted to become mixed with components of another bearing. Put the bearings in a tank containing cleaning solvent, C04-002. Let the bearings reach the temperature of the cleaning solvent before you do the pressure-flush cleaning. This will prevent corrosion caused by condensation. Pressure-flush each bearing and component with clean solvent-air spray C04-002, taking care not to let assembled bearings spin during flushing. Solution should be held at approximately 1308 F (548 C) in a tank equipped with a pump and 10-micron filtration. Immerse bearings for 5-10 minutes, and dip several times to ensure thorough rinsing action before removal. NOTE: Filter and solution must be changed regularly to minimize contamination. Solution should not contain visible particles or more than 10 percent oil. WARNING: CARBON REMOVAL COMPOUNDS ARE TOXIC. WEAR PROTECTIVE CLOTHING, NEOPRENE OR PLASTIC GLOVES, AND GOGGLES OR FACE SHIELD. IF COMPOUND CONTACTS THE SKIN, WASH IMMEDIATELY WITH SOAP AND WATER, AND APPLY AN EMOLLIENT CREAM.
(b) (c)
(d)
CAUTION: DO NOT PLACE SEALED OR SHIELDED BEARINGS CONTAINING RUBBER SEALS IN AN ULTRASONIC CLEANING TANK. (e) If carbon deposits, varnish, gum, or other stubborn accumulations of foreign material remain on the bearing, soak it in a carbon remover C04-076 or C04059. Time of immersion will vary widely, depending upon the type and amount of carbon formation. Ultrasonic cleaning for a five minute burst may be used to aid the carbon remover cleaning cycle. DO NOT EXCEED THE FIVE MINUTE ULTRASONIC CYCLE IN THE CARBON REMOVAL STEP ON NON-SEPARABLE OR SEMI-SEPARABLE BEARING ASSEMBLIES. Flush as directed in Step (c). Do not let the carbon remover contaminate the solvent. NOTE: The disposal of compounds such at Turco 2538, containing cresylic acid, into a sewage system is prohibited by some communities. It is a hazard to aquatic life.
EFFECTIVITY: ALL
70-22-01
STANDARD PRACTICES MANUAL AS907-1-1A (f) Rinse bearings in Stoddard solvent at room temperature in a tank equipped with recirculating pump and 10-micron filtration. Dip bearings or components, handled with tongs, clean gloves, or a plastic coated metal diprack, into the solvent at least five times. Drain for at least one minute. Immediately after rinsing and thorough draining, immerse bearing in fingerprint neutralizer C02-054. Make sure that the neutralizer contacts all surfaces. Remove neutralizer by rinsing in Stoddard solvent C04-002.
(g)
(5)
Protect bearings until next processing operation as follows: (a) If a bearing is to be used immediately, immerse it in preservative oil C02-050, C02-025, or C02-063 or engine oil C02-023. NOTE: The preferred preservation oil for shop standardization is C02-050. Place in a clean plastic bag or wrap in Grade A grease proof paper C10-009. Place in closed and covered individual containers. (b) Preserve bearings to be stored for an indefinite or extended period by covering with protective grease C02-024. Wrap in Grade A grease-proof paper C10-009, glossy side toward bearing, and place in individual covered containers. NOTE: An alternative method of extended period storage may be used with preservation oil C02-050 provided bearings are packed in shrinkwrap or plastic bags to minimize exposure to moisture.
TASK 70-22-01-110-046 2. Special Cleaning Procedure No. 1 - Cleaning Of Bearings Using A Water-Based Cleaning Solution (Method 2) SUBTASK 70-22-01-99G-046 A. General - Method 2. (1) This procedure has two different methods. Unless specified differently, all procedures that reference Method 2 can use Method 1 TASK 70-22-01-110-013, Special Cleaning Procedure No. 1 - Cleaning of Bearings Using Solvent Cleaning Materials (Method 1)] as an alternate. The difference between the two methods is that one is a solvent based cleaning process and the second method is a water based process. Either of these two methods can be used to clean bearings. Bearings must be handled with clean gloves and plastic or plastic-coated equipment. Rooms in which bearings are cleaned must be equipped with a filtered air system, and supplied with lint-free cloths, gloves, etc. The rooms must be closed off from areas in which other maintenance operations are performed.
(2)
EFFECTIVITY: ALL
70-22-01
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: DO NOT PERMIT ANY DELAY BETWEEN THE INDIVIDUAL STEPS OF THE WATER BASED PROCESS. CAUTION: DO NOT USE COMPRESSED AIR TO BLOW EXCESS SOLVENTS OR LUBRICANTS FROM ASSEMBLED BEARINGS AS SPINNING CAN DAMAGE THE BEARING. (3) The water based process flow is to demagnetize the bearing(s), load the pieces in/ on a non-metallic carrier, process through a hot alkaline carbon remover, a cold water rinse, a dewatering oil, and a preservative oil. There should also be capability for a fingerprint neutralizer should the bearing come in contact with human skin or skin oils, and a station to apply preservative grease should the bearing be stored for indefinite or long periods of time. In this procedure, several different bearing types will be mentioned. They are nonseparable, semi-separable (semi-demountable), and fully separable (fully demountable). Non-separable means that the bearing cannot be disassembled. Semi-separable means that the bearing can be partially disassembled so the inner or outer race can be removed but, the cage and rolling parts stay attached to the other race. Fully separable means that the bearing can be disassembled where the inner race, outer race, and cage/rolling parts are separate from each other as three distinct subassemblies. NOTE: Refer to TASK 70-14-00-620-003, Handling of Bearings for handling techniques to prevent damage to the bearings. SUBTASK 70-22-01-110-465 B. Tools, Equipment, and Consumable Materials. NOTE: Equivalent alternatives are permitted for Tools, Equipment, and Consumable Materials. It is the responsibility of the repair source to demonstrate the equivalency based on use and application. (1) Safety equipment. (a) Surface treatment shop standard equipment such as: Eye bath. Emergency showers. Protective clothing. Must protect against electroplating products. A procedure to neutralize acid or alkaline splashing. (b) (c) (d) A processing plant to neutralize waste and used solutions. An efficient ventilation system to remove and neutralizing vapors. Gloves and other personal safety equipment that will permit the operator to touch the bearings and also protect the operator if they come in contact with the solutions. Make sure all equipment used will not damage the bearings.
(4)
(2)
Special Tools.
EFFECTIVITY: ALL
70-22-01
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: WHENEVER POSSIBLE, KEEP ALL TANKS COVERED TO MINIMIZE CONTAMINATION FROM AIRBORNE PARTICLES. (a) Four tanks made of stainless steel and as follows: All the tanks should have bottom racks or some other device to prevent the baskets or parts from resting on the bottom on the tank. 1 A heated alkaline cleaning tank (cleaning tank) designed as follows: a The tank must be capable of heating the alkaline cleaning solution and maintaining a working temperature of 150-2008 F (82938 C). The tank must have a continuous filtration system that has a 10 micron filtration element. The tank must have a mechanical agitation system. The preferred method is by mechanically stirring or recirculating the fluid. Ultrasonic agitation is permitted for some applications, but is not to be the only means of agitation. If ultrasonic agitation is used, the power rating must be 4-10 watts for each square inch of tank bottom. The transducer(s) should operate in the 20 to 40 kilohertz range.
b c
A water hose must be available to rinse the bearings as they come out of the hot alkaline degreasing tank. Make sure the hose uses cold water that has been filtered through a 10 micron filtration system. Air/ water (hydro-air nozzles) combination rinsing systems are not permitted. A water rinse tank. This tank must use cold water only. The tank must also have a mechanical agitation system. There must be enough water change out (by continuous overflow or by manual recharge) to make sure all the alkaline residue is removed from the bearings during the cleaning cycle. This water rinse tank must be equipped with a continuous filtration system that has a 10 micron filtration element. A bearing dewatering tank (dewatering tank) designed as follows: a The tank must be designed to permit the water that is removed from the bearings to be siphoned off without dumping the tank. Typically, this is accomplished by installing a bottom valve. The tank bottom should have a pyramid shape to provide a low point to remove the water. The water removed from the bearings will accumulate in the low point of the tank bottom. The tank must be equipped with a continuous filtration system that has a 10 micron filtration element.
c 5
A preservative tank. A tank that contains clean engine oil C02-023, preservation oil C02-025, or preservation oil C02-063.
EFFECTIVITY: ALL
70-22-01
STANDARD PRACTICES MANUAL AS907-1-1A (b) (c) A station to apply the long term preservation grease necessary for bearings that are to be stored for an indefinite period of time. A tank containing fingerprint neutralizer C02-054, is recommended. Fingerprint neutralizer will remove all body oils that could cause corrosion on the bearings. Demagnetizing equipment and a Gaussmeter or magnetic compass to check for residual magnetism. Soft bristle brushes to aid in removing carbon residues from the bearings as necessary. Non-metallic or coated metallic carriers or baskets to hold the bearings while immersed in the cleaning and preserving liquids.
(d) (e) (f)
SUBTASK 70-22-01-110-466 C. Consumable Materials. Consumable Material No. C02-023 C02-024 C02-025 C02-063 C02-054 C02-064 C04-009 (S1006) or C04-182 (S1150) C10-009 C10-064 See TASK 70-00-05-800-006, Water Types.
Materials Engine oil Preservative grease Preservation oil Fingerprint neutralizer Oil, water displacing Alkaline degreaser Grease-proof paper Hand cream Water
Operating Temp 8F (8C) Ambient Ambient Ambient Ambient Ambient 180-200 (82-93) 180-200 (82-93) N/A N/A Ambient
SUBTASK 70-22-01-110-467 D. Procedure. CAUTION: HOLD THE INNER AND OUTER RACES OF NONSEPARABLE BEARINGS TOGETHER TIGHTLY TO PREVENT THE BALLS OR ROLLERS FROM VIBRATING. (1) Demagnetize the nonseparable bearings as an assembly. Demagnetize the component parts of separable bearings individually. Do not mix the parts of one bearing with those of another.
EFFECTIVITY: ALL
70-22-01
STANDARD PRACTICES MANUAL AS907-1-1A (2) Pass the bearings, or bearing components, through the demagnetizer at a rate not exceeding 12.00 feet (3.7 m) per minute. Remove the parts from the demagnetizing field before you de-energize the coil. After demagnetization, use a Gaussmeter or magnetic compass to test the parts for residual magnetism. If the Gaussmeter indication exceeds 5 Gauss at any point, the demagnetization is incomplete and must be repeated until within limits. If a compass is used, place the bearing at the east or west points of the compass and immediately adjacent to it. Slowly rotate the entire bearing, or the components, 360 degrees while next to the compass. Deviation of the compass needle indicates incomplete demagnetization.
(3)
CAUTION: NEVER SPIN ASSEMBLED BEARINGS BEFORE CLEANING. DO NOT PERMIT COMPONENTS OF BEARINGS TO STRIKE EACH OTHER SHARPLY DURING THE CLEANING PROCESS. DO NOT HANDLE BEARINGS OR COMPONENTS WITH BARE HANDS: USE EITHER CLEAN GLOVES OR A PROTECTIVE HAND CREAM C10-064 IS RECOMMENDED). (4) After demagnetization, prepare bearings for the cleaning process: (a) (b) (c) Semi-separable and fully separable bearings are to be disassembled before they are cleaned. Make sure you keep all the components of the bearing together. Do not mix the parts of one bearing with those of another. Load the bearing, or bearing components, in the carriers or on the hooks. Do not permit the components to touch, or lay on top of, each other.
CAUTION: DO NOT PLACE SEALED OR SHIELDED BEARINGS CONTAINING RUBBER SEALS IN THE ALKALINE CLEANING TANK. CAUTION: ULTRASONIC AGITATION IS ALLOWED FOR ONLY ONE FIVE MINUTE INTERVAL FOR EACH BEARING CLEANING CYCLE. IT IS PREFERRED THAT THE CLEANING OF BEARINGS BE ACCOMPLISHED BY A PROCESS WITH MECHANICAL AGITATION OTHER THAN ULTRASONIC MEANS. CAUTION: THIS PROCESS MUST BE ACCOMPLISHED WITH NO INTERRUPTIONS OR DELAYS BETWEEN PROCESSING STEPS. THIS IS TO PREVENT THE POSSIBILITY OF AN UNPRESERVED BEARING SURFACE BEING EXPOSED TO AIR FOR A PERIOD OF TIME THAT WOULD ALLOW OXIDATION (ALSO KNOWN AS FLASH RUSTING) OF THE ELEMENT TO OCCUR. (5) Place the bearings in the alkaline cleaning tank for five to ten minutes. Mechanical agitation of the solution is required to make sure you get the best possible cleaning. This mechanical agitation should be by solution recirculation, mechanical stirring, or by ultrasonic agitation. If ultrasonic agitation is used, it can only be used for five minutes of the ten minute cycle. During the other five minutes
EFFECTIVITY: ALL
70-22-01
STANDARD PRACTICES MANUAL AS907-1-1A of the cycle, the ultrasonics must be turned off and another means of mechanical agitation must be used. NOTE: Stains apparent after the cleaning process do not have to be removed. However, make sure they are stains and not accumulated dirt, carbon or oil varnish. NOTE: The rinsing water should be filtered with a 10 micron filtration element. (6) Immediately following the end of the alkaline cleaning step, remove the cleaning basket from the alkaline solution. Cold water rinse the bearings and the basket while positioned over the alkaline cleaning tank. Check the bearing for cleanliness. If necessary, use a soft bristle fiber brush to remove dirt or accumulated deposits. If the bearing, or bearing components, are still dirty, the alkaline cleaning process can be repeated one time only. Do not repeat the ultrasonics procedure. If the bearing, or bearing components, do not come clean after the second cleaning, the alkaline solution should be regenerated or replaced. Immediately after rinsing, move the basket into the cold water rinse tank. At this time, counter rotate the components of semi-separable and non-separable bearings to make sure they are fully flushed. This cold water rinse should not take longer than two minutes.
(7)
CAUTION: MAKE SURE THE WATER BUILD-UP IN THE BOTTOM OF THE TANK DOES NOT GET HIGH ENOUGH SO THAT THE CLEANED BEARING RESTS IN THE WATER LAYER. PROVIDE PROCESS CONTROL TO MAKE SURE THE WATER LEVEL IN THE DEWATERING OIL TANK STAYS BELOW THIS LEVEL. (8) Remove the basket, or bearing components, from the cold water rinse tank and immediately place it in the dewatering tank. At this time, agitate or manipulate the bearing, or bearing components, to make sure all the water is removed from all the surfaces. Counter rotate the components of the semi-separable and non-separable bearings. The bearing, or bearing components, must stay in the dewatering tank for a minimum of five minutes. Remove the basket from the dewatering tank and permit the bearings, or bearing components, to drain. Keep the amount of drain time to a minimum. Do not permit the bearings, or bearing components, to drain for a long period of time.
(9)
(10) Place the basket in the preservative tank containing engine oil C02-023, preservative oil C02-025, or preservation oil C02-063. Agitate the bearings, or bearing components, to make sure all the surfaces are fully coated. Counter rotate the parts of the non-separable or semi-separable bearings to help coat the surfaces. (11) If the bearing is to be used or inspected immediately, remove the bearing from the preservative tank and place it in a clean plastic bag or wrap it in Grade A grease proof paper C10-009 or both. Place the bearing in individual containers or wrap in protective bubble wrap to protect it from handling and the shop environment.
EFFECTIVITY: ALL
70-22-01
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: PROTECTIVE GREASE SHOULD BE KEPT COVERED AND CLEAN. IF IT IS SUSPECTED THAT GREASE HAS BEEN CONTAMINATED BY DIRT OR GRIT, DISCARD AND REPLACE WITH FRESH GREASE. (12) If the bearing is to be stored for an indefinite period of time, preserve the bearing by covering it with protective grease C02-024. Make sure the grease is worked onto all the surfaces of the bearing. Counter-rotate the bearing parts to work the grease into the cage and rolling parts. Wrap the bearing in Grade A grease proof paper C10-009, glossy side towards bearing. Place the bearing in individual covered containers to protect it from handling and the shop environment. NOTE: An alternative method of extended period storage may be used with preservation oil C02-050 provided bearings are packed in shrink wrap or plastic bags to minimize exposure to moisture. SUBTASK 70-22-01-110-468 E. Process Control. CAUTION: ALKALINE DEGREASING SOLUTION, AND ALL OTHER SOLUTIONS USED IN THIS PROCESS, SHALL BE USED FOR BEARINGS ONLY. DO NOT USE THIS PROCESS TO CLEAN OTHER ENGINE OR NON-ENGINE COMPONENTS. (1) (2) (3) Do not permit an oil film to remain on the surface of the alkaline cleaning solution. Make sure all the requirements of the appropriate alkaline cleaning solution sheets are met. If water spotting is noticed or becomes a problem, the water used in the rinsing and alkaline tank should be switched to demineralized or deionized water. Refer to TASK 70-00-05-800-006, Water Types. Inspect and change the solution particle filters on a frequent basis to make sure the process baths are particulate free. Make sure, on frequent scheduled basis, that the dewatering oil is free of water and particulate contamination. Change oil according to manufacturers recommendations.
(4) (5)
CAUTION: DO NOT FILL THE TANK WITH USED OIL. (6) Make sure the preservative or engine oil in the preservative tank is free of contaminants. If contaminants are suspected, remove the oil, clean the tank and refill with fresh new oil C02-023, C02-025 or C02-063. Keep the tanks covered when they are not in use. Make all attempts to isolate, as much as practically possible, the bearing cleaning and inspection areas from the rest of the facility to prevent the possibility of particulate contamination.
(7) (8)
EFFECTIVITY: ALL
70-22-01
SPECIAL CLEANING NO. 2 - SPECIAL CLEANING PROCEDURE NO. 2 - TITANIUM CLEANING TASK 70-22-02-110-014 1. Special Cleaning Procedure No. 2 SUBTASK 70-22-02-99G-014 A. General. (1) Titanium requires special care in processing to avoid contamination by oxygen or halogen-containing (fluorine, chlorine, bromine, iodine) agents. For that reason, titanium cleaning should be done in an area that is isolated from that area in which TASK 70-21-02-110-002, Vapor Degreasing (Cleaning Method No. 2), or other partscleaning operations are performed. Initial cleaning should be done in accordance with TASK 70-21-03-160-001, Steam Cleaning (Method No. 3). If scale, oxide coating, or other stubborn surface coatings remain after steam cleaning, shellblasting per TASK 70-21-04-120-003, Dry Abrasive Blast (Method 4B), may be used.
SUBTASK 70-22-02-110-141 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. The alkaline degreasing station shall consist of a stainless steel tank with a heating coil capable of heating the solution to 2008F (938C). A water rinse tank made from stainless steel with a polypropylene lining used after alkaline degreasing bath. The decarbonizing station shall consist of a stainless steel tank with a heating coil capable of heating the solution to 2808F (1388C). An automatic leveling device for water make-up must be included. Tanks constructed of mild steel are suitable but the heating coil or exchangers should be fabricated from a stabilized stainless steel. A hot water rinse tank made from stainless steel with a heating coil in tank capable of heating water to 1408F (608C) and an air/hot water spray gun, used after decarbonizing bath. A water rinse tank made from stainless steel with a polypropylene lining used after hot water rinse.
SPECIAL CLEANING PROCEDURE NO. 2 - TITANIUM CLEANING Page 1 Dec 01/03
(b) (c) (d) (e) (f)
(g)
(h)
EFFECTIVITY: ALL
70-22-02
STANDARD PRACTICES MANUAL AS907-1-1A (i) (j) The acid stripping station shall consist of a stainless steel tank with a polypropylene lining. A water rinse tank made from stainless steel with polypropylene lining used after the acid stripping bath.
SUBTASK 70-22-02-110-142 C. Materials. Table 1. Consumables Consumable Turco 524 Maskant Turco 625 Demask No. C03-052 C03-053 Operating Temperature 8F (8C) Ambient Ambient
Table 2. Alkaline Degreasing Solution for Titanium Solution Turco 4181 or Turco 4181L Turco Vitro-Klene Cee-Bee C46 Cee-Bee J84A or Cee-Bee J84AL Ardrox 185 or Ardrox 185L MagChem HDL-202 Eldorado HTP-1150 or 1150L Applied 5-840 No. S1003 S1010 S1030 S1139 S1140 S1151 S1168 S1175 Operating Temperature 8F (8C) 180-190 (82-88) 160-180 (71-82) 180-190 (82-88) 180-190 (82-88) 180-190 (82-88) 180-190 (82-88) 180-190 (82-88) 180-190 (82-93)
Table 3. Oxide Conditioning Solution for Titanium Solution Turco 4338-C or Turco 4338-L Ardrox 188 or Ardrox 188RFU Alkaline permanganate MagChem HDP-2524 Cee-Bee J88, Cee-Bee J88A, or Cee-Bee J88L Eldorado HTP 1190 Eldorado HTP 1190L Applied 5-770 No. S1012 S1001 S1004 S1018 S1014 S1163 S1164 S1177 Operating Temperature 8F (8C) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 180-200 (82-93)
EFFECTIVITY: ALL
70-22-02
Table 3. Oxide Conditioning Solution for Titanium (Cont) Solution No. Operating Temperature 8F (8C)
Table 4. Acid Stripping Solution for Titanium Solution Turco 4104 + HNO3 HF + HNO3 Ardrox 1635 + HNO3 Cee-Bee P-109B + HNO3 Ammonium bifluoride + HNO3 No. S1013 S1002 S1029 S1192 S1191 Operating Temperature 8F (8C) Ambient Ambient Ambient Ambient Ambient
NOTE: The use of solution S1002 in Table 4 requires the handling of concentrated Hydrofluoric Acid C04-011. This material is unusually hazardous. The use of one of the alternative solutions listed in Table 4 in place of solution S1002 is highly recommended.
SUBTASK 70-22-02-110-143 D. Special Instructions. (1) Handle titanium parts that will be subjected to temperatures of 10008F (5388C) or more after cleaning, with clean, lint-free, white cotton gloves, and protect the part with polyethylene wrapping or bag. Do not permit adhesive paper or tapes containing chlorine compounds to come in direct contact with titanium parts. To prevent possible attack of the hardware, ensure that any temporary markers used on titanium hardware meet the requirements of TASK 70-16-02-350-017, Temporary Marking. Critical dimension parts may not be processed for more than five minutes through solutions in table 4, Page 3 of Subtask 70-22-02-110-142, Material. For longer times, masking must be used.
(2) (3)
(4)
EFFECTIVITY: ALL
70-22-02
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: ACETONE AND METHYL-ETHYL-KETONE ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPORS AND CONTACT WITH THE SKIN, AND KEEP AWAY FROM SPARKS OR FLAME.
(5)
When the local water supply contains natural or added chlorine, fluorine, bromine, or iodine, (or their compounds) in excess of 100 ppm, immersion rinsing can be done in tap water if (1) the subsequent operation is done without delay, or (2) the part is immediately pressure-rinsed with distilled or deionized water and blown dry with filtered shop air, or thoroughly wiped dry with clean, lint-free cloth moistened with acetone or methyl-ethyl-ketone. Filler wire, as well as parts to be weld repaired must be cleaned by the acid pickling process. Refer to Subtask 70-22-02-110-144, Procedure. Cleaned wire can be stored in polyethylene bags with desiccant up to 48 hours. When directed by the repair procedure for a given part, mask specified areas as follows before acid pickling. (a) Dip or brush one coat of Turco 524 Maskant C03-052 or equivalent, on all surfaces to be masked. Masking coat should extend approximately 0.25 inch (6.4 mm) beyond the surfaces to be protected to ensure a good seal. Let the coat dry for about 20 minutes, or until it is dry to the touch. Apply a second coat of masking material, and let dry for 2-3 hours before continuing with acid pickle. Refer to Subtask 70-22-02-110-144, Procedure. IF REMOVING MASKING BY HAND, WEAR RUBBER OR NEOPRENE GLOVES TO PROTECT SKIN FROM ACID WHICH COULD HAVE GOTTEN UNDER THE MASKING. NEVER ADD WATER TO ACIDS. ADD ACIDS TO WATER WHILE STIRRING VIGOROUSLY. LOCALIZED HEAT OF SOLUTION CAN CAUSE BOILING AND SPATTERING. WEAR FACE MASK OR TIGHT-FITTING GOGGLES, AND RUBBER OR NEOPRENE GLOVES. IN CASE OF ACCIDENT, FLUSH EYES OR SKIN WITH COOL WATER, AND SEEK IMMEDIATE MEDICAL AID.
(6)
(7)
WARNING:
WARNING:
(b)
Remove masking compound after the rinse following acid pickling either by peeling it off by hand, or by dipping or brushing masked area with Turco Demask 625 C03-053 or equivalent.
SUBTASK 70-22-02-110-144 E. Procedure. (1) Clean using a solvent as indicated in the applicable manual.
EFFECTIVITY: ALL
70-22-02
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING OF VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (2)
Immerse the part in a tank containing one of the alkaline degreasing solutions listed in table 2, Page 2 of Subtask 70-22-02-110-142, Materials. Maintain the solutions at the specified temperature. Duration: 10 to 15 minutes.
(3) (4)
Rinse by immersion in water at room temperature. Immerse the part in a tank containing the oxide conditioning solution and maintain at the specified temperature. The oxide conditioning solutions are listed in table 3, Page 2 of Subtask 70-22-02-110-142, Materials. Duration: 30 to 60 minutes. Rinse by immersion in hot water at 1408F (608C) and pressure spray. Rinse over tank while withdrawing the part. Rinse by immersion in water to cool the part. NOTE: The part must be thoroughly cooled before immersing it in the next solution.
(5) (6) (7)
WARNING:
SOLUTION IS A STRONG ACID. ACID/FLUORIDE SOLUTIONS ARE VERY HAZARDOUS. USE IN A WELL VENTILATED AREA, TAKE ALL NECESSARY PRECAUTIONS TO AVOID SKIN AND EYE CONTACT. IF SOLUTION CONTACTS SKIN OR EYES, WASH IMMEDIATELY WITH LARGE AMOUNTS OF CLEAR WATER AND OBTAIN MEDICAL ATTENTION IMMEDIATELY. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING: (8) (9)
Immerse the part in a tank containing one of the acid stripping solutions listed in table 4, Page 3 of Subtask 70-22-02-110-142, Materials. Duration: 5 to 20 minutes.
(10) Rinse by immersion in water at room temperature. (11) Rinse by immersion and by spraying with hot water at 1408F (608C). (12) Rinse by immersion in deionized water (ambient).
EFFECTIVITY: ALL
70-22-02
STANDARD PRACTICES MANUAL AS907-1-1A (13) Dry using clean, dry air. NOTE: When immersing titanium parts in acid solutions, take precautions to avoid setting up a galvanic cell (electrolytic coupling) with associated handling devices. Baskets and other handling devices used in the acid pickling process should be coated with Teflon or other electrolytically inert material to provide the necessary protection to parts. Steps E.(2) through E.(6) may be repeated any number of times. Step E.(7) may be repeated for a total time of 20 minutes. SUBTASK 70-22-02-110-145 F. Quality Assurance. (1) Make sure that the part is completely dry and that all oxide traces have been removed. If traces of oxide remain after treatment, repeat the procedure and, if required, finish by TASK 70-21-04-120-D01, Dry Abrasive Blast Cleaning - Method 4D.
EFFECTIVITY: ALL
70-22-02
SPECIAL CLEANING NO. 3 - SPECIAL CLEANING PROCEDURE NO. 3 CLEANING EXTERNAL TUBES AND HOSES - METHODS 1 AND 2 TASK 70-22-03-110-015 1. Special Cleaning Procedure No. 3 - Cleaning External Tubes and Hoses - Method 1 SUBTASK 70-22-03-99G-015 A. General. (1) This cleaning method is recommended for removal of gum varnish and coked oil from the bores and outside surfaces of external tubes and hoses. This procedure has two different methods. Unless specified differently, all procedures that reference Method 1 can use Method 2 ( TASK 70-22-03-110-016, Special Cleaning Procedure No. 3 - Cleaning External Tubes and Hoses - Method 2) as an alternative.
SUBTASK 70-22-03-110-151 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline cleaning tank made of stainless steel. (Optional) Ultrasonic tank unit made of stainless steel.
(b) (c) (d) (e)
SUBTASK 70-22-03-110-152 C. Materials Stoddard solvent Acetone Carbon remover (Turco Super Carb) Detergent solution Isopropyl Alcohol Materials. Consumable Material No. C04-002 C04-003 C04-076 S1025 C04-035 Operating Temperature 8F (8C) Ambient Ambient Ambient Ambient* Ambient
SPECIAL CLEANING PROCEDURE NO. 3 CLEANING EXTERNAL TUBES AND HOSES - Methods 1 and 2 Page 1 Dec 01/03
Materials
Consumable Material No.
Operating Temperature 8F (8C)
NOTE: * The use of hot water to mix the solution will assist in the cleaning process.
SUBTASK 70-22-03-110-153 D. Procedure. (1) Clean air, fuel and oil hoses and tubes fabricated from, or lined with, silicone rubber as follows: WARNING: DO NOT TAKE DETERGENTS INTERNALLY. DO NOT GET IN EYES. WEAR GOGGLES OR FACE SHIELD WHEN HANDLING DETERGENTS.
(a) (b)
Scrub the internal passages of the hose or tube with a bristle brush using detergent solution S0125. Refer to TASK 70-00-99-801-025, Solution S1025. Rinse the internal passages of the hose or tube in clear water and air dry. STODDARD SOLVENT C04-002, ACETONE C04-003, OR ISOPROPYL ALCOHOL C04-035 ARE FLAMMABLE. DO NOT USE NEAR WELDING AREAS, NEAR OPEN FLAMES OR ON VERY HOT SURFACES. USE ONLY WITH ADEQUATE VENTILATION. AVOID PROLONGED OR REPEATED BREATHING OF VAPORS. DO NOT SMOKE WHEN USING IT. USE PROTECTIVE CREAMS. WEAR ARROW AND GOGGLES (OR FACE SHIELD) TO PROTECT EYES AND SKIN. STORE IN APPROVED METAL SAFETY CONTAINERS.
WARNING:
CAUTION: EXCESSIVE EXPOSURE TO STODDARD SOLVENT C04-002, ACETONE C04-003, OR ISOPROPYL ALCOHOL C04-035 MAY CAUSE DETERIORATION OF HOSES MADE WITH SILICONE RUBBER. FLUSHING IN SUCH CASES IS LIMITED TO A FIVE-MINUTE PERIOD. (c) (d) (2) Flush the lines with stoddard solvent C04-002, Acetone C04-003, or Isopropyl Alcohol C04-035. Flush with filtered water and air dry.
Clean unlined, metallic external oil tube bores and external surfaces in accordance with the following steps: NOTE: Tubes and hoses fabricated or lined with silicon rubber are cleaned per paragraph D.(1). (a) Immerse tube in carbon remover C04-076 that is at room temperature. The carbon removers are listed in Subtask 70-22-03-110-152, Materials. Let the tube soak for 1 to 2-1/2 hours. Ultrasonic cleaning may also be used.
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: MAKE CERTAIN THAT NO PART OF SWAB OR CLOTH IS LEFT IN THE TUBE. THE RESULTING OIL-FLOW RESTRICTION COULD CAUSE SERIOUS ENGINE DAMAGE. (b) (c) (d) (e) TASK 70-22-03-110-016 2. Special Cleaning Procedure No. 3 - Cleaning External Tubes and Hoses - Method 2 SUBTASK 70-22-03-99G-016 A. General. (1) This cleaning method is recommended for removal of gum varnish and coked oil from the bores and outside surfaces of external tubes and hoses. This procedure has two different methods. Unless specified differently, all procedures that reference Method 2 can use Method 1 ( TASK 70-22-03-110-015, Special Cleaning Procedure No. 3 - Cleaning External Tubes and Hoses - Method 1) as an alternative. After soaking is complete, pull a clean swab or lint-free cloth through the bore of the tube to remove softened carbon residue if required. Rinse the tube thoroughly in stoddard solvent C04-002, Acetone C04-003, or Isopropyl Alcohol C04-035. Dry the part using clean, dry air. Procedure may be repeated.
SUBTASK 70-22-03-110-154 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline cleaning tank made of stainless steel. (Optional) Ultrasonic tank unit made of stainless steel.
(b) (c) (d) (e)
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-22-03-110-155 C. Materials Stoddard solvent Acetone Alkaline Rust Remover Detergent solution Isopropyl Alcohol Materials. Consumable Material No. C04-002 C04-003 S1189 S1025 C04-035 Operating Temperature 8F (8C) Ambient Ambient 175-194 (80-90) Ambient* Ambient
NOTE: * The use of hot water to mix the solution will assist in the cleaning process.
SUBTASK 70-22-03-110-156 D. Procedure. (1) Clean air, fuel and oil hoses and tubes fabricated from, or lined with, silicone rubber as follows: WARNING: DO NOT TAKE DETERGENTS INTERNALLY. DO NOT GET IN EYES. WEAR GOGGLES OR FACE SHIELD WHEN HANDLING DETERGENTS.
(a) (b)
Scrub the internal passages of the hose or tube with a bristle brush using detergent solution S1025. Rinse the internal passages of the hose or tube in clear water and air dry. STODDARD SOLVENT C04-002, ACETONE C04-003, AND ISOPROPYL ALCOHOL C04-035 ARE FLAMMABLE. DO NOT USE NEAR WELDING AREAS, NEAR OPEN FLAMES OR ON VERY HOT SURFACES. USE ONLY WITH ADEQUATE VENTILATION. AVOID PROLONGED OR REPEATED BREATHING OF VAPORS. DO NOT SMOKE WHEN USING IT. USE PROTECTIVE CREAMS. WEAR ARROW AND GOGGLES (OR FACE SHIELD) TO PROTECT EYES AND SKIN. STORE IN APPROVED METAL SAFETY CONTAINERS.
WARNING:
CAUTION: EXCESSIVE EXPOSURE TO STODDARD SOLVENT C04-002, ACETONE C04-003, AND ISOPROPYL ALCOHOL C04-035 MAY CAUSE DETERIORATION OF HOSES MADE WITH SILICONE RUBBER. FLUSHING IN SUCH CASES IS LIMITED TO A FIVE-MINUTE PERIOD. (c) (d) Flush the lines with Stoddard Solvent C04-002, Acetone C04-003, or Isopropyl Alcohol C04-035. Flush with filtered water and air dry.
STANDARD PRACTICES MANUAL AS907-1-1A (2) Clean unlined, metallic external oil tube bores and external surfaces in accordance with the following steps: NOTE: Tubes and hoses fabricated or lined with silicon rubber are cleaned per Step D.(1). (a) Immerse tube in Alkaline Rust Remover S1189. Let the tube soak for up to 25 minutes 5 minutes. Ultrasonic cleaning may also be used.
CAUTION: MAKE CERTAIN THAT NO PART OF SWAB OR CLOTH IS LEFT IN THE TUBE. THE RESULTING OIL-FLOW RESTRICTION COULD CAUSE SERIOUS ENGINE DAMAGE. (b) (c) (d) (e) After soaking is complete, pull a clean swab or lint-free cloth through the bore of the tube to remove softened carbon residue if required. Rinse the tube by immersion in hot water at 150 to 200 8F (66 to 938C). Dry the part using clean, dry air. Procedure may be repeated.
SPECIAL CLEANING NO. 4 - SPECIAL PROCEDURE NO. 4 - CLEANING URETHANE-COATED ACOUSTIC PANELS TASK 70-22-04-110-016 1. Special Procedure No. 4 - Cleaning Urethane-Coated Acoustic Panels SUBTASK 70-22-04-99G-016 A. General. (1) The three cleaning methods described in this procedure are effective for removing flight contamination (dirt, oil, organic matter, etc.) from sound-suppression panels. These cleaning methods do not damage the panels when used as directed.
SUBTASK 70-22-04-110-161 B. Equipment. (1) Specialized equipment is required for each procedure and is identified in each section.
SUBTASK 70-22-04-110-162 C. Materials. Table 1. Steam Cleaning Materials Materials Plaudit Jet Clean B Consumable No. C04-078 C04-078 Operating Temperature 8F (8C) 225-250 (107-121) 225-250 (107-121)
Table 2. High Pressure Cleaning Materials Materials MagChem Aerodet SUBTASK 70-22-04-110-163 D. Procedure I: Steam Cleaning. (1) Use a steam cleaner such as the Malsbary Model 230SVC or Walters Model 248F (or equivalent) with a fan spray nozzle. Refer to or in the List of Suppliers in Step D. of Subtask 70-80-00-800-003. Mix detergent cleaning solution to obtain a concentration of two percent by volume of detergent solution in water. Use one of the materials indicated in Table 1, Page 1 of Subtask 70-22-04-110-062, Materials.
SPECIAL PROCEDURE NO. 4 - CLEANING URETHANE-COATED ACOUSTIC PANELS Page 1 Dec 01/03
Operating Temperature 8F (8C) 120-150 (49-66)
(2)
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: DO NOT DIRECT THE SPRAY ON ANY ONE AREA LONGER THAN FIVE SECONDS. (3) At a pressure of 80-100 psi (552-690 kPa) direct the spray into the sound suppression holes in the face of the panel while keeping the nozzle moving across the face of the panel at a distance of 14-18 inches (356-457 mm) and at a rate of 1025 seconds from one end of the panel to the other. After cleaning, turn off the detergent, and rinse the panel thoroughly with clear water. Drain and blow dry with clean shop air.
(4)
SUBTASK 70-22-04-110-164 E. Procedure II: High-Pressure Detergent Wash. (1) (2) Use a high-pressure nozzle equipped Magnus Jet-Off Gun (Magnus Equipment). Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. Mix solution to obtain a concentration of 50 percent by volume of detergent solution in water. Use one of the materials indicated in Table 2, Page 1 of Subtask 70-22-04110-062, Materials. Using this solution at a pressure of 80-100 psi (552-690 kPa), direct the spray into the sound-suppression holes of the panel from a distance of 4-6 inches (102-152 mm). After cleaning, drain panel and rinse thoroughly with clear water. Blow dry with clean shop air.
(3)
(4)
SUBTASK 70-22-04-110-165 F. Procedure III: Ultrasonic Cleaning. (1) Using TASK 70-21-15-130-001, Cleaning Method No. 15 - Ultrasonic Cleaning, place panels in cleaner tank, being careful to let air escape from cavities in which it might be entrapped. Turn on ultrasonic generator and clean for 3-5 minutes. After cleaning, drain panel and rinse thoroughly with clear water. Blow dry with clean shop air.
(2) (3)
SPECIAL PROCEDURE NO. 4 - CLEANING URETHANE-COATED ACOUSTIC PANELS Page 2 Dec 01/03
SPECIAL CLEANING NO. 5 - SPECIAL CLEANING PROCEDURE NO. 5 - CLEANING INTERNAL LUBE OIL TUBES TASK 70-22-05-110-017 1. Special Cleaning Procedure No. 5 - Cleaning Internal Lube Oil Tubes SUBTASK 70-22-05-99G-017 A. General. (1) This cleaning method is effective for removal of coke from internal lube oil tubes where the tube can be disconnected to permit flow through or plugged to permit a flow through type of flushing. This solution is not to enter sumps or lube system components which cannot be thoroughly flushed and purged. Apply to tubes per applicable manual repairs.
SUBTASK 70-22-05-110-171 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. The permanganate cleaning station shall consist of a stain-less steel tank with a heating coil capable of heating the solution to 2158F (1028C). A cold water rinse tank. Suitable pump constructed from materials not affected by the strong hot alkaline cleaning or acid solutions. Tubular connections, short in length to minimize heat loss, to connect pump, lube oil tubes, permanganate solution, and water rinse system. A small stainless steel tank for mixing and holding acid solutions.
(b) (c) (d) (e) (f) (g) (h)
SPECIAL CLEANING PROCEDURE NO. 5 - CLEANING INTERNAL LUBE OIL TUBES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-22-05-110-172 C. Solutions Alkaline permanganate Materials. No. S1012 S1014 S1001 S1004 Alkaline Rust Remover Oxalic acid SUBTASK 70-22-05-110-173 D. Procedure. (1) Attach steel tubing and a suitable pump to lube tube to be cleaned, to supply cleaning solution to the tube and return it to the tank. Refer to applicable manual repair for specific part details. THIS CLEANING SOLUTION IS STRONGLY ALKALINE. VENT AREA AND WEAR FACE SHIELD AND PROTECTIVE CLOTHING. IF SOLUTION CONTACTS THE SKIN OR EYES, FLUSH EXPOSED AREAS THOROUGHLY WITH COOL WATER AND SEEK IMMEDIATE MEDICAL AID. S1189 C04-099 Operating Temp 8F (8C) 190-200 (88-93) 190-200 (88-93) 205-215 (96-102) 190-200 (88-93) 175-194 (80-90) Ambient
WARNING:
(2)
Pump alkaline permanganate (S1012, S1014, S1001, or S1004) or alkaline rust remover solution (S1189) through the tube and back to the tank for 3 hours maximum. Soaking time is a function of the coke thickness. NOTE: Solution flow rate is not critical but should be sufficient to maintain tube and cleaning solution operating temperature. Tubing may be rigid or flexible, however, length should be as short as possible to reduce heat losses. The pump packing should be nonoxidizable material, such as, Teflon.
(3)
After cleaning, disconnect lines and drain tube. Flush tube with cold tap water until distinctive color of cleaning solution disappears.
CAUTION: DO NOT MIX CLEANING AGENT AND STAIN REMOVER. KEEP TANKS SEPARATED. (4) To remove cleaning solution stain on the internal surface of the tube when using one of the alkaline permanganate solutions in Subtask 70-22-05-110-172, Materials, pump a second solution, oxalic acid C04-099 through the tube for 2-3 minutes at room temperature. Use oxalic acid C04-099 mixed 0.75 pounds/gallon (90 grams/ liter) with tap water at room temperature. NOTE: Hoses may be used with the stain remover solution. Various plastics and elastomers are compatible with this material.
STANDARD PRACTICES MANUAL AS907-1-1A (5) (6) (7) Disconnect lines and drain tube. Flush with cold tap water until the effluent water has the same acidity as the inlet water (use indicator paper). Disconnect lines, drain tube and dry with clean shop air. Procedure may be repeated.
SPECIAL CLEANING NO. 6 - SPECIAL CLEANING PROCEDURE NO. 6 - BOLTHOLE CLEANING FOR EDDY CURRENT INSPECTION TASK 70-22-06-110-043 1. Special Cleaning Procedure No. 6 - Bolthole Cleaning for Eddy Current Inspection SUBTASK 70-22-06-99G-043 A. General. (1) Two bolt hole cleaning methods are given in this procedure, Method A: ScotchBrite Cleaning, and Method B: Flex-Hone Cleaning. Method A is the initial cleaning method recommended prior to or during Eddy Current Inspection. Method B is to be used only when the repeated use of Method A fails to reduce indications below the reject threshold.
SUBTASK 70-22-06-110-431 B. Equipment. (1) The equipment necessary to do this process is as follows. (a) (b) (c) 0.375 in. (9.5 mm) variable speed drill, 0.33 hp electric drill, or equivalent. 2.0 in. (50.8 mm) nylon screws with a diameter of 0.15 in. (3.8 mm), or a nonmetallic equivalent. 1.2 in. (31 mm) OD washers with a 0.35 in. (8.9 mm) ID and 0.050 in. (1.27 mm) thick, or nonmetallic equivalent.
SUBTASK 70-22-06-110-432 C. Materials. No. C04-001 C04-003 C04-004 C04-014 C10-010 C10-108 C10-173 C10-164,C10-165,C10-168, and C10-172
Consumable Product A. Solvent
B. Scotch Brite pads C. Bristle brush D. Cotton swabs or equivalent E. Stainless Steel Brush F. 120 Grit Silicon Carbide Flex-Hone
EFFECTIVITY: ALL
70-22-06
SPECIAL CLEANING PROCEDURE NO. 6 - BOLTHOLE CLEANING FOR EDDY CURRENT INSPECTION Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-22-06-110-433 D. Method A: Scotch Brite Cleaning. (1) Prepare the cleaning tool as follows. Refer to Figure 1, steps 1-5. (a) (b) (c) (d) (e) (2) Cut the head off the nylon screw. Cut a strip of Scotch Brite C10-010 about 0.5 in. (13 mm) wide by 4.0 in. (102 mm) long. Fold the Scotch Brite over the nylon screw. Insert the flap ends into the drill chuck until 1.5 in. (38 mm) is exposed. Tighten the drill chuck. Place the washer over the screw and seat it against the chuck.
Clean the boltholes as follows. Refer to Figure 1, step 6. (a) Align the drill so that the nylon screw/pad is in line with the bolthole. Start the drill and insert into the hole. NOTE: For the Scotch Brite to be effective, the rotation speed of the drill should not exceed 2500 rpm. (b) Move the pad in and out of the hole until all scale and deposits are removed. Be sure that the nylon screw/pad stays aligned at 90 degrees to the entry surface. NOTE: If the bolthole length is greater than the nylon screw/pad, clean the hole from each end. (c) Clean each bolthole and replace the Scotch Brite pad as necessary. NOTE: In severe cases, it is not uncommon to replace the pad every other bolthole. (d) After cleaning each hole with the Scotch Brite, clean each bolthole with a cotton swab or bristle brush C10-108 and solvent.
SUBTASK 70-22-06-110-434 E. Method B: Flex-Hone Cleaning. NOTE: Flex-Hone is to be used only when a repeated use of Method A fails to clean up the bolt hole. (1) (2) (3) Select the correct Flex-Hone size for the hole to be cleaned. Refer to table 1, Page 3. Cut the Flex-Hone so that there is approximately a 3.0 in. (76 mm) shaft beyond the brush. Insert the Flex-Hone shaft into the drill chuck and tighten.
EFFECTIVITY: ALL
70-22-06
STANDARD PRACTICES MANUAL AS907-1-1A (4) Clean the bolt hole to remove all oil, dirt, etc. Use a cotton swab and an approved solvent to clean the bolt hole.
CAUTION: ONLY ONE FLEX-HONE IS TO BE USED PER HOLE. THIS IS VERY IMPORTANT. (5) Align the drill so that the Flex-Hone is in line with the bolt hole and perpendicular to the entry surface. Start the drill and insert into the hole. Clean the entire hole by moving the Flex-Hone up and down in the hole for 30 seconds. Avoid concentrating on a specific area. NOTE: The recommended drill speed for Flex-Hone is 500-1200 rpm and is not to be used with air or high speed. NOTE: Make sure the Flex-Hone is rotating upon entry and removal from the bolt hole. (6) (7) Remove any abrasive residue in the bolt hole using a cotton swab and an approved solvent. Honing process may be repeated, at 30 second intervals, for a maximum of 4 minutes per bolt hole. NOTE: Clean the Flex-Hone between each 30 second interval by passing the stainless steel brush C10-173 over the Flex-Hone for approximately 10 seconds while it is rotating in the drill. Table 1. Flex-Hone Sizes Bolt Hole Size .245"-.255" .295"-.302" .309"-.318" .312"-.319" .329"-.338" .331"-.338" .336"-.345" .338"-.345" .396"-.403" Flex-Hone Part Number BC 6.4MM (.250") BC 8MM (.315") BC 8MM (.315") BC 8MM (.315") BC 9MM (.354") BC 9MM (.354") BC 9MM (.354") BC 9MM (.354") BC 10MM (.394") Consumable No. C10-164 C10-165 C10-165 C10-165 C10-168 C10-168 C10-168 C10-168 C10-172
EFFECTIVITY: ALL
70-22-06
EFFECTIVITY: ALL
70-22-06
SPECIAL CLEANING NO. 9 - SPECIAL CLEANING PROCEDURE NO. 9 FLUORESCENT PENETRANT REMOVAL BETWEEN SPECIAL REPETITIVE FLUORESCENT PENETRANT INSPECTIONS TASK 70-22-09-110-049 1. Special Cleaning Procedure No. 9 - Fluorescent Penetrant Removal Between Special Repetitive Fluorescent Penetrant Inspections SUBTASK 70-22-09-99G-049 A. General. (1) The cleaning methods described in this procedure are effective in removing fluorescent penetrant residue from components. This is to make sure the second FPI procedure, in a double FPI process, is started with a part that is free of FPI residue from the first FPI inspection. This method is designed to remove penetrant, not only from the component surfaces, but also from cracks, pits, or other anomalies present in the part at the time of inspection. The procedure has two interchangeable methods. Method 1 is a hydrophylic remover scrub followed by a room temperature soak in a solvent material. Refer to Subtask 70-22-09-110-493, Method 1: Cold Soak Procedure. Method 2 is a hydrophylic remover scrub followed by an elevated temperature water based cleaning procedure. Either procedure may be used. Refer to Subtask 70-22-09-110494, Method 2: Hot Tank Procedure. If alternates for the materials listed in this procedure are desired, it must be demonstrated that the materials/ processes used are effective in removing penetrant residue from sample cracks. Acceptability of alternate materials should be validated using the GE P/N 2C8095 LCF Block Known Defect Test Specimens only. The validation test should demonstrate that the materials and processes used will remove all traces of the FPI penetrant from all cracks in the block set.
(2)
(3)
(4)
SUBTASK 70-22-09-110-491 B. Equipment. (1) Equipment needed for Subtask 70-22-09-110-493, Method 1: Cold Soak Procedure. Nylon or fiber bristle bushes of various shapes. Water rinse by tank or spray. Oven capable of 1408F (608C) minimum. A steel or stainless steel tank suitable for holding the cold solvent material, and large enough for the part to be processed is necessary. It is recommended, but not required, that the tank have a filtration method and a removable cover.
(2)
Equipment needed for Subtask 70-22-09-110-494, Method 2: Hot Tank Procedure. Nylon or fiber bristle bushes of various shapes.
SPECIAL CLEANING PROCEDURE NO. 9 FLUORESCENT PENETRANT REMOVAL BETWEEN SPECIAL REPETITIVE FLUORESCENT PENETRANT INSPECTIONS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A Water rinse by tank or spray. Equipment as required per TASK 70-21-22-110-042, Cleaning Method No. 22 Light Duty Aqueous Cleaning. Oven capable of 1408F (608C) minimum.
SUBTASK 70-22-09-110-492 C. Materials. (1) (2) (3) Light Duty Cleaning Solution. See Subtask 70-21-22-110-422 in TASK 70-21-22-110042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning - Method 1. Solvent Cold Soak. See TASK 70-21-01-110-001, Cleaning Method No. 1 - Solvent Degreasing. Hydrophilic Remover. Refer to approved penetrant systems per MIL-L-23135 QPL. See TASK 70-32-02-230-001, Fluorescent-Penetrant Inspection, Class G.
SUBTASK 70-22-09-110-493 D. Method 1: Cold Soak Procedure. (1) After completion of the first FPI procedure, clean the part with hydrophylic remover. The remover concentration is to be 100 percent concentrated or a 20 percent V/V solution of hydrophylic remover in water. Use nylon or natural fiber bristle brushes for cleaning. Clean all the surfaces of the part paying particular attention to any special areas identified by the inspection procedure in the applicable manual. Use small brushes as necessary to make sure the surface and small recessed areas in the part are correctly cleaned. After all areas of the part have been cleaned, rinse the part with water. Make sure all hydrophylic remover is removed from the surface of the part. WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG (206 KPA). WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS.
(2)
WARNING:
(3) (4) (5)
Using clean, filtered shop air, suction device or clean paper or cloth blotters, remove excess water from the surfaces, holes, and cavities of the part. Dry the part thoroughly at elevated temperature to make sure there is no moisture remaining on the part. Use a minimum temperature of 1408F (608C) to dry the part. Place the part in a tank containing one of the materials listed in Subtask 70-22-09110-492, Materials. Soak as follows: (a) For Solution S1147: soak for a minimum of 4 hours.
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG (206 KPA). WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS.
(6) (7)
Remove the part from the tank and dry. Drying may be expedited using an oven, or clean, filtered shop air on the surface of the part. Proceed to the next step. If the next step is FPI, make sure the part is clean and dry. If the part is to be stored for a period of time before it is inspected, cover the part to protect all the surfaces from dirt and moisture.
SUBTASK 70-22-09-110-494 E. Method 2: Hot Tank Procedure. (1) After completion of the first FPI procedure, clean the part with hydrophylic remover. The remover concentration is to be 100 percent concentrated or a 20 percent V/V solution of hydrophylic remover in water. Use nylon or natural fiber bristle brushes for cleaning. Clean all the surfaces of the part paying particular attention to any special areas identified by the inspection procedure in the applicable manual. Use small brushes as necessary to make sure the surface and small recessed areas in the part are correctly cleaned. After all the areas of the part have been cleaned, rinse the part with water. Place part into a tank containing one of the water based cleaning materials listed in Subtask 70-22-09-110-492, Materials. Refer to TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning - Method 1, for materials and process instructions. Make sure the bath is operating within the correct temperature range and that there is good agitation of the bath. Soak the part in the tank for a minimum of one hour. After the tank soak, rinse in accordance with TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning. Proceed to the next step. If the next step is FPI, dry part thoroughly at elevated temperature to make sure there is no moisture on the part. Use a minimum temperature of 1408F (608C) to dry the part. If the part is to be stored for a period of time before it is inspected, cover the part to protect all the surfaces from dirt and moisture.
(2) (3)
(4)
SUBTASK 70-22-09-110-495 F. Quality Assurance. (1) Examine the cleaned part under UV light in a darkened environment. Inspect for evidence of remaining fluorescent penetrant. If fluorescent penetrant is present, repeat the process on the part until the fluorescent penetrant is completely removed.
CLEANING METHOD - CLEANING METHOD FOR CLEANING OF BOLTS, SCREWS, AND SHOULDERED STUDS TASK 70-22-10-120-001 1. Cleaning Method for Cleaning of Bolts, Screws, and Shouldered Studs SUBTASK 70-22-10-99G-001 A. General. (1) Serviced induced oxides, assembly coatings, and other contaminants prevent inspection for reuse without effective cleaning methods to remove these surface contaminants. Unless applicable standard practices manuals, service bulletins, or repair procedures specify otherwise, fasteners removed from an engine may be cleaned for inspection by these methods. Inspection will be visual with a 10x binocular microscope on the washer face and threaded root areas for cracks and thread damage. Fasteners are to be kept as an engine set so if a crack is detected, all remaining fasteners from that set or common joint are discarded. The cleaning method used must remove all contaminants and not alter the torque tension characteristics of the fastener system.
SUBTASK 70-22-10-120-001 B. Tools, Equipment, and Materials. (1) The following equipment is required for the application of this process. Other equipment required will be specified in each particular process required to attain an inspectable surface. Dry blast cabinet series BNP 50, 65 or 220-30 series system fitted with tumble basket system 603-6 or 603-7 specifying a #404-267 tumble basket ( Figure 1, Page 2). The cabinet is available from Clemco Industries. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. Mini-tumble blast cabinet model DCM-161 fitted with suitable filtration system conforming to local waste system regulations ( Figure 2, Page 3). The cabinet is available from Clemco Industries. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. Vibratory Mill (Sweco or equivalent). Wet blast equipment. 10x binocular microscope.
(2)
Consumable Materials: C04-223 Tacks, No. 3 Blued Cut, for cleaning. C04-040 Compound Cleaner, for cleaning. C04-117 Fruit Stones, for cleaning.
EFFECTIVITY: ALL
70-22-10
CLEANING METHOD FOR CLEANING OF BOLTS, SCREWS, AND SHOULDERED STUDS Page 1 Dec 01/03
Dry Blast Cabinet System fitted with Tumble Basket System Figure 1
EFFECTIVITY: ALL
70-22-10
Mini -Tumble Blast Cabinet Figure 2
EFFECTIVITY: ALL
70-22-10
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-22-10-120-002 C. Procedures Referenced in Document. (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) TASK 70-21-03-160-001, Steam Cleaning. TASK 70-21-04-120-004, Dry Abrasive Blast Cleaning, Method 4C. TASK 70-21-04-120-006, Dry Abrasive Blast Cleaning, Method 4E. TASK 70-21-05-120-003, Wet Abrasive Blast Cleaning, Method 5A. TASK 70-21-06-110-004, Cleaning Method 6, Heavy-Duty Alkaline Cleaner (without inhibited phosphoric acid). TASK 70-21-07-110-005, Cleaning Method 7, Three-Step Heavy- Duty Alkaline Descaling (without inhibited phosphoric acid). TASK 70-21-09-110-007, Cleaning Method 9, Light-Duty Alkaline Cleaning of Titanium Alloys. TASK 70-21-10-110-008, Cleaning Method 10, Four-Step Alkaline Cleaning and Acidic Descaling (without inhibited phosphoric acid). TASK 70-21-20-110-038, Cleaning Method 20, Four-Step Alkaline Cleaning and Acidic Descaling (with inhibited phosphoric acid). TASK 70-24-02-110-035, Dip Etching Procedure. TASK 70-32-02-230-001, Fluorescent Penetrant Inspection. TASK 70-23-25-110-001, Stripping Nickel and Silver Plate.
SUBTASK 70-22-10-120-003 D. Procedure. (1) (2) Remove all nuts, cotter pins, washers and lockwire from bolts, and discard as instructed. Clean externally threaded fasteners as follows: (a) (b) Nitric acid strip for 5 minutes, per TASK 70-23-25-110-001, Stripping Nickel and Silver Plate, to remove coating deposits. For fasteners without scale, clean per one of the following: TASK 70-21-03-160-001, Steam Cleaning, TASK 70-21-06-110-004, Cleaning Method 6, Heavy-Duty Alkaline Cleaner (without inhibited phosphoric acid), or TASK 70-21-07-110-005, Cleaning Method 7, Three-Step Heavy-Duty Alkaline Descaling (without inhibited phosphoric acid).
EFFECTIVITY: ALL
70-22-10
STANDARD PRACTICES MANUAL AS907-1-1A (c) Alternative procedure available. If there is scale on the parts, clean per TASK 70-21-20-110-038, Cleaning Method 20, Four-Step Alkaline Cleaning and Acidic Descaling (with inhibited phosphoric acid). NOTE: Use either Cleaning Method 10 or 20 depending on the surface condition of the fasteners. (d) Alternative procedure. If there is scale on the parts, clean per TASK 70-2110-110-008, Cleaning Method 10, Four-Step Alkaline Cleaning and Acidic Descaling (without inhibited phosphoric acid).
CAUTION: THE USE OF TITANIUM CLEANERS REFERENCED IN CLEANING METHOD 9, MAY RESULT IN ATTACK OF ALUMINUM PARTS IN THE VIBRATORY MILL MACHINERY. (e) Alternative procedures available. Vibratory mill (Sweco or equivalent) 1 hour with No. 3 upholstery tacks, and compound cleaner C04-040 or titanium cleaners listed in TASK 70-21-09-110-007, Cleaning Method 9, Light-Duty Alkaline Cleaning of Titanium Alloys. Concentration should be sufficient to wet parts. Use concentration of 40 oz/gal. Alternative procedure. Vibratory mill (Sweco or equivalent) 1-2 hours dry with 80-85% No. 3 upholstery tacks, and 15-20% ground fruitstones C04-117. Alternative procedure. Wet abrasive blast per TASK 70-21-05-120-003, Wet Abrasive Blast Cleaning, Method 5A. Alternative procedure. Dry abrasive blast per TASK 70-21-04-120-004, Dry Abrasive Blast Cleaning, Method 4C. See Figure 1 and Figure 2. Alternative procedure. Plastic media blast per TASK 70-21-04-120-006, Dry Abrasive Blast Cleaning, Method 4E. Nitric acid strip per TASK 70-23-25-110-001, Stripping Nickel and Silver Plate, to remove tack residue if tack cleaning was used.
(f) (g) (h) (i) (j) (3) (4)
Alternative procedure available. Visually inspect with 10x binocular microscope. Alternative procedure. FPI inspection. (a) (b) (c) (d) Etch per TASK 70-24-02-110-035, Dip Etching Procedure, Class G. Hot water rinse the parts. Dry the parts. FPI etch per TASK 70-32-02-230-001, Fluorescent Penetrant Inspection, Class G.
SUBTASK 70-22-10-120-004 E. Quality Assurance. (1) All parts after clean/inspect must meet applicable manual limits.
EFFECTIVITY: ALL
70-22-10
STANDARD PRACTICES MANUAL AS907-1-1A (2) (3) (4) (5) Visually check for the removal of all traces of oxides and coatings from the threaded areas, and washer face, without attack of parent material. Ensure that the periodic checks are made of solution contents and operating parameters, per the solution sheets. Any fasteners with damaged threads must be discarded. This procedure does not allow the reuse or cleaning of lock washers, tab washers, cotter pins or spring washers.
EFFECTIVITY: ALL
70-22-10
STRIPPING PROCEDURES - STRIPPING PROCEDURES TASK 70-23-00-100-001 1. Stripping Procedures SUBTASK 70-23-00-99G-001 A. General. (1) When necessary to remove surface coatings to permit inspection or repair, the methods described in the following procedures are recommended. Parts or components must be cleaned in accordance with the appropriate cleaning method referenced in the procedures, to permit uniform stripping action. Some materials or solutions used in paint stripping are similar to cleaning solutions; these are included to prevent use of cleaning solutions for paint stripping, which would rapidly impair their use as cleaners. Stripping solutions, generally, contain caustic and other compounds which can destroy aquatic life when released into natural waterways. Provisions for treatment or isolated disposal of waste should be incorporated into the drainage systems for all such effluents.
SUBTASK 70-23-00-110-001 B. Metal Sprayed Coatings. (1) Various metal sprayed coatings are applied to engine parts during initial manufacture and/or as a method of repair. Before stripping coatings from specific areas, the presence of coatings in other areas should be ascertained. If present, the part should be masked to prevent the indiscriminate removal of such coatings. The part is to be masked as directed by the repair procedure for the specific part, or as stated in the particular stripping procedure.
EFFECTIVITY: ALL
70-23-00
STRIPPING PROCEDURES Page 1 Dec 01/03
EFFECTIVITY: ALL
70-23-00
STRIPPING PROCEDURES Page 2 Dec 01/03
STRIPPING METHOD NO. 1 - STRIPPING METHOD NO. 1 STRIPPING EPOXY, POLYSULFIDE, AND POLYURETHANE PAINT SYSTEMS (HOT TANK METHOD) TASK 70-23-01-110-018 1. Stripping Method No. 1 - Stripping Epoxy, Polysulfide, and Polyurethane Paint Systems (Hot Tank Method) SUBTASK 70-23-01-99G-018 A. General. (1) This procedure describes the method and materials required for the removal/ stripping of epoxy, polysulfide, and polyurethane paint systems. This procedure may be used to remove these paint systems from steel, nickel bases, aluminum, cobalt, titanium, and magnesium.
SUBTASK 70-23-01-110-181 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops including: 1 2 3 4 Eye baths. Emergency showers. Means for neutralizing strong acid and alkaline solutions if splashed. Protective clothing. NOTE: Use of a face shield or goggles, rubber gloves, and other protective clothing is recommended to avoid skin or eye contact. (b) (c) (d) (e) (f) Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline cleaning tank capable of heating the solution to 2308F (1108C). A water rinse tank made from either stainless steel or carbon steel with a polypropylene liner. A pressure wash gun using pressurized water only or a water/air mixture for rinsing the part.
EFFECTIVITY: ALL
70-23-01
STRIPPING METHOD NO. 1 STRIPPING EPOXY, POLYSULFIDE, AND POLYURETHANE PAINT SYSTEMS (HOT TANK METHOD) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-23-01-110-182 C. Materials. Table 1. Solutions for Removing Paint Solution Cee-Bee A-477 Ardrox 2302 MagChem Kemstrip 596 Turco 5668 No. S1160 S1187 S1155 S1171 Operating Temperature 8F (8C) 160-212 (70-100) 176-230 (80-110) 175-230 (80-110) 160-180 (71-82)
Table 2. Pre-rinse Solution for Ardrox 2303 Material Ardrox 6333 Ardrox 1900B Ardrox 6025 SUBTASK 70-23-01-110-183 D. Procedure. WARNING: THIS PROCEDURE USES A STRONG ALKALINE SOLUTION. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAN RESULT IN SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITIES OF WATER. AVOID BREATHING VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES. Consumable No. C04-163 C04-210 C04-249 Operating Temperature 8F (8C) Ambient Ambient Ambient
(1)
Degrease parts per TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning, or TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning, to remove oils and light soils before immersion in the paint stripping solution.
CAUTION: PARTS MUST BE FREE OF MOISTURE BEFORE IMMERSION IN THE CLEANER OR DAMAGE TO THE SUBSTRATE MAY RESULT. (2) Immerse parts slowly into one of the solutions listed in Table 1, Page 2 in Subtask 70-23-01-110-182, Materials. (a) Ensure that the part is fully immersed into the lower layer and soak. NOTE: Total immersion time should be 1-2 hours. Parts can be raised out of the solution and lightly brushed during this time to speed paint removal.
EFFECTIVITY: ALL
70-23-01
STANDARD PRACTICES MANUAL AS907-1-1A (3) Drain the part over the stripping tank to allow the excess remover to drain back into the tank.
CAUTION: WATER RINSE MUST BE PERFORMED AWAY FROM THE STRIPPING TANK TO AVOID CONTAMINATION OF THE TANK WITH WATER. (4) If using Ardrox 2302, immerse components in a 10% V/V aqueous solution of one of the materials listed in Table 2, Page 2, Subtask 70-21-08-110-063, Materials. This will reduce vapors and facilitate subsequent pressure rinsing. NOTE: Follow the manufacturers recommendations for maintenance and replenishment of this solution. (5) Immerse the part in the water rinse tank at room temperature. (a) (b) (6) (7) Rinse the part with the water/air spray gun over the water rinse tank. Scrub the part with the soft bristle brush if necessary to remove residual paint.
Dry the part using clean dry air. Apply rust preventative as necessary.
SUBTASK 70-23-01-110-184 E. Quality Assurance. (1) (2) Visually check for the complete removal of all paint residues. Maintain stripping solutions in accordance with the solution sheets.
EFFECTIVITY: ALL
70-23-01
EFFECTIVITY: ALL
70-23-01
STRIPPING METHOD NO. 2 - STRIPPING METHOD NO. 2 STRIPPING SERMETEL W PAINT TASK 70-23-02-110-019 1. Stripping Method No. 2 Stripping Sermetel W Paint SUBTASK 70-23-02-99G-019 A. General. (1) The following method provides an effective way of removing SermeTel "W" paint to permit subsequent inspection or refinishing. If it is necessary to strip SermeTel "W" from a part, use the following procedure. NOTE: Because paint residue forms a sludge that reduces the effectiveness of the solution, facilities used for paint stripping should be different from those used for general cleaning. SUBTASK 70-23-02-110-191 B. Materials. (1) Refer to Consumable listing Section TASK 70-21-06-110-004, Cleaning Method No. 6 - Heavy-Duty Alkaline Cleaner (Without Inhibited Phosphoric Acid).
SUBTASK 70-23-02-110-192 C. Procedure. (1) Use the following procedure in conjunction with the materials mentioned. (a) Vapor degrease part as directed in TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, or steam clean. SERMETEL "W" CONTAINS ALUMINUM PARTICLES IN THE 5 TO 10 MICRON RANGE, WHICH REACT LIKE PURE ALUMINUM POWDER IN THE DRY STATE, FORMING EXPLOSIVE MIXTURES WHEN DISPERSED IN AIR. SERMETEL "W" ALSO REACTS WITH ALKALINE SOLUTIONS AND MANY ACIDS TO LIBERATE HYDROGEN, WHICH FORMS EXPLOSIVE MIXTURES WITH AIR. BE SURE THAT CLEANING TANKS ARE THOROUGHLY VENTILATED BY A FORCED-AIR EXHAUST SYSTEM WHEN PROCESSING SERMETEL-COATED PARTS.
WARNING:
(b) (c) (d) (e)
Immerse part for 15-60 minutes in alkaline solution. Rinse by immersion in clear water at 140-1808F (60-828C) for five minutes. Pressure-rinse, using steam or an air-water spray at 1408F (608C) minimum. Blow dry with clean, dry shop air.
EFFECTIVITY: ALL
70-23-02
STRIPPING METHOD NO. 2 STRIPPING SERMETEL W PAINT Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (f) Apply preservative as required.
SUBTASK 70-23-02-110-193 D. Control of Solution. CAUTION: BE SURE TO CHECK ENVIRONMENTAL REGULATIONS BEFORE DISCARDING SOLUTIONS. (1) Maintain water level. When stripping time exceeds 60 minutes, discard the solution.
EFFECTIVITY: ALL
70-23-02
STRIPPING METHOD NO. 2 STRIPPING SERMETEL W PAINT Page 2 Dec 01/03
STRIPPING SILVER PLATE - STRIPPING SILVER PLATE (ELECTROLYTIC METHOD) TASK 70-23-03-110-020 1. Stripping Silver Plate (Electrolytic Method) SUBTASK 70-23-03-99G-020 A. General. (1) The following method is an effective way of removing the silver plate from a part for subsequent inspection or replating.
SUBTASK 70-23-03-110-201 B. Equipment. (1) The following equipment is required: (a) (b) Current source: 4-6 volts, DC. Electrode: stainless steel
SUBTASK 70-23-03-110-202 C. Materials. (1) The following materials are required for electrolytically stripping silver plating from parts; (a) Prepare an electrolytic stripping solution as follows: 1 Fill tank to 60-70 percent of operating level with tap water. ALL CYANIDES ARE EXTREMELY POISONOUS, AND REACT WITH ACIDS TO RELEASE DEADLY HYDROGEN CYANIDE GAS. WEAR FACE SHIELD, RUBBER GLOVES AND APRON, AND USE ONLY IN AN AREA VENTILATED BY A POWER-DRIVEN EXHAUST FAN. WASH HANDS, FACE, AND OTHER EXPOSED SKIN AREAS THOROUGHLY AFTER REMOVAL OF PROTECTIVE WEAR AND BEFORE EATING OR SMOKING.
WARNING:
2 3 4
Add 10-12 ounces of sodium cyanide per gallon of tap water (75-90 grams per liter). Stir thoroughly to mix. Add sodium hydroxide as required to obtain alkalinity of pH 12. When solution has cooled to room temperature, add a measured quantity of water to bring volume of tank to operating level. Adjust concentration and pH by adding 10-12 ounces of sodium cyanide per additional gallon of water, and sodium hydroxide to obtain pH 12.
EFFECTIVITY: ALL
70-23-03
STRIPPING SILVER PLATE (ELECTROLYTIC METHOD) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (b) The following equipment is required: 1 2 Current source: 4-6 volts, dc. Electrode: stainless steel
SUBTASK 70-23-03-110-203 D. Procedure. (1) Strip silver plating, using the materials and equipment specified, according to the following procedure: (a) Attach a wire from the current source to the part, so that the part is made the anode (+ electrode). Connect the stainless steel electrode to the current supply so that it is made the cathode (- electrode). Immerse the part in the stripping solution and apply 4-6 volts, dc, until all plating is removed. Turn off current, withdraw part from tank, and rinse thoroughly with clean tap water.
(b) (c)
CAUTION: MOST LOCAL SEWAGE DISPOSAL REGULATIONS PROHIBIT THE DISCHARGE OF TOXIC WASTES INTO NATURAL WATERWAYS. MAKE SURE THAT USED STRIPPING SOLUTION IS THOROUGHLY OXIDIZED AND NEUTRALIZED, OR OTHERWISE RENDERED HARMLESS, BEFORE DISPOSAL. (d) Obey the instructions from all the applicable authorities when you discard materials.
EFFECTIVITY: ALL
70-23-03
STRIPPING SILVER PLATE (ELECTROLYTIC METHOD) Page 2 Dec 01/03
STRIPPING NICKEL AND SILVER PLATE - STRIPPING NICKEL AND SILVER PLATE (CHEMICAL SOLUTIONS) TASK 70-23-04-110-021 1. Stripping Nickel and Silver Plate (Chemical Solutions) NOTE: TASK 70-23-25-110-001, Stripping Nickel and Silver Plate, is the recommended alternative to remove nickel or silver plate from austenitic alloys, nickel based alloys, stainless, and titanium parts for subsequent inspection or replating. SUBTASK 70-23-04-99G-021 A. General. CAUTION: SOME ATTACK MAY BE EXPERIENCED ON CERTAIN HIGH ALLOY AND CAST IRONS AND ON SOME CASE-HARDENED AND NITRIDED ALLOYS. (1) The following method is an effective way to remove nickel or silver plate from a part for subsequent inspection or replating.
SUBTASK 70-23-04-110-001 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline stripping tank made from stainless steel with a heating coil that is capable of heating the solution to 1308F (558C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and an air/water spray gun.
(b) (c) (d) (e)
SUBTASK 70-23-04-110-002 C. Materials. Table 1. Plating Remover Solution for Nickel Plate Solution Metex Strip Aid Enstrip S
EFFECTIVITY: ALL
No. S0005 S1188
Operating 8F (8C) 68-130 (20-55) 68-130 (20-55)
70-23-04
STRIPPING NICKEL AND SILVER PLATE (CHEMICAL SOLUTIONS) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-23-04-110-003 D. Procedure. WARNING: THE STRIPPING SOLUTION CONTAINS SODIUM CYANIDE, WHICH IS EXTREMELY POISONOUS, AND WHICH REACTS WITH ACIDS TO FORM DEADLY HYDROGEN CYANIDE GAS. WEAR FACE SHIELD, RUBBER GLOVES AND APRON, AND USE ONLY IN AN AREA VENTILATED BY A POWER-DRIVEN EXHAUST FAN. WASH HANDS, FACE, AND OTHER EXPOSED SKIN AREAS THOROUGHLY AFTER REMOVAL OF PROTECTIVE CLOTHING AND BEFORE EATING OR SMOKING.
(1)
Immerse part in one of the plating remover solutions listed in Table 1, Page 1 until all plating is removed. Solution temperature to be 68 to 1308F (20-558C) with 1208F (498C) optimum for effective removal rate. NOTE: Thermal sprayed parts which may be stripped of plating should have the sprayed coating removed first, or assure that the sprayed coating will not be affected by the stripping solution.
(2) (3)
Rinse in clear tap water; dry. Apply preservative as required.
SUBTASK 70-23-04-110-004 E. Quality Assurance. (1) (2) Visually check for the complete removal of plate. Maintain stripping solutions in accordance with the solution sheets.
EFFECTIVITY: ALL
70-23-04
STRIPPING NICKEL AND SILVER PLATE (CHEMICAL SOLUTIONS) Page 2 Dec 01/03
STRIPPING CHROMIUM PLATE - STRIPPING CHROMIUM PLATE TASK 70-23-05-330-001 1. Stripping Chromium Plate - Method No. 1 (Chemical Method) SUBTASK 70-23-05-99G-998 A. General. (1) Chromium plate can be stripped from iron, nickel and cobalt base superalloys by chemical or electrolytic stripping. The chemical solution is described here. Method 2 (Electrolytic) should be used to strip chrome plate from low alloy steels. Before stripping chrome plate, check the applicable manual to make sure that proper method is selected. If there is no listing of preferred method, either TASK 70-23-05-330-001, Stripping Chromium Plate - Method No. 1, or TASK 70-23-05-330002, Stripping Chromium Plate - Method No. 2, may be used.
(2)
SUBTASK 70-23-05-330-011 B. Equipment. (1) (2) (3) Rubber lined tank for acid. Exhaust hood to remove fumes over acid. Water rinse tank (plastic coated or lined).
SUBTASK 70-23-05-330-012 C. Materials. (1) Refer to TASK 70-00-99-800-006, Solution S0006.
SUBTASK 70-23-05-330-013 D. Procedure. (1) Using the materials specified, strip the chromium plating as follows: (a) Degrease parts per TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, or TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning. Mask all areas not to be stripped because selective attack may occur.
(b)
EFFECTIVITY: ALL
70-23-05
STRIPPING CHROMIUM PLATE Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: THIS IS STRONG ACID. WEAR FACE SHIELD AND PROTECTIVE CLOTHING. IF SOLUTION CONTACTS SKIN OR EYES, FLUSH IMMEDIATELY WITH CLEAR WATER AND OBTAIN MEDICAL AID.
(c)
Immerse parts in stripping bath at room temperature until chromium plate is removed. Approximate removal rate is 0.0015 inch (0.038 mm) per hour. NOTE: Chromium plate turns dark-grey to black. When removed, the base metal color is apparent.
(d) (e) (f) (g) TASK 70-23-05-330-002 2.
Remove masking. Water rinse. Blow dry with clean shop air. Apply rust preventative, if required, as specified by the applicable manual.
Stripping Chromium Plate - Method No. 2 (Electrolytic Method) SUBTASK 70-23-05-99G-014 A. General. (1) (2) Chromium plate can be stripped from iron, nickel, and cobalt base alloys using an alkaline, electrolytic stripping process. This process is described here. This process must be used for stripping chromium from low alloys steels. The chemical method described in TASK 70-23-05-330-001, Stripping Chromium Plate Method No. 1, will attack low alloy steel materials. Before stripping chrome plate, check applicable engine manual to make sure that proper method is selected. If there is no listing of preferred method, either TASK 70-23-05-330-001, Stripping Chromium Plate - Method No. 1, or TASK 70-23-05-330002, Stripping Chromium Plate - Method No. 2, may be used. This method is not preferred for use on nickel base alloys Lack of process control and process monitoring can lead to base metal damage. Method 1, the chemical method, is preferred for nickel base alloys. If this method (method 2) is used for nickel base alloys, it should be closely supervised to limit part exposure to the process solution for the time only as necessary to remove the chrome plate.
(3)
(4)
SUBTASK 70-23-05-330-015 B. Equipment. (1) The following equipment is required: Tank and heater: steel Electrode: steel Current source capability: 6 - 12 volts, 125 - 325 amperes per square foot (ASF).
EFFECTIVITY: ALL
70-23-05
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-23-05-330-016 C. Materials. (1) Refer to TASK 70-00-99-800-007, Solution S0007.
SUBTASK 70-23-05-330-017 D. Procedure. (1) Using the materials and equipment specified, strip chromium plating as follows: (a) Degrease parts per TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, or TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning. THIS ELECTROLYTE IS STRONGLY ALKALINE. WEAR FACE SHIELD AND PROTECTIVE CLOTHING. IF SALT OR ELECTROLYTE SOLUTION CONTACTS THE SKIN OR EYES, FLUSH EXPOSED AREAS THOROUGHLY WITH COOL WATER AND SEEK IMMEDIATE MEDICAL AID.
WARNING:
(b)
Mask all areas that are not going to be stripped because selective attack may occur. Low alloy steels do not require masking although masking of the air/ liquid interface (if the part is only partially submerged) is recommended. Make sure cathode to anode area ratio is 3 to 1 or greater and that cathode to anode shape and distance is appropriate for geometry and part configuration. Connect a wire from the current source to the part, so that the part is made the anode. Connect another wire to the electrode(s) that are to be made the cathodes. Immerse both the part (anode) and electrode(s) in the stripping solution. Operate the system at 6V with workpiece anodic at 50 to 75 amps per square foot (ASF). Periodically check the part in the stripping bath to monitor the progress of the stripping operation. The stripping rate on the part surface can be uneven due to variation in current densities. Areas of high current density will strip faster. Check high current density areas (such as maskant/part surface interfaces) for plating removal. It may be necessary to use thieves to balance the current density in the area being stripped. Check stripping operation periodically to ensure that all gas being liberated is being vented. Do not allow gas to be trapped on an active surface (nonmasked surface) as the gas/liquid interface can create a potential base metal attack site. Strip until existing chrome plate is removed. Stripping time can be estimated at removal rate of 0.001 inch chrome (0.03 mm) in approximately 20-30 minutes when the bath is operated at 120 degrees F (approximately 50 degrees C) and 75 ASF. Water rinse.
(c)
(d)
(e)
(f)
(g)
(h)
EFFECTIVITY: ALL
70-23-05
STANDARD PRACTICES MANUAL AS907-1-1A (i) (j) (k) Remove masking and clean part. Blow dry with shop air. Apply rust preventative, if required, as directed by the applicable manual.
EFFECTIVITY: ALL
70-23-05
STRIPPING SILVER THERMAL SPRAY - STRIPPING SILVER THERMAL SPRAY FROM STATIONARY AIR AND OIL SEALS TASK 70-23-06-110-022 1. Stripping Silver Thermal Spray From Stationary Air and Oil-Seals SUBTASK 70-23-06-99G-022 A. General. (1) Thermal sprayed silver coatings may be removed from stationary air and oil seals by machining or by chemical means. This procedure describes the materials and processes to be used for the chemical stripping operation.
SUBTASK 70-23-06-110-221 B. Materials. (1) (2) (3) Refer to TASK 70-00-99-800-001, Solution S0001. Maskant C10-014 Tape C10-067
SUBTASK 70-23-06-110-222 C. Procedure. (1) Strip seal material as directed in the following steps. CAUTION: THIS SOLUTION WILL ATTACK MANY ALLOYS IF USED HOT AT 1608F (718C). DO NOT ELEVATE THE TEMPERATURE WITHOUT PRIOR APPROVAL. CAUTION: THIS SOLUTION WILL ATTACK LOW ALLOY STEELS SUCH AS HASTELLOY B, HASTELLOY W, OR INCOLOY 903. REACTION WITH THESE MATERIALS IS VERY RAPID. BASE MATERIAL MUST BE COMPATIBLE WITH THIS SOLUTION. (a) Vapor degrease parts in accordance with TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing or TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning. Parts must be thoroughly clean to permit uniform stripping. Mask metal sprayed areas that are not to be stripped and resprayed, as follows: NOTE: Masking is required to protect metal sprayed areas that are not to be stripped.
(b)
EFFECTIVITY: ALL
70-23-06
STRIPPING SILVER THERMAL SPRAY FROM STATIONARY AIR AND OIL SEALS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A 1 2 3 Mask metal-sprayed areas and seal all openings with acid-resistant tape C10-067 or equivalent. Dip entire part into C10-014 or equivalent, and let dry. Repeat until three coats have been applied. Trim by cutting through tape and maskant around areas to be stripped. Expose only the area to be stripped by peeling away tape and maskant, but do not remove tape/maskant from openings. IMMERSE PART INTO ACID TANK SLOWLY; REACTION IS VERY VIGOROUS. NITRIC ACID FUMES ARE TOXIC, AND CAN HAVE A DELAYED EFFECT ON THE CENTRAL NERVOUS SYSTEM. EVEN DILUTED NITRIC ACID IN CONTACT WITH THE SKIN WILL CAUSE A CHARACTERISTIC YELLOW STAIN. USE IN A WELL- VENTILATED AREA, AND WEAR ACID-RESISTANT CLOTHING, GLOVES, AND FACE PROTECTION.
WARNING:
(c)
Immerse part in stripping solution ( TASK 70-00-99-800-001, Solution S0001) at room temperature. Immersion time for removal of silver spray will be approximately 10 minutes. When visible effervescence stops, silver is removed. Remove part from tank, and rinse in overflowing water or by using water spray to remove residual acid. Remove bond coat as directed in TASK 70-23-07-110-023, Stripping of Thermal Spray Aluminum Oxide, Non-Ferrous, and Bond Coatings. NOTE: (1) Silver stripping solution will have dissolved a significant quantity of silver by the time it is exhausted. The silver should be reclaimed before discarding the solution. NOTE: (2) Provisions for the disposal of toxic wastes should be followed when discarding exhausted stripping solutions.
(d) (e)
WARNING: (f)
ACETONE IS HIGHLY FLAMMABLE. TAKE PRECAUTIONS AGAINST FIRE. AVOID PROLONGED INHALATION OF VAPOR.
Peel remaining tape/maskant from part. Use acetone to remove any maskant or tape that does not peel away readily. Steam clean entire part as directed in TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning, then follow with a pure steam "rinse".
EFFECTIVITY: ALL
70-23-06
STRIPPING SILVER THERMAL SPRAY FROM STATIONARY AIR AND OIL SEALS Page 2 Dec 01/03
STRIPPING OF THERMAL SPRAY - STRIPPING OF THERMAL SPRAY ALUMINUM OXIDE, NONFERROUS, AND BOND COATINGS TASK 70-23-07-110-023 1. Stripping of Thermal Spray Aluminum Oxide, Non-Ferrous, and Bond Coatings NOTE: For nickel-based alloys, TASK 70-23-12-110-027 is the preferred stripping method. You can use TASK 70-23-12-110-027, Stripping Thermal Sprayed Coating, whenever TASK 70-23-07-110-023 is specified in the Engine/Shop Manual. NOTE: For stripping thermal spray coatings from titanium parts, do not use this procedure. Use TASK 70-23-12-110-027, Stripping Thermal Sprayed Coating. NOTE: TASK 70-23-23-330-008, Removal of Coatings by High Pressure Water Stripping, is an acceptable alternative to the process listed in this procedure, provided that the self-substantiation requirements of the TASK are met. NOTE: TASK 70-23-24-110-001, Ultrasonic Stripping of Rotating Parts, is an acceptable alternative to the process listed in this procedure, provided that the selfsubstantiation requirements of the TASK are met. SUBTASK 70-23-07-99G-023 A. General. (1) When specified in the applicable overhaul manual, this procedure can be used to strip the following thermal spray coatings: Reference sections below. (a) (b) (c) (d) (e) (f) (g) (h) (i) TASK 70-49-04-340-005, Thermal Spraying Copper-Nickel Alloy (Powder) TASK 70-49-05-340-006, Thermal Spraying Copper-Nickel-Indium (Powder) TASK 70-49-02-340-003, Thermal Spraying Aluminum Oxide - Alumina (Powder) TASK 70-49-33-340-034, Thermal Spraying Aluminum Oxide - Alumina (Powder) - Fine TASK 70-49-22-340-023, Thermal Spraying Alumina/Nickel-Aluminum Composite (Powder) TASK 70-49-11-340-012, Thermal Spraying Nickel-Aluminum (Wire) TASK 70-49-10-340-011, Thermal Spraying Nickel-Aluminum (Powder) TASK 70-49-14-340-015, Thermal Spraying 75:25 Nickel-Graphite (Powder) TASK 70-49-15-340-016, Thermal Spraying 85:25 Nickel-Graphite (Powder)
STRIPPING OF THERMAL SPRAY ALUMINUM OXIDE, NON-FERROUS, AND BOND COATINGS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-23-07-110-231 B. Materials. (1) (2) (3) Refer to TASK 70-00-99-800-001, Solution S0001, or TASK 70-00-99-800-004, Solution S0004. Maskant C10-014 Tape C10-067
SUBTASK 70-23-07-110-232 C. Procedure. (1) Strip coating as directed in the following steps. CAUTION: THIS SOLUTION WILL ATTACK MANY ALLOYS IF USED HOT AT 1608F (718C). DO NOT ELEVATE THE TEMPERATURE WITHOUT PRIOR APPROVAL. CAUTION: THIS SOLUTION WILL ATTACK LOW ALLOY STEELS, SUCH AS HASTELLOY B, HASTELLOY W, OR INCOLOY 903. REACTION WITH THESE MATERIALS IS VERY RAPID. BASE MATERIAL MUST BE COMPATIBLE WITH THIS SOLUTION. CAUTION: DO NOT USE THIS STRIPPING METHOD ON TITANIUM PARTS. REFER TO TASK 70-23-12-110-027, STRIPPING THERMAL SPRAYED COATING, FOR STRIPPING TITANIUM. (a) Vapor degrease parts in accordance with TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, or TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning. Parts must be thoroughly clean to permit uniform stripping. Mask any metal-sprayed areas that are not to be stripped and resprayed in accordance with the following steps: NOTE: Masking is required to protect any metal-sprayed areas that are not to be stripped. 1 2 3 Mask metal-sprayed areas and seal all openings with acid-resistant tape C10-067 or equivalent. Dip entire parts into Turco No. 537 C10-014 Bubble-free or equivalent, and let dry. Repeat until three coats have been applied. Trim by cutting through masking tape and maskant around areas to be stripped. Expose only the area to be stripped by peeling away tape and maskant, but do not remove acid-resistant tape/maskant from openings.
(b)
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: STRIPPING SOLUTION IS A STRONG ACID. USE IN A WELL VENTILATED AREA, AND TAKE ALL NECESSARY PRECAUTIONS TO AVOID SKIN- AND EYE-CONTACT. IF SOLUTION CONTACTS SKIN OR EYES, IRRIGATE THOROUGHLY WITH CLEAR WATER AND OBTAIN MEDIAL AID.
(c)
Immerse part in stripping solution for the required time. Solution is used fullstrength, and stripping rate depends on coating thickness and solution temperature. Heating solution increases stripping rate. Eight hours at 708F (218C) to one hour at 1108F (438C) is recommended. Remove part from tank. Rinse with a high-pressure water spray. Loosened aluminum oxide and nickel-graphite coatings will spall off exposing blackened bond coat. Remove bond coat by hand, using stiff-bristled brush and running water. Make certain that all traces of coating are completely removed. ACETONE IS HIGHLY FLAMMABLE. TAKE PRECAUTIONS AGAINST FIRE. AVOID PROLONGED INHALATION OF VAPOR.
(d)
WARNING: (e)
Peel maskant and tape from part. Use acetone to remove any maskant that does not peel away readily. Steam clean entire part as directed in TASK 7021-03-160-001, Cleaning Method No. 3 - Steam Cleaning, then follow with a pure steam "rinse".
STRIPPING ALUMINUM BOND COATS - STRIPPING OF PURE ALUMINUM AND NICKEL-ALUMINUM BOND COATINGS TASK 70-23-08-110-024 1. Stripping of Pure Aluminum and Nickel-Aluminum Bond Coatings NOTE: TASK 70-23-23-330-008, Removal of Coatings by High Pressure Water Stripping, is an acceptable alternative to the process listed in this procedure, provided that the self-substantiation requirements of the TASK are met. SUBTASK 70-23-08-99G-024 A. General. (1) This procedure describes the method of stripping pure aluminum and nickelaluminum thermal spray coatings.
SUBTASK 70-23-08-110-001 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline stripping tank made from stainless steel with a heating coil that is capable of heating the solution to 1908F (888C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and a water spray gun, used after the alkaline stripping bath.
(b) (c) (d) (e)
SUBTASK 70-23-08-110-002 C. Materials. Table 1. Alkalin Degreasing/Rust Removing Solution Solution Turco 4181 or Turco 4181L Turco Vitroklene Cee-Bee C46 No. S1003 S1010 S1030 Operating Temperature 8F (8C) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82)
EFFECTIVITY: ALL
70-23-08
STRIPPING OF PURE ALUMINUM AND NICKEL-ALUMINUM BOND COATINGS Page 1 Dec 01/03
Table 1. Alkalin Degreasing/Rust Removing Solution (Cont) Solution Cee-Bee J84A or Cee-Bee J84AL Ardrox 185 or Ardrox 185L MagChem HDL-202 Eldorado HPT-1150 or 1150L Applied 5-840 SUBTASK 70-23-08-110-003 D. Procedure. (1) Two operations in different solutions are necessary for stripping pure aluminum and nickel-aluminum thermal spray coatings. (a) Clean part thoroughly by TASK 70-21-03-160-001, Cleaning Method No. 3 Steam Cleaning. Rinse thoroughly in overflowing water at room temperature. Dip part at least 3 times, letting it drain for a few seconds between immersions. Strip pure aluminum coating as follows: WARNING: STRIPPING SOLUTION IS EXTREMELY CAUSTIC. WEAR PROTECTIVE CLOTHING, GLOVES AND FACE SHIELD TO PREVENT CONTACT WITH SKIN OR EYES. IF SOLUTION CONTACTS SKIN OR EYES, IRRIGATE THOROUGHLY WITH CLEAR WATER AND OBTAIN MEDICAL AID. USE ADEQUATE VENTILATION AND EXHAUST SYSTEM AS HYDROGEN IS LIBERATED DURING STRIPPING. No. S1139 S1140 S1151 S1168 S1175 Operating Temperature 8F (8C) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82)
(b)
Slowly immerse part in a tank containing one of the alkaline solutions in Table 1, Page 1, Subtask 70-23-08-110-002, Materials. Keep the part in the solution for 10-15 minutes. If reaction is extremely violent, partially withdraw the part from the solution until the action subsides, then proceed with slow immersion until part is completely covered. Be sure that all areas of part have been immersed for the specified times. Stripping of pure aluminum is normally complete when all visible frothing or bubbling has stopped. Rinse thoroughly in overflowing water by dipping and draining at least 3 times. Finish by spray-rinsing, being careful to flush all spaces in
EFFECTIVITY: ALL
70-23-08
STANDARD PRACTICES MANUAL AS907-1-1A which stripping solution could be trapped. Repeat 4.A.(2)(a) and 4.A.(2)(b) if necessary. NOTE: In some instances a discolored area may be observed after stripping. This discoloration can be removed by rinsing in tap water and brushing with a nylon or fiber brush. (Do not use a wire brush.) If necessary, the part may be returned to the stripping solution for an additional 5 minutes, followed by the rinse operation. (c) Strip nickel-aluminum bond coat from titanium as directed in TASK 70-23-12110-027, Stripping Thermal Sprayed Coating, and TASK 70-23-07-110-023, Stripping of Thermal Spray Aluminum Oxide, Non-Ferrous, and Bond Coatings, for other materials.
EFFECTIVITY: ALL
70-23-08
EFFECTIVITY: ALL
70-23-08
STRIPPING TUNGSTEN CARBIDE - STRIPPING TUNGSTEN CARBIDE THERMAL SPRAYED COATING TASK 70-23-09-100-002 1. Stripping Tungsten Carbide Thermal Sprayed Coating NOTE: TASK 70-23-23-330-008, Removal of Coatings by High Pressure Water Stripping, is an acceptable alternative to the process listed in this procedure, provided that the self-substantiation requirements of the TASK are met. SUBTASK 70-23-09-99G-002 A. General. (1) When specified in the applicabl manual, this method will effectively remove tungsten carbide thermal sprayed coating from parts. NOTE: Before beginning this procedure any RTV or solid film lubricant must be removed. Remove copper-nickel-indium from dovetails per TASK 70-2312-110-027, Stripping Thermal Sprayed Coating. SUBTASK 70-23-09-100-021 B. Method 1. Enstrip A/TL. (1) (2) Materials. Refer to TASK 70-00-99-800-003, Solution S0003. Procedure. Strip coating as follows: WARNING: THIS STRIPPING SOLUTION IS STRONGLY ALKALINE. WEAR PROTECTIVE CLOTHING AND FACE SHIELD OR GOGGLES WHEN IMMERSING OR REMOVING PARTS. IF SOLUTION CONTACTS THE SKIN OR EYES, FLUSH AT ONCE WITH CLEAR WATER.
(a)
Immerse part, completely or partially as required, in the stripping solution for about 7 hours at 1508-1608F (668-718C). Stripping time will vary, depending upon the thickness of the coating. Rinse part thoroughly in clean running water. Blow dry with clean shop air. If required, grit blast to remove adhering traces of coating. Do not remove parent metal. Use 150-mesh aluminum oxide grit. Grit blast nozzle should be about 3 inches (76.2 mm) from surface of part, and air pressure should be about 40 psi (275.8 kPa). Blow all residual grit from part, using clean, dry shop air.
(b) (c)
(d)
EFFECTIVITY: ALL
70-23-09
STRIPPING TUNGSTEN CARBIDE THERMAL SPRAYED COATING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-23-09-100-022 C. Method 2. Enstrip GT-317 NOTE: This method may not remove an underlying bond coat if one is present. WARNING: ENSTRIP GT-317A AND GT-317C C04-156 ARE ACIDIC. ENSTRIP GT-317B C04-156 CONTAINS HYDROGEN PEROXIDE WHICH IS A STRONG OXIDIZING AGENT AND VERY CORROSIVE. WEAR FACE SHIELD, RUBBER GLOVES, PROTECTIVE SHOES, AND PROTECTIVE CLOTHING WHEN PREPARING AND USING THE STRIPPING SOLUTION. IN CASE OF CONTACT WITH THE SKIN OR EYES FLUSH WITH LARGE AMOUNTS OF COOL, CLEAN WATER AND GET IMMEDIATE MEDICAL ATTENTION. STORE ENSTRIP GT317B IN A COOL, DRY PLACE AWAY FROM HEAT, SPARKS OR OPEN FLAMES. KEEP ENSTRIP GT-317B AWAY FROM COMBUSTIBLE MATERIALS SUCH AS WOOD, SAWDUST, PAPER OR CLOTH AND AWAY FROM CHEMICAL REDUCING AGENTS AND ORGANIC MATERIALS.
(1) (2)
Materials. Refer to TASK 70-00-99-801-138, Solution S1138. Procedure. Strip coating as follows: CAUTION: ALL PARTS SHOULD BE INDIVIDUALLY RACKED AND PREVENTED FROM CONTACTING EACH OTHER. IF AN INDIVIDUAL PART IS NOT COMPLETELY IMMERSED, MASKING OF THE AIR/LIQUID INTERFACE IS REQUIRED. (a) (b) Mix solution thoroughly prior to part immersion. Maintain and control the bath temperature at 80-858F (26.78-29.48C). Do not exceed the maximum temperature. If the maximum temperature is exceeded, the effectiveness of the solution will be greatly reduced. The process is exothermic and, as a result of the heat generated, the solution may require cooling. Immerse each part completely or partially in the stripping solution as required and soak for approximately 7 hours. NOTE: Stripping rate will vary depending on coating composition, porosity and service history. Typical strip rate is 0.002 inch (0.05 mm) per hour for conventional coating and 0.001 inch (0.025 mm) or less for D-gun coatings. (d) (e) (f) Remove parts, rinse and scrub coated area with a stiff-bristle fiber brush. Inspect for coating removal and degradation. Repeat paragraphs C.(2)(c) through C.(2)(e) until examination reveals complete coating removal. NOTE: This process may take 35-40 hours to complete.
(c)
EFFECTIVITY: ALL
70-23-09
STANDARD PRACTICES MANUAL AS907-1-1A (g) Rinse part by immersion in an overflowing cold tap water rinse tank and/or use an air pressurized water rinse to remove any smut or residual acid solution from part.
EFFECTIVITY: ALL
70-23-09
EFFECTIVITY: ALL
70-23-09
STRIPPING URETHANE COATING - STRIPPING URETHANE COATING FROM UNPERFORATED METAL AND PLASTIC PARTS TASK 70-23-10-110-025 1. Stripping Urethane Coating from Unperforated Metal and Plastic Parts SUBTASK 70-23-10-99G-025 A. General. (1) This procedure is useful for removing urethane coatings from unperforated aluminum and fiber-glass surfaces to permit inspection and repair. The active ingredients of the stripping solution are the same for both kinds of surfaces; however, the different methods of application require the addition of an inert ingredient for use on fiber-glass surfaces.
SUBTASK 70-23-10-110-251 B. Materials. (1) Refer to TASK 70-00-99-800-008, Solution S0008.
SUBTASK 70-23-10-110-252 C. Procedure. (1) (2) Step (2) contains instructions for stripping aluminum surfaces, and Step (3) covers stripping of fiber-glass surfaces. Strip aluminum surfaces as follows: (a) Pour stripping solution S0008-A ( TASK 70-00-99-800-008, Solution S0008) into a metal or polyethylene container large enough to permit complete immersion of the coated area of the part. Submerge the part, and let it remain in the stripping solution for at least 15 minutes to soften the urethane coating enough to permit removal. Scrape the softened urethane coating from the part with a Teflon or polyethylene scraper, being careful to avoid damaging the surface. NOTE: If the urethane coating is not completely softened, scrape off the softened surface, and repeat steps (a) and (b). WARNING: METHYL-ETHYL-KETONE IS TOXIC AND HIGHLY FLAMMABLE. AVOID PROLONGED INHALATION OF VAPORS OR CONTACT WITH THE SKIN. TAKE PRECAUTIONS AGAINST FIRE.
(b) (c)
(d)
Wipe the softened residue from the part with excelsior, coarse cloth, or treated pads [Scotch-Brite Pads, 6 x 9-1/2 inches (152.4 x 241.3 mm), No.
STRIPPING URETHANE COATING FROM UNPERFORATED METAL AND PLASTIC PARTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A 7447, General Purpose; 3M Company; St. Paul, Minnesota 55101, or equivalent]. Finish cleaning the surface, using paper towels or industrial wipers saturated with methyl-ethyl-ketone. (3) Strip fiber-glass surfaces as follows: WARNING: (a) DO NOT IMMERSE OR SOAK FIBER-GLASS PARTS IN STRIPPING SOLUTION.
Apply stripping paste ( TASK 70-00-99-800-008, Solution S0008) approximately 1/8-inch (3.18 mm) thick to the urethane-coated fiber-glass surface. Agitate the mix during application to prevent separation of the microballoons from the solvent. Let the stripping paste remain on the part for at least 5 minutes, but no longer than 2 hours. Record actual time. Remove as much of the microballoon paste from the surface as possible without scraping off any urethane coating. The microballoons can be used again if they are not contaminated with urethane. Scrape the softened urethane carefully from the part, using a Teflon or polyethylene scraper, and being careful to avoid damaging the fiber-glass surface. NOTE: If the urethane coating is not completely softened, scrape off the softened surface and repeat steps (a) through (d). Do not exceed the 2-hour total time.
(b) (c)
(d)
WARNING:
METHYL-ETHYL-KETONE IS TOXIC AND HIGHLY FLAMMABLE. AVOID PROLONGED INHALATION OF VAPORS OR CONTACT WITH THE SKIN. TAKE PRECAUTIONS AGAINST FIRE.
(e)
Wipe the softened residue from the part with excelsior, coarse cloth, or treated pads [Scotch-Brite Pads, 6 x 9-12 inches (152.4 x 241.3 mm); 3M Company, St. Paul, Minnesota 55101, or equivalent]. Finish cleaning with paper towels or industrial wipers saturated with methyl-ethyl-ketone.
STRIPPING URETHANE COATING FROM UNPERFORATED METAL AND PLASTIC PARTS Page 2 Dec 01/03
MOLTEN SALT METHOD - MOLTEN SALT METHOD FOR STRIPPING SPRAYED TUNGSTEN OR CHROME CARBIDE TASK 70-23-11-110-026 1. Molten Salt Method for Stripping Sprayed Tungsten or Chrome Carbide SUBTASK 70-23-11-99G-026 A. General. WARNING: TANK SHOULD BE HOODED AND VENTILATED. WEAR PROTECTIVE CLOTHING, GLOVES, AND FACE SHIELD OR GOGGLES WHEN HANDLING OR USING STRIPPING SALTS. IF EITHER HOT OR COLD SALT CONTACTS THE SKIN, FLUSH IMMEDIATELY WITH CLEAR WATER AND TREAT AS AN ALKALI BURN.
CAUTION: DO NOT IMMERSE TITANIUM OR OTHER NON-FERROUS PARTS IN THE STRIPPING TANK. DO NOT USE THIS METHOD FOR PARTS INCORPORATING BRAZED JOINTS UNLESS AUTHORIZED FOR A SPECIFIC PART BY THE APPLICABLE SHOP MANUAL. CAUTION: DO NOT STRIP COATINGS FROM COBALT BASE ALLOYS UNLESS SPECIFICALLY DIRECTED BY APPLICABLE SHOP MANUAL, SINCE PARENT METAL REMOVAL MAY OCCUR. CAUTION: PROTECT CONTENTS OF TANK FROM INTRODUCTION OF WATER AT ANY TIME. BOTH TEMPERATURE OF MOLTEN SALT AND HEAT OF REACTION CAN CAUSE EXPLOSIVE VAPORIZATION OF WATER AND SPATTERING OF CONTENTS. (1) This procedure for stripping thermal-sprayed coating from nickel base alloys makes use of molten sodium hydroxide, with additives, to provide controlled oxidizing and solvent properties. It should be used only when directed by the applicable Shop Manual. The method must not be used on titanium parts, nor parts made of other non-ferrous metals, since the molten sodium hydroxide can react violently with titanium, and can form water-soluble compounds with other nonferrous metals.
SUBTASK 70-23-11-110-262 C. Procedure. (1) Parts to be stripped must be thoroughly dry and free from any organic material. Degrease if necessary, TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor
MOLTEN SALT METHOD FOR STRIPPING SPRAYED TUNGSTEN OR CHROME CARBIDE Page 1 Dec 01/03
EFFECTIVITY: ALL
70-23-11
STANDARD PRACTICES MANUAL AS907-1-1A Degreasing. If wet, blow parts, baskets, fixtures, etc. dry with shop air, and heat to remove residual moisture if necessary. Strip parts as follows: (a) Load parts in heat and corrosion-resistant baskets or fixtures, using care to see that no coated area (tungsten carbide or chrome carbide) are shielded from direct contact with the molten salt by basket, fixture, or other parts. Position parts so that air pockets will not be formed when they are immersed in the bath, and so that cavities will not dip out salt when the parts are removed from the bath. The number of parts to be processed in one batch is not critical. Lower the parts into the molten salt bath until they are completely covered. Tungsten carbide will be removed within approximately 30 minutes. Chrome carbide coatings will require approximately 3 hours immersion time for removal. Remove parts from the bath, let them drain for 4-5 seconds over the salt bath, then immerse them in a water-rinse tank at room temperature. Avoid delay between the salt bath and the water rinse; if the salt cools enough to solidify on the surface of the parts, before rinsing, they must be soaked in the water for several minutes to dissolve the residual salt. NOTE: If solidified salt is observed on the parts before rinsing in the water tank, the salt may be remelted by reimmersion in the salt bath as an alternative to soaking the salt free in water. If the coatings (tungsten carbide or chrome carbide) are not completely removed, the parts may be reprocessed for a second cycle, but must be thoroughly dried before immersion in the salt bath. (d) If required, grit blast to remove adhering traces of coating. Do not remove parent material. Use 150 mesh aluminum oxide grit. Grit blast nozzle should be about 3 inches (75 mm) from surface of part, and air pressure should be about 40 psi (275 kPa).
(b)
(c)
EFFECTIVITY: ALL
70-23-11
MOLTEN SALT METHOD FOR STRIPPING SPRAYED TUNGSTEN OR CHROME CARBIDE Page 2 Dec 01/03
STRIPPING THERMAL SPRAY - STRIPPING THERMAL SPRAYED COATINGS TASK 70-23-12-110-027 1. Stripping Thermal Sprayed Coatings NOTE: TASK 70-23-23-330-008, Removal of Coatings by High Pressure Water Stripping, is an acceptable alternative to the process listed in this procedure, provided that the self substantiation requirements of the TASK are met. NOTE: TASK 70-23-24-110-001, Ultrasonic Stripping of Rotating Parts, is an acceptable alternative to the process listed in this procedure, provided that the self substantiation requirements of the TASK are met. SUBTASK 70-23-12-99G-027 A. General. (1) This procedure is recommended for the removal of thermal spray coatings from titanium and nickel-based alloy parts. Refer to TASK 70-23-07-110-023, Stripping of Thermal Spray Aluminum Oxide, Non-Ferrous, and Bond Coatings, for procedure covering other materials. The following thermal spray coating systems may be stripped by this procedure. (a) Alumina/Nickel-Aluminum (Duplex): TASK 70-49-02-340-003, Thermal Spraying Aluminum Oxide - Alumina (Powder), and TASK 70-49-10-340-011, Thermal Spraying Nickel-Aluminum (Powder) and TASK 70-49-33-340-034, Thermal Spraying Nickel-Aluminum (Powder) - Fine. Alumina/Nickel-Aluminum (Composite): TASK 70-49-22-340-023, Thermal Spraying Alumina/Nickel- Aluminum Composite (Powder). Copper-Nickel: TASK 70-49-04-340-005, Thermal Spraying Copper-Nickel Alloy (Powder). Copper-Nickel-Indium: TASK 70-49-05-340-006, Thermal Spraying CopperNickel-Indium (Powder). Molybdenum: TASK 70-49-07-340-008, Thermal Spraying Molybdenum (Powder), and TASK 70-49-08-340-009, Thermal Spraying Molybdenum (Wire). Nickel-Aluminum: TASK 70-49-10-340-011, Thermal Spraying NickelAluminum (Powder), and TASK 70-49-11-340-012, Thermal Spraying NickelAluminum (Wire). Nickel-Graphite: TASK 70-49-14-340-015, Thermal Spraying 75:25 NickelGraphite (Powder), and TASK 70-49-15-340-016, Thermal Spraying 85:15 Nickel-Graphite (Powder).
(b) (c) (d) (e)
(f)
(g)
EFFECTIVITY: ALL
70-23-12
STRIPPING THERMAL SPRAYED COATINGS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (h) Aluminum Bronze: TASK 70-49-25-340-026, Thermal Spraying Aluminum Bronze (Powder), and TASK 70-49-26-340-027, Thermal Spraying Aluminum Bronze (Wire).
SUBTASK 70-23-12-110-272 C. Procedure. (1) Parts must be cleaned and masked (if necessary) before stripping is begun. Proceed as follows: CAUTION: THIS SOLUTION WILL ATTACK MANY ALLOYS IF USED HOT AT 1608F (718C). DO NOT ELEVATE THE TEMPERATURE WITHOUT PRIOR APPROVAL. CAUTION: THIS SOLUTION WILL ATTACK LOW ALLOY STEELS, SUCH AS HASTELLOY B, HASTELLOY W, INCOLOY 903. REACTION WITH THESE MATERIALS IS VERY RAPID. BASE MATERIAL MUST BE COMPATIBLE WITH THIS SOLUTION. (a) Steam clean parts in accordance with TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning, or TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning. Parts other Parts other than titanium may be degreased per TASK 70-21-02-110-002, Cleaning Method No. 2 Vapor Degreasing. Mask any metal sprayed areas that are not to be stripped as follows: NOTE: Masking may not be required if all coated areas are to be stripped. Paragraphs C.(1)(b) and C.(1)(d) can be ignored in such instances. 1 2 Mask metal sprayed areas with masking tape, and seal all part openings with acid-resistant tape. Dip entire part into Turco No. 537 Bubble-free maskant (Turco Products, Inc.; Joliet, Illinois) or equivalent, and let dry. Repeat until a minimum of 3 coats have been applied. Trim by cutting through masking tape and maskant around areas to be stripped. Expose only the area to be stripped by peeling away tape and maskant, but do not remove acid-resistant tape/maskant from openings.
(b)
EFFECTIVITY: ALL
70-23-12
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: NITRIC ACID AND ITS FUMES ARE TOXIC. MIX AND USE IN A WELL VENTILATED AREA, AND WEAR ACID-RESISTANT CLOTHING, GLOVES AND FACE PROTECTION. IF NITRIC ACID CONTACTS THE SKIN, WASH IMMEDIATELY IN CLEAR WATER. A CHARACTERISTIC YELLOW STAINING OF THE SKIN WILL REMAIN AFTER WASHING.
(c)
Immerse part in stripping solution so that all areas are completely covered. Typical exposure time to acid is 1.5 to 2.0 hours. 1 The stripping may be enhanced by the following steps: a Remove the part from the bath every 20-30 minutes during the strip cycle to enhance the stripping process, especially for the seal teeth areas. Scrub the coating by hand with a non-metallic brush, Scotch Brite pad C10-010, or equivalent. NOTE: This intermediate scrubbing removes the layer of reacted coating and re-activates the surface for additional acid stripping. c High pressure water rinse [1500 psi max (10350 kPa)] the part to remove the reacted coating layer.
(d)
Remove the part from the tank. Blast off the blackened bond coat with a highpressure water rinse. Rinse and blow dry. Remove any remaining bond coat by hand, using a stiff brush and flowing water. Make sure that coatings are completely removed. Repeat paragraph C.(1)(c) if necessary. ACETONE IS HIGHLY FLAMMABLE. TAKE PRECAUTIONS AGAINST FIRE. AVOID PROLONGED INHALATION OF VAPOR.
WARNING: (e)
Peel maskant from part. Use acetone or methyl-ethyl-ketone to remove any maskant or tape that does not peel away readily. Steam clean entire part as directed in TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning, then follow with a pure steam "rinse".
EFFECTIVITY: ALL
70-23-12
EFFECTIVITY: ALL
70-23-12
STRIPPING NICKEL PLATE - STRIPPING NICKEL PLATE TASK 70-23-13-110-028 1. Stripping Nickel Plate SUBTASK 70-23-028-99G-028 A. General. (1) The following nickel plate stripper has been found to be an effective way to strip and clean metal and other deposits from titanium compressor blades.
SUBTASK 70-23-13-110-282 C. Procedure. (1) Using the materials specified, strip the parts as directed in the following steps. WARNING: ALL CYANIDES ARE EXTREMELY POISONOUS, AND REACT WITH ACIDS TO FORM DEADLY HYDROGEN CYANIDE GAS. WEAR FACE SHIELD, RUBBER GLOVES AND APRON, AND USE ONLY IN AN AREA VENTILATED BY A POWER-DRIVEN EXHAUST FAN. WASH HANDS, FACE, AND OTHER EXPOSED SKIN AREAS THOROUGHLY AFTER REMOVAL OF PROTECTIVE CLOTHING AND BEFORE EATING OR SMOKING.
(a) (b)
Mix solution as per TASK 70-00-99-800-010, Solution S0010. Immerse parts in solution to a maximum of 72 hours. Stripping (cleaning) time will vary depending on the thickness and type of deposit. Temperature of solution is 1138-1208F (458-498C). Rinse parts thoroughly in clean running water. Blow dry with clean shop air.
(c)
EFFECTIVITY: ALL
70-23-13
STRIPPING NICKEL PLATE Page 1 Dec 01/03
EFFECTIVITY: ALL
70-23-13
STRIPPING NICKEL PLATE Page 2 Dec 01/03
STRIPPING EPOXY RESIN - STRIPPING EPOXY RESIN FROM ALUMINUM TASK 70-23-14-110-029 1. Stripping Epoxy Resin from Aluminum SUBTASK 70-23-14-99G-029 A. General. (1) This procedure is useful for stripping epoxy resin from aluminum and is to be used when directed by applicable Shop Manual repair or other Standard Practice procedure. This procedure is specifically adapted to strip parts which have been improperly processed. It may also be used on stainless steel panels.
SUBTASK 70-23-14-110-292 C. Procedure. (1) Strip epoxy resin from aluminum as follows: WARNING: AVOID SKIN CONTACT WITH STRIPPER. WEAR PROTECTIVE CLOTHING, GLOVES AND FACE SHIELD TO PREVENT CONTACT WITH SKIN OR EYES. IF COMPOUND CONTACTS SKIN OR EYES, IRRIGATE THOROUGHLY WITH CLEAR WATER AND OBTAIN MEDICAL AID.
(a)
Remove any detail part to be stripped from its assembly, when possible, and strip it in its entirety. If part cannot be removed, mask area with polyethylene film and acetate fibertape. Using a paint brush, coat the detail to be stripped with a 1/16 inch (1.59 mm) minimum thickness of stripper. Allow stripper to react for one half hour to one hour. ACETONE AND MEK ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPORS AND CONTACT OF LIQUIDS WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME. OBSERVE ALL FEDERAL AND LOCAL REGULATIONS IN THEIR USE.
(b)
WARNING:
(c)
When stripping local areas of an assembly which has been masked, allow stripping compound to stand one half hour maximum. Wipe compound with methyl-ethyl-ketone, acetone or equivalent to avoid continuous stripping of the assembly around the masking tape.
EFFECTIVITY: ALL
70-23-14
STRIPPING EPOXY RESIN FROM ALUMINUM Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (d) Using scrapers, remove as much of the stripper and softened primer as possible. Wipe the effected surface dry with paper towels or industrial wipers. Immediately after scraping and drying, scrub the residual primer off down to the bare metal surfaces using a Scotch-Brite Pad C10-010. Wet pads with water to flush off stripper. Dry the surface with clean dry shop air. Using Scotch Brite Pads C10-010 and TASK 70-21-14-110-012, Cleaning Method No. 14 - Manually-Assisted Detergent Cleaning, lightly and uniformly abrade the stripped surface. Using damp cotton wipes, wipe all residue of primer and Scotch Brite from the stripped surface then rinse thoroughly in/with tap water. Wet the surface uniformly with a clean wet cloth and check for water breaks as evidenced by the water not cascading from the parts in a smooth, continuous sheet. If water break occurs, repeat steps C.(1)(f) through (h). Air dry for 2 hours minimum or oven dry at 1508F 258F (668 148C) for 1/2 hour minimum. Refinish as directed by applicable manual or Standard Practice procedure.
(e) (f)
(g) (h)
(i) (j)
EFFECTIVITY: ALL
70-23-14
STRIPPING EPOXY RESIN FROM ALUMINUM Page 2 Dec 01/03
STRIPPING ANODIZED COATING - STRIPPING ANODIZED COATING FROM ALUMINUM TASK 70-23-15-110-030 1. Stripping Anodized Coating from Aluminum SUBTASK 70-23-15-99G-030 A. General. (1) The following procedure is useful for stripping anodized coating from aluminum parts.
SUBTASK 70-23-15-110-301 B. Materials.
CAUTION: COMPLETE REMOVAL OF PROTECTIVE ANODIZED COATING WILL RESULT IN MATERIAL LOSS OF APPROXIMATELY 0.001 (0.03 MM) EACH TIME A PART IS STRIPPED. CAUTION MUST BE EXERCISED WHEN STRIPPING PRECISION PARTS. (1) Refer to TASK 70-00-99-800-012, Solution S0012.
SUBTASK 70-23-15-110-302 C. Procedure. (1) Using the materials specified, strip the parts as directed in the following steps. WARNING: HYRDOCARBON SOLVENTS ARE FLAMMABLE AND TOXIC. AVOID PROLONGED CONTACT WITH THE SKIN, AND OBSERVE PRECAUTIONS AGAINST FIRE.
(a)
Clean parts per TASK 70-21-01-110-001, Cleaning Method No. 1 - Solvent Degreasing, TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning, or as directed by specific applicable Shop Manual Repair. Mask areas not to be stripped, per specific applicable manual procedure. Mix solution as per TASK 70-00-99-800-012, Solution S0012. Immerse part/s into solution until anodized protective coating is removed. Thoroughly rinse part/s with running tap water. Inspect part/s for removal of anodize. Re-cycle, if necessary. Remove masking if applicable. Re-rinse with running tap water, if required.
(b) (c) (d) (e) (f) (g) (h)
EFFECTIVITY: ALL
70-23-15
STRIPPING ANODIZED COATING FROM ALUMINUM Page 1 Dec 01/03
EFFECTIVITY: ALL
70-23-15
STRIPPING ANODIZED COATING FROM ALUMINUM Page 2 Dec 01/03
STRIPPING CHROMIUM CARBIDE - STRIPPING CHROMIUM CARBIDE (WITH OR WITHOUT METCO 450 UNDERCOAT) THERMAL SPRAYED COATING TASK 70-23-16-100-003 1. Stripping Chromium Carbide (with or without Metco 450 undercoat) Thermal Sprayed Coating SUBTASK 70-23-16-99G-003 A. General. (1) This method uses a two-step acid/alkaline permanganate process for removal of chromium carbide thermal sprayed coating applied originally per TASK 70-49-03340-004, Thermal Spraying Chromium Carbide Powder. Bond coat applied per TASK 70-49-10-340-011, Thermal Spraying Nickel-Aluminum (Powder) is also removed by this process.
SUBTASK 70-23-16-100-031 B. Materials. (1) Refer to TASK 70-00-99-800-013, Solution S0013 (nitric/phosphoric acid) and TASK 70-00-99-800-014, Solution S0014 (alkaline permanganate).
SUBTASK 70-23-16-100-032 C. Procedure. (1) Strip coating as directed by the following steps: (a) Vapor degrease parts in accordance with TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, or TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning. Parts must be thoroughly clean to permit uniform stripping. STRIPPING SOLUTION IS A STRONG ACID. USE IN A WELL VENTILATED AREA, AND TAKE ALL NECESSARY PRECAUTIONS TO AVOID SKIN AND EYE CONTACT. IF SOLUTION CONTACTS SKIN OR EYES, IRRIGATE THOROUGHLY WITH CLEAR WATER AND OBTAIN MEDICAL AID.
WARNING:
(b) (c) (d) (e)
Immerse part in stripping solution S0013 for one hour. Rinse in hot or cold overflowing water. Immerse part in solution S0014 for one hour. Rinse in hot or cold overflowing water.
STRIPPING CHROMIUM CARBIDE (WITH OR WITHOUT METCO 450 UNDERCOAT) THERMAL SPRAYED COATING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (f) Repeat steps C.(1)(b) through C.(1)(e), above, until total time in acid solution S0013 is three hours and total time in alkaline permanganate solution S0014 is two hours. Dry with clean shop air after final water rinse. Dry abrasive grit blast softened thermal sprayed coating per TASK 70-21-04120-002, Dry Abrasive Blast - Method 4A using 120 mesh aluminum oxide grit. Blow all residual grit from part, using clean, dry shop air.
(g) (h) (i)
STRIPPING CHROMIUM CARBIDE (WITH OR WITHOUT METCO 450 UNDERCOAT) THERMAL SPRAYED COATING Page 2 Dec 01/03
STRIPPING ALUMINUM HONEYCOMB - STRIPPING ALUMINUM HONEYCOMB BONDED WITH NARMCO METAL BOND 328 TASK 70-23-17-110-031 1. Stripping Aluminum Honeycomb Bonded with Narmco Metal Bond 328 SUBTASK 70-23-17-99G-031 A. General. (1) This procedure is useful for stripping open face aluminum honeycomb seal material which has been bonded with Metal Bond 328 to aluminum. This procedure is to be used when directed by the applicable Shop Manual.
SUBTASK 70-23-17-110-312 C. Equipment. (1) Tank material to be 304L or 316L stainless steel.
CAUTION: WHEN NOT IN USE, REDUCE SOLUTION TEMPERATURE TO BELOW 2008F (938C) AND KEEP COVERED. (2) Maintain solution operating temperature by insulating the tanks external surface. Construct the tank to minimize volume of solution required.
SUBTASK 70-23-17-110-313 D. Procedure. (1) (2) Disassemble part as directed by the specific applicable manual repair procedure. Steam clean per TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning, or as directed by the specific repair procedure. Blow off residual moisture with dry shop air. STRIPPER SHOULD ONLY BE USED IN A WELL VENTILATED AREA. WEAR PROTECTIVE CLOTHING, GLOVES, RESPIRATOR AND FACE SHIELD WHEN USING STRIPPING SOLUTION. IF EITHER HOT OR COLD SOLUTION CONTACTS THE SKIN, FLUSH IMMEDIATELY WITH CLEAR WATER.
WARNING:
(3)
Immerse part in stripping solution so that area to be stripped is completely covered. Raise temperature of solution to 2108-2308F (998-1108C). Allow part to
STRIPPING ALUMINUM HONEYCOMB BONDED WITH NARMCO METAL BOND 328 Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A remain in solution at elevated temperature for approximately 5 hours, or until the honeycomb unbonds from the part. NOTE: For operator convenience, it is permissible to immerse the part while solution is at or near room temperature, raise solution to operating temperature and hold for specified time. Prior to unloading part, solution may be allowed to cool to room temperature. (4) Remove part from the stripping solution and allow to drain. Move part from the tank and spray rinse thoroughly with hot tap water. Blow off residual water with dry shop air. Lift out the loosened honeycomb and, if present, peel out any retained sealants. Wipe part to remove the flaked adhesive, using a No. 7447 Scotch Brite abrasive pad C10-010. Residual adhesive which cannot be removed by wiping may be removed by scraping with a flat, sharpened aluminum or plastic tool or by repeating steps (3), (4) and (6).
(5) (6) (7)
STRIPPING ALUMINUM HONEYCOMB BONDED WITH NARMCO METAL BOND 328 Page 2 Dec 01/03
STRIPPING OF THERMAL SPRAY - STRIPPING OF THERMAL SPRAYED ALUMINUM OXIDE/ NICKEL ALUMINIDE COATINGS - INCO-718, TI-17 OR TI-6-4 TASK 70-23-18-110-032 1. Stripping of Thermal Sprayed Aluminum Oxide/Nickel Aluminide Coatings - Inco-718, Ti-17, or Ti-6-4
CAUTION: SOLUTION SHOULD NOT BE USED ON PARTS THAT REQUIRE MASKING. CAUTION: SOLUTION SHOULD ONLY BE USED ON PARTS MADE OF INCO-718, TI-17, OR TI-6-4. SUBTASK 70-23-18-99G-032 A. General. (1) This stripping method allows parts to be stripped of alumina-nickel aluminum (single coating, ref. TASK 70-49-09-340-010) or Metco 450/aluminum oxide (two coatings, ref. TASK 70-49-02-340-003) without removing chromium plating or Ni-CrAl thermal spray coatings.
SUBTASK 70-23-18-110-001 B. Equipment. (1) The following equipment is required for the application of this process. (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. An alkaline stripping tank made from stainless steel with a heating coil that is capable of heating the solution to 1908F (888C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and a water spray gun, used after the alkaline stripping bath. A nitric acid stripping tank made from 316 stainless steel with a heating coil that is capable of heating the solution to 1808F (828C) and is equipped with a fume collector/scrubber. A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and a water spray gun, used after the acid stripping bath.
(b) (c) (d) (e)
(f)
(g)
EFFECTIVITY: ALL
70-23-18
STRIPPING OF THERMAL SPRAYED ALUMINUM OXIDE/ NICKEL ALUMINIDE COATINGS - Inco-718, Ti-17 or Ti-6-4 Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-23-18-110-002 C. Materials. Table 1. Alkaline Degreasing/Rust Removing Solution Solution Turco 4181 or Turco 4181L Turco Vitroklene Cee-Bee C46 Cee-Bee J84A or Cee-Bee J84AL Ardrox 185 or Ardrox 185L MagChem HDL-202 Eldorado HTP-1150 or 1150L Applied 5-840 No. S1003 S1010 S1030 S1139 S1140 S1151 S1168 S1175 Operating Temperature 8F (8C) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82) 160-180 (71-82)
Table 2. Acid Stripping Solution Solution Nitric Acid SUBTASK 70-23-18-110-003 D. Procedure. (1) Immerse the part in a tank containing one of the alkaline cleaning solutions listed in Table 1, Page 2, Subtask 70-23-18-110-002, Materials. Keep the part in the solution for 50-70 minutes. Rinse in overflowing tap water for 3 to 5 minutes. Thoroughly pressure water rinse. Immerse the part in a tank containing the acid stripping solution listed in Table 2, Page 2, Subtask 70-23-18-110-002, Materials. Keep the part in the solution for 3 hours at 1708-1808F (778-828C) or until the remaining film turns grayish-green, whichever is less. Rinse in overflowing tap water. Remove residual coating by dry abrasive blast per TASK 70-21-04-120-001, Cleaning Method No. 4 - Dry Abrasive Blast Cleaning, using 120-150 mesh Aluminum oxide grit. Blow dry with air. No. S0016 Operating Temperature 8F (8C) 170-180 (77-82)
(2) (3) (4)
(5) (6)
(7)
EFFECTIVITY: ALL
70-23-18
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-23-18-110-004 E. Quality Assurance. WARNING: ALKALINES AND ACIDS BURN SKIN. WEAR FACE SHIELDS RUBBER GLOVES, RUBBER APRON AND PROTECTIVE FOOTWEAR. IF ALKALINES OR ACIDS GETS ON SKIN, FLUSH IMMEDIATELY WITH WATER.
(1)
Visually inspect to ensure complete coating removal.
EFFECTIVITY: ALL
70-23-18
EFFECTIVITY: ALL
70-23-18
STRIPPING OF THERMAL SPRAY - STRIPPING OF THERMAL SPRAYED ALUMINUM OXIDE/ NICKEL ALUMINIDE COATINGS INCO-718, TI-17, TI-6-4, RENE 95, AND RENE 41 TASK 70-23-19-100-004 1. Stripping of Thermal Sprayed Aluminum Oxide/Nickel Aluminide Coatings - Inco-718, Ti-17, Ti6-4, Rene 95 and Rene 41 SUBTASK 70-23-19-99G-004 A. General. (1) This stripping method allows parts to be stripped of alumina-nickel aluminum (single coating, Ref. TASK 70-49-09-340-010), or Metco 450/aluminum oxide (two coatings, Ref. TASK 70-49-02-340-003) without removing chromium plating or NiCr-Al Thermal Spray Coatings. NOTE: This stripping method to be used on parts made of Inco 718, Ti-17, Ti-6-4, Rene 41 and Rene 95. SUBTASK 70-23-19-100-041 B. Materials. (1) Refer to TASK 70-00-99-800-017, Solution S0017.
SUBTASK 70-23-19-100-042 C. Procedure. WARNING: THIS IS AN ALKALINE SODIUM CYANIDE SOLUTION CONTAINING AN ORGANIC OXIDIZING AGENT. THIS SOLUTION IS VERY POISONOUS AND WILL REACT WITH ACIDS TO FORM DEADLY HYDROGEN CYANIDE GAS. WEAR FACE SHIELD, RUBBER GLOVES AND APRON. USE ONLY IN A WELL VENTILATED AREA. WASH HANDS, FACE AND ANY EXPOSED SKIN AREAS AFTER REMOVAL OF PROTECTIVE CLOTHING.
CAUTION: DO NOT BLAST EXCESSIVELY, PARTICULARLY IF COATING IS SPALLED OR MISSING IN PATCHES. (1) (2) Grit blast per TASK 70-21-04-120-002, Dry Abrasive Blast Cleaning - Method 4A, using 120-150 mesh aluminum oxide grit at 90 PSI. Mask any metal sprayed areas that are not to be stripped as follows: (a) (b) Mask metal sprayed areas to be stripped with masking tape, and seal all part opening with alkaline resistant tape. Dip entire part into Turco No. 537 Bubble-free maskant (Turco Products, Inc.; Joliet, IL) or equivalent, and let dry. Repeat until a minimum of 3 coats have been applied.
STRIPPING OF THERMAL SPRAYED ALUMINUM OXIDE/ NICKEL ALUMINIDE COATINGS INCO-718, Ti-17, Ti-6-4, RENe 95, AND RENe 41 Page 1 Dec 01/03
EFFECTIVITY: ALL
70-23-19
STANDARD PRACTICES MANUAL AS907-1-1A (c) Trim by cutting through masking tape and maskant around areas to be stripped. Expose only the area to be stripped by peeling away tape and maskant, but do not remove alkaline resistant tape/maskant from opening.
(3) (4) (5) (6) (7) (8)
Immerse part in stripping solution S0017 for 6-8 hours at 1408-1608F (608-718C). Cold water rinse. Hot water rinse. Air dry or oven dry. Lightly grit blast as in 3.A. to remove loose residual coating. Blow all residual grit from part using clean, dry air. ACETONE IS HIGHLY FLAMMABLE. TAKE PRECAUTIONS AGAINST FIRE. AVOID PROLONGED INHALATION OF VAPOR.
WARNING: (9)
Peel maskant from part. Use acetone or methyl-ethyl-ketone to remove any maskant or tape that does not peel away readily. Steam clean entire part as directed in TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning, then follow with a pure steam "rinse".
EFFECTIVITY: ALL
70-23-19
STRIPPING OF THERMAL SPRAYED ALUMINUM OXIDE/ NICKEL ALUMINIDE COATINGS INCO-718, Ti-17, Ti-6-4, RENe 95, AND RENe 41 Page 2 Dec 01/03
STRIPPING SILICONE RUBBER - STRIPPING SILICONE RUBBER FROM TITANIUM AND ALUMINUM TASK 70-23-20-110-037 1. Stripping Silicone Rubber from Titanium and Aluminum SUBTASK 70-23-20-99G-037 A. General. (1) This procedure provides an effective way of removing silicone rubber to permit inspection and reassembly of engine components. This solution has been approved for use only on titanium and aluminum components. Components made of other materials shall not be immersed in the solution without testing for detrimental attack. Attack will occur on high strength steels.
SUBTASK 70-23-20-110-371 B. Equipment. (1) The following equipment is required for the application of this process. (a) Personnel safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency shower, protective clothing against electro-plating products and means for neutralizing acid or alkaline splashing. Fire safety equipment and extinguishers. Processing plant for neutralizing waste and used solutions if required by government regulations. Efficient ventilation system for extracting and neutralizing vapors. A solution tank made of mild steel, rigid polypropylene, or a 316 or equivalent type stainless steel and fitted with a cover to minimize evaporation and to avoid contamination from water spillage, dust, and atmospheric humidity. A water rinse tank made of stainless steel or rigid plastic and a water spray gun.
(b) (c) (d) (e)
(f)
SUBTASK 70-23-20-110-372 C. Material. Solution No. S1130 S1131 S1132 Operating 8F Ambient Ambient Ambient
STRIPPING SILICONE RUBBER FROM TITANIUM AND ALUMINUM Page 1 Dec 01/03
Product Identification A. Turco 6045 B. Cee-Bee 105HF C. Ardrox 2204
Temp 8C
EFFECTIVITY: ALL
70-23-20
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-23-20-110-373 D. Procedure. (1) If not previously accomplished, steam clean per TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning, to remove dust and dirt especially in crevices and other surface irregularities on the silicone rubber material.
CAUTION: COMPONENTS TO BE IMMERSED IN THE STRIPPING SOLUTION MUST BE COMPLETELY FREE OF WATER. (2) (3) Dry by blowing with shop air or in an oven at 2008F (938C) for 2 hours minimum. Remove thick deposits of silicone rubber by pulling or scraping with a sharpened plastic scraper or similar tool that will not damage the part. THIS SOLUTION CONTAINS ACIDS AND VOLATILE MATERIALS. AVOID INHALATION OF VAPORS AND TAKE PRECAUTIONS AGAINST FIRE. AVOID CONTACT WITH CLOTHING, EYES, AND SKIN. IF EYE CONTACT OCCURS, FLUSH WITH WATER AND OBTAIN MEDICAL ATTENTION. IF SKIN CONTACT OCCURS, WASH WITH SOAP AND WATER AND OBTAIN MEDICAL MEDICATION IF DISCOMFORT PERSISTS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING, AND PROTECTIVE SHOES.
WARNING:
WARNING:
CAUTION: DO NOT CONTAMINATE THE SOLUTION WITH WATER AS IT MAY RESULT IN THE SOLUTION BECOMING CORROSIVE. CAUTION: ANODIZED COATING ON ALUMINUM PARTS MAY BE DEGRADED OR STRIPPED IF IMMERSION TIME EXCEEDS TWO HOURS. (4) Immerse component in stripping solution. NOTE: The stripping action can be speeded by periodically brushing with a fiber brush to remove degraded material. (a) (b) (5) Aluminum Parts: Immerse the entire part for one hour. Titanium Parts: Immerse the part to completely cover the areas coated with silicone rubber. Stripping should be completed within a four hour period.
Remove the part from the tank, brush with a fiber brush, and visually inspect for complete removal of the silicone rubber. Continue stripping if removal was incomplete. Maximum total immersion time allowed is 18 hours. Rinse the part in water or an acceptable rinsing solution, then pressure rinse cavities and recesses. Dry the part with shop air. For aluminum parts only: If necessary, touch up bare aluminum surface per TASK 70-43-07-380-007, Chemical Touch-Up Surface Refinishing Process for Aluminum.
(6) (7) (8)
EFFECTIVITY: ALL
70-23-20
STRIPPING SILICONE RUBBER FROM TITANIUM AND ALUMINUM Page 2 Dec 01/03
STRIPPING ELECTROLESS NICKEL - STRIPPING ELECTROLESS NICKEL FROM MARAGE 250 TASK 70-23-21-110-040 1. Stripping Electroless Nickel from Marage 250 SUBTASK 70-23-21-99G-040 A. General. (1) This procedure describes an alternate chemical strip method for removal of Electroless Nickel (AMS 2405) from Marage 250 (B50TF95).
SUBTASK 70-23-21-110-402 B. Equipment. (1) The following equipment is required for the application of this process. (a) Personnel safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency shower, protective clothing against electro-plating products and means for neutralizing acid or alkaline splashing. Fire safety equipment and extinguishers. Processing plant for neutralizing waste and used solutions if required by government regulations. Efficient ventilation system for extracting and neutralizing vapors. A stainless steel (300 series) plating remover solution tank deep enough to allow a sufficient clearance between the bottom of the parts being stripped and bottom of the tank to allow for sludge accumulation. The tank should also have the following: 1 A plain steel heater, teflon electric heater or plate coils capable of heating the bath solution to 1808F (828C)
(b) (c) (d) (e)
CAUTION: DO NOT USE AIR AGITATION. 2 Mechanical agitation. NOTE: Mechanical agitator with plastisol shaft and propeller is recommended. 3 Exhaust ventilation.
EFFECTIVITY: ALL
70-23-21
STRIPPING ELECTROLESS NICKEL FROM MARAGE 250 Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: ALL HARDWARE, FOR EXAMPLE, STIRRER SHAFT/MOTOR, AND TANK MUST BE AT GROUND POTENTIAL. STRAY CURRENT THAT MAY EXIST IN IMPROPERLY GROUNDED HARDWARE WILL SET UP A GALVANIC CELL CAUSING SEVERE ATTACK OF THE STEEL. (f) A water rinse tank made of stainless steel or rigid plastic and a water spray gun.
SUBTASK 70-23-21-110-401 C. Solution Enstrip EN-79 Enstrip EN-86 Material Oil, Water Displacing SUBTASK 70-23-21-110-403 D. Procedure. WARNING: THE PLATING REMOVER OPERATING SOLUTIONS AND THEIR INDIVIDUAL PARTS ARE STRONGLY ALKALINE IN NATURE AND MAY CAUSE SKIN AND EYE BURNS. AVOID SKIN AND EYE CONTACT. IN CASE OF CONTACT, FLUSH SKIN AND EYES WITH PLENTY OF COOL, CLEAN WATER FOR 15 MINUTES. IN THE EVENT OF EYE CONTACT OBTAIN IMMEDIATE MEDICAL ATTENTION. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES. Materials. No. S1133 S1186 No. C02-059 Operating Temperature 8F (8C) 175-185 (79-85) 175-185 (79-85) Operating Temperature 8F (8C) Ambient
WARNING: (1) (2) (3) (4)
Prepare one of the Plating Remover Solutions listed in Subtask 70-23-21-110-401, Materials. Heat the tank of prepared plating remover to 175-1858F (79-858C). Allow the solution to stabilize at temperature for 1 hour. Keep the tank cover closed during this period. Load the parts into an appropriate basket and immerse the parts in the plating remover solution.
EFFECTIVITY: ALL
70-23-21
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: PARTS TO BE STRIPPED MUST BE ELECTRICALLY INSULATED FROM THE TANK. ALL EQUIPMENT IN CONTACT WITH THE STRIPPING SOLUTION MUST BE FREE FROM STRAY POTENTIAL CURRENT CAPABLE OF SETTING UP A GALVANIC CELL WITHIN THE STRIPPING SOLUTION. DO NOT ALLOW THE PARTS TO TOUCH THE BOTTOM OR SIDES OF THE TANK OR COME INTO CONTACT WITH THE HEATING COILS. (5) (6) (7) (8) Mechanically agitate the solution and allow the parts to soak for 8-12 hours in the plating remover solution. Remove parts, hot water rinse, and air dry. If parts are to be stored without recoating, apply a protective oil, such as MIL-C16173 Grade 3 C02-059 to part by immersion. Replace cover on plating remover solution and turn off tank heater.
SUBTASK 70-23-21-110-404 E. Quality Assurance. (1) Visually inspect to ensure complete coating removal.
EFFECTIVITY: ALL
70-23-21
EFFECTIVITY: ALL
70-23-21
STRIPPING OF THERMAL BARRIER - STRIPPING OF THERMAL BARRIER TOP COATINGS AND NICKEL-CHROMIUM-ALUMINUM-YTTRIA BOND COATINGS TASK 70-23-22-110-041 1. Stripping of Thermal Barrier Top Coatings and Nickel-Chromium-Aluminum-Yttria Bond Coatings NOTE: TASK 70-23-23-330-008, Removal of Coatings by High Pressure Water Stripping, is an acceptable alternative to the process listed in this document, provided the selfsubstantiation requirements of the TASK are met. SUBTASK 70-23-22-99G-041 A. General. (1) This procedure provides a method to remove the duplex thermal barrier coatings (TBC) found on combustor and turbine mid frame casings. Use this procedure only in accordance with applicable engine manual repairs. Some base materials may require thermal treatments prior to use per the applicable engine manual repair section.
SUBTASK 70-23-22-110-411 B. Materials. No. S1137 C10-012
Consumable Product Acid Stripping Solution Fluorglas Masking Tape SUBTASK 70-23-22-110-412 C. Procedure. (1) (2) (3) (4)
Mask areas adjacent to TBC areas using masking tape C10-012. Grit blast area to remove ceramic top coat per TASK 70-21-04-120-002, Dry Abrasive Blast Cleaning - Method 4A. Use medium mesh (120 grit) alumina. Blow residual grit and coating from part using dry shop air. Remove masking tape.
CAUTION: DO NOT HEAT ACID MIXTURE TO INCREASE STRIPPING RATE. (5) (6) Remove NiCrAlY bondcoat by immersing in stripping solution S1137 for 3-4 hours. Maintain bath at room temperature, approximately 708F (218C). Remove part and rinse in cold water.
STRIPPING OF THERMAL BARRIER TOP COATINGS AND NICKEL-CHROMIUMALUMINUM-YTTRIA BOND COATINGS Page 1 Dec 01/03
EFFECTIVITY: ALL
70-23-22
STANDARD PRACTICES MANUAL AS907-1-1A (7) (8) (9) Rinse again with hot water. Air dry. If necessary, grit blast per TASK 70-21-04-120-002, Dry Abrasive Blast Cleaning Method 4A, using medium or fine mesh grit to remove loose residual coating.
(10) Using clean, dry shop air, blow residual grit from the surface. (11) If required, repeat Steps C.(5) through C.(10). SUBTASK 70-23-22-110-413 D. Quality Assurance. (1) Visually inspect to ensure complete coating removal.
EFFECTIVITY: ALL
70-23-22
STRIPPING OF THERMAL BARRIER TOP COATINGS AND NICKEL-CHROMIUMALUMINUM-YTTRIA BOND COATINGS Page 2 Dec 01/03
HIGH PRESSURE WATER STRIPPING - REMOVAL OF COATINGS BY HIGH PRESSURE WATER STRIPPING TASK 70-23-23-330-008 1. Removal of Coatings by High Pressure Water Stripping SUBTASK 70-23-23-99G-008 A. General. (1) This stripping method uses jets of high pressure water directed by small rotating nozzles to remove coatings. The procedure must have a high degree of control and repeatability. The equipment for this procedure must supply water to the stripping jets at a very high pressure. The materials (stripping coupons and sample piece part for evaluation) are to be provided by the source seeking approval.
(2) (3)
SUBTASK 70-23-23-330-081 B. Equipment. (1) The equipment to do the high pressure water stripping procedure must: (a) Permit the stripping head to be positioned as necessary to remove the coating. Generally standoff distances of 0.5 in. (13 mm) to 3.0 in. (76 mm) are used. Permit the nozzles to be set up in the same position for each operation. Stripping is normally accomplished with a nozzle to work piece angle between 80 and 100 degrees. Keep the part and/or the stripping head moving to prevent erosion of the part surface, i.e. maintain relative motion between work piece and water jet nozzle. Static stripping (the part and stripping head do not move) is not permitted. Have an interlock feature which prevents operation of the water jets until the part or the stripping head is in motion. The interlock should deactivate the water jets and the pump in the event the parameters fall outside the acceptable motion parameters limit. The control system used will prevent part damage from the water jets by accurately monitoring and controlling parameters. The system used, either articulated arm or robot should have a collision sensor which automatically activates an emergency stop. Have pressures and flows that will remove the coating with minimum effect from the surface of the part. This water pressure will be between 20,000 and 60,000 psi (138,000-410,000 kPa). Water flows are typically from 0-4 gallons (015 liters) per minute.
REMOVAL OF COATINGS BY HIGH PRESSURE WATER STRIPPING Page 1 Dec 01/03
(b)
(c)
(d)
(e)
EFFECTIVITY: ALL
70-23-23
STANDARD PRACTICES MANUAL AS907-1-1A (f) Single or multiple orifice stripping heads can be used to remove coatings with minimal base metal removal. No requirements on the orifice size and/or number of orifices is defined. Process parameters are dependent on the specific stripping head design chosen, depending on repair requirements. In order to facilitate the use of this process with multiple repair cycles, it is recommended that the maximum amount of base material removed per repair cycle be limited to less than 0.001 in. (0.0025 mm). There are exceptions to this, depending on the type of hardware processed. It will be necessary to verify machine stripping parameters on sample coupons, both coated and uncoated.
(g)
(2)
Vendors that have been identified as sources of complete systems are: Progressive Technologies. Refer to the List of Suppliers in Step D. of Subtask 7080-00-800-003. Praxair / TAFA Concord. Refer to the List of Suppliers in Step D. of Subtask 70-8000-800-003. Advanced Systems Technologies Incorporated (AST). Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. Flow International Corporation. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003.
(3)
The equipment parameters will be established prior to the use of the water jet stripping system for stripping of engine components. It is recommended that uncoated coupons of the appropriate base material (including any heat treatment required) be processed at the selected parameters and metallographically inspected for maximum material loss. Additionally, one section of the coupon should be processed for three or more strip cycles or passes to determine the base material erosion as a result of multiple strip cycles on the bare metal substrate. After machine parameters have been established, a scrap part should be stripped to verify machine stripping parameters and manipulator programming.
(4)
SUBTASK 70-23-23-330-082 C. Process Requirements. (1) A demonstration of the procedure is necessary to achieve internal approval to strip hardware using the waterjet system. Unless special requirements are stated in the process document, the internal approval package should include the following data: NOTE: Parameters used on identical machines in use at other facilities will reduce the amount of work effort required to start stripping parts. (a) (b) A description of the system and appropriate positioning and interlocking features. A demonstration of the stripping procedure on sample coupons with photo micrographs to verify the amount of base metal erosion. Reference Subtask 70-23-23-330-081, Equipment. for base material removal amounts allowed for the coated and un-coated sections of the sample. The coupons shall
EFFECTIVITY: ALL
70-23-23
STANDARD PRACTICES MANUAL AS907-1-1A represent the same base material/coating combination as the part that is to be stripped. (c) Identification of the following parameters involved with the stripping procedure: 1 2 3 4 5 6 7 8 (d) Turntable speed (relative surface speed) Stripping head rpm Stripping head stand off distance Angle of attack to the part surface System pressure used Nozzle sizes used Number of nozzles used in the stripping head Number of passes required for coating removal.
A demonstration on sample hardware.
SUBTASK 70-23-23-330-083 D. Procedure. (1) Set up and fixture the part to be stripped in the water jet cell. The part must be fixtured to prevent excessive part movement during stripping and allow for precise nozzle to part orientation. Do the high pressure water jet stripping as follows: (a) (b) Load appropriate CNC control program into the water jet cell controller for the type of part to be stripped. Make sure the correct stripping head is attached to the machine as identified by the computer programmed instructions. Verify that each nozzle has the correct orifice size loaded. Make sure the proper pressure is correctly set on the pump, if manual setting is necessary. Start part rotation and/or stripping head moving. Both must achieve process parameter speeds before stripping starts (i.e., water on). NOTE: Movement of the part or stripping head is not the same as the rotational movement of the water nozzles on the stripping head. There must be relative movement between the stripping head and work piece. The water jets must not remain at the same place on the part.
(2)
(c) (d)
EFFECTIVITY: ALL
70-23-23
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: DO NOT START THE WATER JETS UNLESS THE PART OR THE STRIPPING HEAD IS MOVING. THE PART WILL BE DAMAGED IF THE WATER JETS ARE PERMITTED TO REMAIN IN ONE PLACE. (e) (f) Initiate the normally closed on/off valve to start waterflow to the nozzle or stripping head assembly. Operate the equipment for the number of passes required to remove the coating or until the maximum number of passes allowed for the base metal has been achieved. The maximum number of passes is determined by the repair process evaluation or by specific criteria in the applicable manual. Deactivate the on/off valve to stop the water flow to the nozzle or stripping head assembly. Stop the part and/or stripping head movement. Record serial number of the stripped part in the work cell control log.
(g) (h) (i) (3)
Visually inspect the stripped surface of the part to verify the coating has been removed. Areas of residual coating after stripping prior to prep-for-thermal spray are allowed up to 5 percent as a percentage of the total coated surface area. If some of the coating remains on the surface, remove as follows: (a) (b) If the procedure plan permits, do the high pressure water strip procedure again. If the procedure plan does not permit the high pressure water stripping procedure to be done again, remove the coating with a chemical stripping procedure. Refer to the applicable manual that contains the part to be stripped or contact Product Support Engineering to get the correct chemical stripping procedure. COMPRESSED AIR FOR CLEANING OR DRYING SHALL BE REDUCED TO LESS THAN 30 PSIG (207 KPA). PROTECT EYES AND SKIN FROM FLYING CHIPS OR PARTICLES.
(4)
WARNING:
(5)
Clean the part with compressed air or a water rinse and remove the part from the cell.
SUBTASK 70-23-23-330-084 E. Quality Assurance. (1) Make sure the water jet orifices are not eroded. Determine the maximum number of operating hours before the nozzle becomes worn. Replace the nozzle inserts on a regular schedule. As part of the regular equipment maintenance schedule, do a check of the part movement/water pump safety interlock. Verify motion speed indications on the stripping nozzle or head assembly and part rotation tooling.
(2) (3)
EFFECTIVITY: ALL
70-23-23
ULTRASONIC STRIPPING - ULTRASONIC STRIPPING OF ROTATING PARTS TASK 70-23-24-110-001 1. Ultrasonic Stripping of Rotating Parts SUBTASK 70-23-24-99G-001 A. General. (1) This ultrasonic stripping procedure establishes the controls necessary to assure proper operation to remove bond coat and prevent damage to rotating engine hardware.
SUBTASK 70-23-24-110-001 B. Equipment. (1) The following equipment is required for the application of this process: (a) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products, and means for neutralizing acid or alkaline splashing. Processing plant for neutralizing waste and used solutions. Efficient ventilation system for extracting and neutralizing vapors. NOTE: The ultrasonic cleaning energy will heat the cleaning solution due to its own energy. This needs to be taken into consideration in any application that requires strict temperature control. (d) Processing tank with temperature control. 1 The tank should be made of stainless steel and be equipped with either a heat exchanger or heating coil capable of controlling the working solution in the temperature range of 708-1708F (218-778C). The tank must be clearly labeled with the power density, frequency of the unit, and rated capacity in gallons (or liters). This label shall be fixed to the outside of the face of the tank in full view of the operator.
(b) (c)
(e)
Generator Requirements: 1 2 The generator must be a fixed power rating and not be adjustable by the operator. 20 kHz minimum, 6-10 watts/square inch (0.93-1.55 watts/square cm) of tank bottom.
EFFECTIVITY: ALL
70-23-24
ULTRASONIC STRIPPING OF ROTATING PARTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A 3 Recommended watts per gallon (watts per liter) for tank sizes are as follows: 4 Less than 30 gallons (114 liters): 30-40 watts per gallon (7.9-10.6 watts per liter) 31-100 gallons (115-379 liters): 20-30 watts per gallon (5.3-7.9 watts per liter) 101-250 gallons (380-946 liters): 15-25 watts per gallon (4.0-6.6 watts per liter).
Piezoelectric type transducers should be equipped with High Sweep Modulation capability for optimum cleaning efficiency. The sweep range should be 2 to 3 kHz. This requirement is not necessary for magnetostrictive type transducers.
(f)
Fixture Requirements: CAUTION: IT IS CRITICAL THAT THERE BE NO DIRECT MECHANICAL CONTACT BETWEEN THE ENGINE COMPONENT AND THE ULTRASONIC TRANSDUCER. IF CONTACT DOES OCCUR, HOLD THE PARTS AND CONSULT YOUR HONEYWELL REPRESENTATIVE FOR DISPOSITION. 1 2 3 The parts must be suspended in the tank completely independent of the tank sidewalls, tank bottom, or transducer surface. Parts are not to be hung from the side of the tank without a rack to insulate it from mechanical vibration. Parts must be fully submerged in the solution. If the part has holes and/ or cavities the fixture/part must be rotated to assure that they are filled with cleaning solution and all air is removed. If more than one part is cleaned at a time, they must not touch each other.
SUBTASK 70-23-24-110-002 C. Materials. (1) For ultrasonic stripping use a 50:50 Nitric acid and water solution at 708-908F (218328C). Refer to TASK 70-00-99-800-001, Solution S0001.
SUBTASK 70-23-24-110-003 D. Requirements. (1) A demonstration of the procedure is necessary for each new application and each model type of ultrasonic equipment to achieve internal approval to strip hardware using an ultrasonic system. Unless special requirements are stated in the process document, the internal approval package must include the following data as a minimum:
EFFECTIVITY: ALL
70-23-24
STANDARD PRACTICES MANUAL AS907-1-1A (a) Identification of following process parameters involved in the stripping procedure: 1 2 3 4 5 6 7 8 9 Description of tank including rated capacity and actual gallons (liters) used. Description of generator and frequency used. Watts/square inch (watts/square cm). Watts/gallon (watts/liter). Description of High End Modulation (sweep frequency) range. Process time in tank (range) permitted per procedure. Fixture identification number and description of how supported. Solution concentration and temperature. Description of temperature control (heat exchanger). NOTE: The seal teeth coating must initially be removed using the standard strip procedure without ultrasonics. The pre-test FPI is then taken to document the part as received. NOTE: Typical stripping times required to remove bond coat materials are less than four hours. A 24 hour qualification test therefore represents 6x to 10x safety measure. (b) A demonstration of the stripping procedure is necessary on the application in question. This demonstration must involve a 24 hour exposure of the component using the processing parameters developed for that application. A fluorescent penetrant inspection per the procedure and sensitivity defined on the process documents is to be performed before and after this exposure test to document that no cracks were initiated and that the conditions are appropriate for the given application. A demonstration of the stripping procedure is necessary on a stock loss coupon of the alloy in question. This demonstration must use 2x (two times) the maximum permitted time developed for the application. Stock loss testing to be performed per ARP 1755.
(c)
SUBTASK 70-23-24-110-004 E. Procedure. WARNING: NITRIC ACID, O-N-350, IS HIGHLY TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION AND VAPOR CONTROL ARE REQUIRED. AVOID ALL CONTACT.
(1)
Fill tank with the cleaning solution specified for the application to the rated capacity of the tank. If the solution is to be heated, turn on the heater and monitor temperature.
EFFECTIVITY: ALL
70-23-24
STANDARD PRACTICES MANUAL AS907-1-1A (2) Degas the cleaning solution by running the ultrasonic generator for approximately thirty minutes to degas the solution. If the solution has been previously run, but the unit has been turned off for some time, run the unit for a minimum of 10 minutes to assure degassing is again complete. Position parts to be cleaned in required fixture. Turn off ultrasonic generator. NOTE: The ultrasonic generator should be OFF during loading and unloading of parts. CAUTION: THE PART OR FIXTURE MUST NOT COME INTO DIRECT CONTACT WITH THE TANK SIDEWALL, TANK BOTTOM, OR TRANSDUCER SURFACE DURING OPERATION OR MECHANICAL DAMAGE TO THE PART COULD OCCUR. (5) (6) Load the fixtured part(s) into the tank to appropriate depth. Turn on the ultrasonic generator and clean for amount of time specified for the specific application. If appropriate, confirm that the High Sweep Modulation accessory is in use. Turn off the generator and remove the fixtured part(s) from the ultrasonic tank. Drain solution from the part and rinse carefully under running water. Dry the part using clean, dry air.
(3) (4)
(7) (8)
SUBTASK 70-23-24-110-005 F. Quality Assurance. (1) Visually check the part to see that all thermal spray coatings have been removed from the part.
EFFECTIVITY: ALL
70-23-24
NICKEL AND SILVER PLATE - STRIPPING NICKEL AND SILVER PLATE TASK 70-23-25-110-001 1. Stripping Nickel and Silver Plate SUBTASK 70-23-25-99G-001 A. General. (1) The following is an effective method to remove nickel or silver plate, or mechanically deposited (smeared) plating from austenitic alloys, nickel based alloys, stainless, and titanium, for subsequent inspection, cleaning, or replating.
CAUTION: THE STRIPPING SOLUTION USED IN THIS PROCEDURE WILL ATTACK MARTENSITIC OR LOW ALLOY STEELS SUCH AS HASTELLOY B, HASTELLOY W, INCOLOY 903, R95, OR R88DT. REACTION WITH THESE MATERIALS IS VERY RAPID. BASE ALLOY MUST BE COMPLETELY COMPATIBLE WITH THIS SOLUTION. (2) Make sure the base alloy is compatible with this stripping solution.
SUBTASK 70-23-25-110-001 B. Materials. (1) (2) (3) (4) Refer to TASK 70-00-99-800-001, Solution S0001. Maskant C10-014 Tape C10-067 Acetone C04-003
SUBTASK 70-23-25-110-002 C. Procedure. (1) Strip nickel or silver plate as follows: (a) Clean non-titanium parts with one of the procedures that follow. Parts must be thoroughly clean to permit uniform stripping. 1 Alternative procedures available. Clean non-titanium parts in accordance with TASK 70-21-22-110-042, Cleaning Method No. 22, Light-Duty Aqueous Cleaning Method 1. Alternative procedure. Clean non-titanium parts in accordance with TASK 70-21-22-110-050, Cleaning Method No. 22, Light-Duty Aqueous Cleaning Method 2.
EFFECTIVITY: ALL
70-23-25
STRIPPING NICKEL AND SILVER PLATE Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A 3 Alternative procedure. Clean non-titanium parts in accordance with TASK 70-21-06-110-004, Cleaning Method No. 6, Heavy-Duty Alkaline Cleaner (without inhibited phosphoric acid). Alternative procedure. Clean non-titanium parts in accordance with TASK 70-21-07-110-005, Cleaning Method No. 7, Three-Step Heavy-Duty Alkaline Descaling (without inhibited phosphoric acid. Alternative procedure. Clean non-titanium parts in accordance with TASK 70-21-03-160-001, Cleaning Method No. 3, Steam Cleaning.
5 (b)
Clean titanium parts with one of the procedures that follow. Parts must be thoroughly clean to permit uniform stripping. 1 Alternative procedures available. Clean titanium parts in accordance with TASK 70-21-22-110-042, Cleaning Method No. 22, Light-Duty Aqueous Cleaning Method 1. Alternative procedure. Clean titanium parts in accordance with TASK 70-21-22-110-050, Cleaning Method No. 22, Light-Duty Aqueous Cleaning Method 2. Alternative procedure. Clean titanium parts in accordance with TASK 70-21-09-110-007, Cleaning Method No. 9, Light-Duty Alkaline Cleaning of Titanium Alloys. Alternative procedure. Clean titanium parts in accordance with TASK 70-21-03-160-001, Cleaning Method No. 3, Steam Cleaning.
4 (c)
Mask plated or coated areas that are not to be stripped if applicable to the configuration. 1 2 3 Seal all openings with acid-resistant tapeC10-067. Dip entire part into maskantC10-014, and let dry. Repeat until three coats have been applied. Trim by cutting through the tape and maskant around the areas to be stripped. Expose only the area to be stripped by peeling away the tape and maskant, but do not remove tape/maskant from the openings.
(d) (e) (f) (g)
Immerse part slowly in stripping solution ( TASK 70-00-99-800-001, Solution S0001) at ambient to 1608F (718C), for 30 5 minutes. Remove the part from the tank, and rinse in overflowing water and/or by using water spray to remove residual acid. Peel remaining tape/maskant from the part. Use acetone C04-003 to remove any maskant or tape that does not peel away readily. Alternative procedures available. Steam clean the entire part as described in TASK 70-21-03-160-001, Cleaning Method 3, Steam Cleaning, then follow with a pure steam rinse (no detergent added).
EFFECTIVITY: ALL
70-23-25
STANDARD PRACTICES MANUAL AS907-1-1A (h) (i) Alternative procedure. Clean parts in accordance with TASK 70-21-22-110042, Cleaning Method No. 22, Light-Duty Aqueous Cleaning Method 1. Alternative procedure. Clean parts in accordance with TASK 70-21-22-110050, Cleaning Method No. 22, Light-Duty Aqueous Cleaning Method 2.
SUBTASK 70-23-25-110-003 D. Quality Assurance. (1) (2) Visually check for the removal of all traces of oxides and coatings from the threaded areas and washer face. Ensure that the periodic checks are made of solution contents and operating parameters, per the solutions sheets. If the solution fails to strip the parts within the specified time, check the acid content, decant, and add. If the solution fails to strip the parts within two times the specified time, discard the solution and recharge the tank.
EFFECTIVITY: ALL
70-23-25
EFFECTIVITY: ALL
70-23-25
STRIPPING THREE-LAYER SERMATEL - STRIPPING OF THREE-LAYER SERMATEL 1638 COATING TASK 70-23-26-110-001 1. Stripping of Three-Layer SermaTel 1638 Coating SUBTASK 70-23-26-99G-001 A. General. (1) The method that follows gives an effective way to remove the three-layer SermaTel 1638 coating to permit subsequent inspection or refinishing. If it is necessary to strip the three-layer SermaTel 1638 coating from a part, use the procedure that follows.
SUBTASK 70-23-26-110-001 B. Equipment. (1) Safety equipment and devices which are standard equipment in surface treatment shops such as: eye bath, emergency showers, protective clothing against electroplating products, and means for neutralizing acid or alkaline splashing. Processing plant to neutralize waste and used solutions. Efficient ventilation system to extract and neutralize vapors. An alkaline degreasing tank made from stainless steel with a heating coil that is capable of heating the solution to 2008F (938C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and a water spray gun, used after the degreasing bath. A permanganate cleaning tank made from stainless steel with a heating coil that is capable of heating the solution to 2008F (938C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and a water spray gun, used after the alkaline permanganate bath. An acid stripping tank made from polypropylene equipped with a fume hood and a heating coil that is capable of heating the solution to 1408F (608C). A water rinse tank made from stainless steel (or a carbon steel tank with a polypropylene lining) and a water spray gun, used after the acid stripping bath.
(2) (3) (4) (5) (6) (7)
(8) (9)
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70-23-26
STRIPPING OF THREE-LAYER SERMATEL 1638 COATING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-23-26-110-002 C. Materials. Table 1. Consumable Materials Consumable Product Scotch Brite No. C10-010
Table 2. Alkaline Degreasing/Rust Removing Solution Description Turco 4781-7 or Turco 4781-7L Ardrox 185 or Ardrox 185L Turco 4181 or Turco 4181-L Ferlon Cee-Bee J84A or Cee-Bee J84AL MagChem HDL-202 Eldorado HTP-1150 Eldorado HTP-1150L Applied 5-840 Solution No. S1005 S1024 S1006 S1027 S1026 S1150 S1161 S1162 S1176 Operating Temperature 8F (8C) 180-200 (82-93) 180-190 (82-88) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93) 180-200 (82-93)
Table 3. Alkaline Permanganate Solution Description Turco 4338-C or Turco 4338-L Ardrox 188 or Ardrox 188RFU Alkaline Permanganate Cee-Bee J88, Cee-Bee J88A, or Cee-Bee J88L Eldorado HTP-1190 Eldorado HTP-1190L Applied 5-770 Solution No. S1012 S1001 S1004 S1014 S1163 S1164 S1177 Operating Temperature 8F (8C) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 160-200 (71-93) 180-200 (82-93)
Table 4. Acid Stripping Solution Description HCl + Inhibitor Solution No. S1190 Operating Temperature 8F (8C) 130-140 (54-60)
EFFECTIVITY: ALL
70-23-26
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-23-26-110-003 D. Procedure. (1) If there is excessive dirt on the part, clean the part as follows. Use a solvent or, if necessary, a light duty aqueous cleaning process as specified in the applicable manual. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH A LARGE AMOUNT OF WATER. AVOID BREATHING VAPORS. USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
WARNING:
WARNING: (2)
Immerse the part in a tank that contains one of the alkaline degreasing/rust removing solutions. Refer to paragraph B.(4) and Table 2. Make sure the solution is kept at the specified temperature for 30 minutes (plus or minus 5 minutes). Rinse the part with a water jet or immerse the part in a tank with water at room temperature. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH A LARGE AMOUNT OF WATER. AVOID BREATHING VAPORS. USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
(3)
WARNING:
WARNING: (4)
Immerse the part in a tank that contains one of the alkaline permanganate solutions. Refer to paragraph B.(6) and Table 3. Make sure the permanganate solution is kept at the specified temperature for 60 minutes (plus or minus 5 minutes). NOTE: If you operate the alkaline permanganate solution bath in the low end of the temperature range it will extend the bath life but can decrease the solution effectiveness. Conversely, if you operate the alkaline permanganate solution bath at the high end of the temperature range it will improve the cleaning ability of the solution but can decrease the bath life and increase the frequency of de-sludging.
(5)
Rinse the part with a water jet or immerse the part in a tank with water at room temperature.
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70-23-26
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: HYDROCHLORIC ACID IS TOXIC. DO NOT LET THIS MATERIAL TOUCH YOU. USE PERSONAL PROTECTION EQUIPMENT. USE VAPOR/FUME CONTROL OR A RESPIRATOR. USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
WARNING: (6)
Immerse the part in a tank that contains the stripping solution. Refer to paragraph B.(8) and Table 4. Make sure the stripping solution is kept at the specified temperature for 30 minutes plus or minus 5 minutes. Rinse the part with a water jet or immerse the part in a tank with water at room temperature. If necessary, brush the part with a non-metallic brush or Scotch Brite pad C10-010. USE THERMAL GLOVES WHEN YOU MOVE OR TOUCH HOT OR COLD PARTS. HOT OR COLD PARTS CAN CAUSE INJURY.
(7)
WARNING: (8)
Immerse the part in hot water at 150 to 2008F (66 to 938C) minimum. Keep the part submerged until the part temperature reaches the water temperature. USE EYE PROTECTION WHEN YOU USE COMPRESSED AIR TO CLEAN, COOL, OR DRY PARTS OR TOOLS. PARTICLES CAN CAUSE AN INJURY TO YOUR EYES. DO NOT USE MORE THAN 30 PSIG (200 KPA). DO NOT POINT COMPRESSED AIR AT YOURSELF OR OTHER PERSONS.
WARNING:
(9)
Dry the part. Use clean, dry shop air.
(10) Do a visual inspection for the removal of all traces of coating. (11) If there is coating still on the part, repeat paragraph D.(6) through paragraph D.(10).
EFFECTIVITY: ALL
70-23-26
SOLUTION SHEETS - SOLUTION SHEETS FOR CONSUMABLE MATERIALS TASK 70-23-99-800-001 1. Solution Sheets for Consumable Materials SUBTASK 70-23-99-800-001 A. General. (1) The 70-23-99 section has been moved to 70-00-99 and the Solution Sheets have new, 4-digit numbers. Since some repairs and other documents might still refer to the old numbers, the following information is provided as a cross-reference. New Solution Sheet Number in 70-00-99 TASK 70-00-99-800-001, Solution S0001
Old Solution Sheet Number in 70-23-99 S1
Title of Solution Sheet Consumable Materials Stripping Silver and CopperNickel-Indium Thermal Sprayed Coatings Consumable Materials Stripping Pure Aluminum Thermal Spray Consumable Materials Stripping Tungsten Carbide Thermal Sprayed Coating Consumable Materials Stripping Bond and Finish Coatings Consumable Materials Stripping Nickel or Silver Plate Consumable Materials Chemical Stripping of Chromium Plate Consumable Materials Electrolytic Stripping of Chromium Plate Consumable Materials Urethane Stripping Compounds Consumable Materials Stripping Tungsten or Chrome Carbide Thermal Spray Consumable Materials Stripping Nickel Plate
S2
TASK 70-00-99-800-002, Solution S0002 TASK 70-00-99-800-003, Solution S0003 TASK 70-00-99-800-004, Solution S0004 TASK 70-00-99-800-005, Solution S0005 TASK 70-00-99-800-006, Solution S0006 TASK 70-00-99-800-007, Solution S0007 TASK 70-00-99-800-008, Solution S0008 TASK 70-00-99-800-009, Solution S0009 TASK 70-00-99-800-010, Solution S0010
S3
S4
S5 S6
S7
S8
S9
S10
EFFECTIVITY: ALL
70-23-99
SOLUTION SHEETS FOR CONSUMABLE MATERIALS Page 1 Dec 01/03
Old Solution Sheet Number in 70-23-99 S11
New Solution Sheet Number in 70-00-99 TASK 70-00-99-800-011, Solution S0011 TASK 70-00-99-800-012, Solution S0012 TASK 70-00-99-800-013, Solution S0013 TASK 70-00-99-800-014, Solution S0014 TASK 70-00-99-800-015, Solution S0015
Title of Solution Sheet Consumable Materials Stripping Epoxy Resin from Aluminum Consumable Materials Stripping Anodized Coating from Aluminum Consumable Materials - Acid Bath Consumable Materials Oxidizing - Alkaline Cleaners Consumable Materials Stripping Aluminum Honeycomb Bonded with Narmco Metalbond 328 Consumable Materials Stripping of Alumina-Nickel Aluminum Composite and Duplex Coatings Consumable Materials Cyanide Stripping Aluminum Oxide/Nickel Aluminide Coatings
S12
S13 S14 S15
S16
TASK 70-00-99-800-016, Solution S0016
S17
TASK 70-00-99-800-017, Solution S0017
EFFECTIVITY: ALL
70-23-99
SOLUTION SHEETS FOR CONSUMABLE MATERIALS Page 2 Dec 01/03
ETCHING PROCEDURES - ETCHING PROCEDURES FOR FLUORESCENT-PENETRANT INSPECTION TASK 70-24-00-110-033 1. Etching Procedures for Fluorescent-Penetrant Inspection SUBTASK 70-24-00-99G-033 A. General. Chemical etching is primarily used on stationary weldments as a preliminary step before fluorescent-penetrant inspection. Smeared surface material, caused by operations such as benching of welds, can mask cracks and flaws in metal parts preventing identification during the inspection process. Etchants are selected to remove this extraneous material and open the flaws to detection. The etchants are classified in the following text by their application to specific metals; however, other applications may be made when authorized by the applicable manual. Chemical etching may be done by one of two methods: TASK 70-24-01-110-034, Swab Etching Procedure, or TASK 70-24-02-110-035, Dip Etching Procedure. SUBTASK 70-24-00-110-331 B. Classification. (1) Etchants of the following classes shall be used only on the metals listed, unless otherwise specified by the applicable manual. (a) Swab Etchants. Refer to TASK 70-24-01-110-034, Swab Etching Procedure. Class A: Magnesium alloys Class B: Titanium alloys Class C: Stainless Steel Etchant (Schantz Reagent): 300 and 400-series stainless steels, precipitation hardening steels, A-286, maraging steels, Rene 77, Rene 80, Rene 95, Rene 100, Rene 125, Udiment 500, Sel 15, TDNi-Cr, Waspalloy, M152, 17-4 PH, Hastelloy B, C and W. Class D: Superalloy Etchant, Rene 41, Astroloy, Hastelloy X, HS 188, Inconel 718 and all other Inconel metals. Class E: Carbon steel, bearing and gear alloys. Class F: Aluminum alloys. Class G: Inconel 718 (Alternate), and all other nickel based alloys. (b) Dip Etchants. Not applicable.
EFFECTIVITY: ALL
70-24-00
ETCHING PROCEDURES FOR FLUORESCENT-PENETRANT INSPECTION Page 1 Dec 01/03
EFFECTIVITY: ALL
70-24-00
ETCHING PROCEDURES FOR FLUORESCENT-PENETRANT INSPECTION Page 2 Dec 01/03
SWAB ETCHING PROCEDURE - SWAB ETCHING PROCEDURE TASK 70-24-01-110-034 1. Swab Etching Procedure SUBTASK 70-24-01-99G-034 A. General. This procedure describes the materials and process for swab etching used as a preliminary step before fluorescent-penetrant inspection. These etchants are used as described herein or with exceptions as specified for individual parts in the applicable manual. SUBTASK 70-24-01-110-341 B. Materials. (1) Refer to TASK 70-24-99-990-005, Consumable Materials - Etching Solutions. (a) Storage: Plastic containers (polyethylene or polypropylene, acid-resistant quality) are recommended for storing all stock etchant solutions. Class B etchant attacks glass. Class B and Class F etchants must be stored in plastic bottles; Class A, C, D, E, and G etchants may be stored in glass bottles, if desired. Store away from heat, and keep from freezing. Shelf Life: The shelf life of each class of etchants is as follows: Class A: 1 year. Class B: One month in a stoppered plastic bottle. Allow 60 minutes for gas evolution and discharge after mixing and before replacing the bottle stopper. Class C: 6 months. Class D: 60 minutes (after mixing with the HCl), hydrochloric acid has a shelf life of one year. Class E: 6 months. Class F: 1 year Class G: 1 year. (c) Handling: Each container of stock solution should be labelled with the Class identification of the contents, and the expiration date of the shelf-life period. A supply of distilled water should be available for mixing etchants, and for rinsing them from the etched area of the work.
(b)
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70-24-01
SWAB ETCHING PROCEDURE Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-24-01-110-342 C. Procedure. WARNING: THE SHORT SHELF LIFE OF CLASS D ETCHANT MUST BE OBSERVED AS IT CAN BECOME HAZARDOUS TO PERSONNEL. AFTER ONE HOUR, THE MIXTURE MAY BECOME UNSTABLE AND GIVE OFF NITROUS OXIDE. IF TIGHTLY CAPPED, THE CONTAINER MAY BURST. THE MIXTURE MAY ALSO BECOME QUITE HOT. THE ACTIVE INGREDIENTS OF ETCHANTS ARE TOXIC AND CORROSIVE. USE IN A WELL VENTILATED AREA, WEAR PROTECTIVE CLOTHING, GLOVES AND FACE SHIELD. AVOID PROLONGED BREATHING OF VAPORS AND CONTACT WITH THE SKIN. IF ETCHING SOLUTION GETS INTO EYES, FLUSH THOROUGHLY WITH COOL WATER UNDER EYELIDS, AND OBTAIN MEDICAL ATTENTION AT ONCE.
WARNING:
(1)
Unless otherwise specified in the applicable Shop Manual, etch specimens as follows: (a) (b) All surfaces to be etched must be free from oil, grease, scale, or other extraneous material. Pour a small quantity of stock solution into a clean plastic beaker or dish. This quantity will be the working solution, and is not to be returned to the stock bottle. Saturate a cotton swab with the working solution, and swab the surface to be etched for 60-90 seconds, all Classes, except Class G. Class G etching time is 3-4 minutes. Keep the etching solution within defined boundaries of the area to be etched. Masking may be required to contain etchant to areas for etching. NOTE: Keep fresh solution in contact with the metal surface at all times by dipping the swab into the working solution periodically. Rub the swab continuously over the surface of the metal being etched, to prevent the formation of an inert sludge. (d) (e) After etching, blot up etching solution from the metal surface with a clean paper towel or cloth. Gently wipe the etched area at least three times with a cloth or paper towel saturated with clean water. Blot dry with clean cloth or paper towel.
(c)
CAUTION: DO NOT POUR WORKING SOLUTION BACK INTO STOCK CONTAINER. DISPOSE OF THE USED WORKING SOLUTION IN ACCORDANCE WITH LOCAL ENVIRONMENTAL, HEALTH, AND SAFETY REGULATIONS. (f) Discard used working solution, rinse and dry plastic container for future use.
EFFECTIVITY: ALL
70-24-01
SWAB ETCHING PROCEDURE Page 2 Dec 01/03
DIP ETCHING PROCEDURE - DIP ETCHING PROCEDURE TASK 70-24-02-110-035 1. Dip Etching Procedure CAUTION: THIS SOLUTION WILL ATTACK THERMAL SPRAYED SILVER COATINGS AND BRAZE ALLOYS. REACTION WITH THESE MATERIALS IS VERY RAPID. BASE MATERIAL MUST BE COMPATIBLE WITH THIS SOLUTION. SUBTASK 70-24-02-99G-035 A. General. Not applicable.
EFFECTIVITY: ALL
70-24-02
DIP ETCHING PROCEDURE Page 1 Dec 01/03
EFFECTIVITY: ALL
70-24-02
DIP ETCHING PROCEDURE Page 2 Dec 01/03
ETCHING SOLUTIONS - CONSUMABLE MATERIALS - ETCHING SOLUTIONS TASK 70-24-99-990-005 1. Consumable Materials - Etching Solutions SUBTASK 70-24-99-99G-005 A. General. The following commercially available reagents are required for the formulation of etchants used to prepare metals for localized swab prior to fluorescent-penetrant inspection. Compound* Acetic Acid Cupric Chloride Ferric Chloride (FeCl3.6H20) Hydrochloric acid (Muriatic) 208 Be Hydrofluoric acid Methanol (Methyl alcohol) Nitric Acid Oxalic acid Sodium hydroxide Sulfuric acid Tartaric acid Water Strength 99.7% __ __ 36.5-38% 48% __ 69-71% __ Pellets 95-98% __ Distilled or de-ionized
*Commercial grade or better is satisfactory as long as concentration/strength is as stated. SUBTASK 70-24-99-990-051 B. Instructions. CAUTION: ALWAYS ADD ACIDS TO WATER WHILE STIRRING; NEVER ADD WATER TO ACIDS. (1) (2) Add chemicals in the order and proportions given in the following formulas. Mix each thoroughly before adding the next. Ferric chloride, used in formulating the Class C and G etchants, is usually supplied in lump form. To facilitate mixing, it may be added in molten form (melting point: 378C or 98.68F). It may also be crushed and added in granular or powdered form
EFFECTIVITY: ALL
70-24-99
CONSUMABLE MATERIALS - ETCHING SOLUTIONS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A with constant stirring until dissolved. Ferric chloride is extremely hygroscopic; keep unused supply tightly sealed. NOTE: Ferric chloride dissolves fastest when hot 1508-1908F (65.68-87.88C) water is used. (3) Glacial (99.7%) acetic acid freezes at slightly below room temperature 628F (16.68C). To facilitate pouring and mixing, immerse the container in lukewarm water for a few minutes. Loosen stoppers or caps from full bottles carefully to prevent spurting.
(4)
SUBTASK 70-24-99-990-052 C. Formulas and Swab Etchants. WARNING: THE ACTIVE INGREDIENTS OF ETCHANTS ARE TOXIC AND CORROSIVE. USE IN A WELL VENTILATED AREA, AND WEAR PROTECTIVE CLOTHING, GLOVES AND FACE SHIELD. AVOID PROLONGED BREATHING OF VAPORS AND CONTACT WITH THE SKIN. IF ETCHING SOLUTION GETS INTO EYES, FLUSH THOROUGHLY WITH COOL WATER UNDER EYELIDS AND OBTAIN MEDICAL ATTENTION AT ONCE.
(1)
The following formulas are based on quantities that, with average usage, are estimated not to last beyond the shelf-life period of the etchant. Larger or small quantities may be mixed, as desired, as long as proportions are equal to those given. Oxalic acid or Tartaric acid Distilled water Distilled water Nitric acid Hydrofluoric acid Distilled water Sulfuric acid Hydrochloric acid Nitric acid Acetic acid Ferric chloride* 10 grams 90 ml 62 ml 35 ml 3 ml 750 ml 150 ml 1800 ml 500 ml 750 ml 454 grams (1 pound)
CLASS A: Magnesium Alloys CLASS B: Titanium Alloys CLASS C: Stainless Steels Schantz Reagent
NOTE: *NOTE: Add ferric chloride without delay. Refer to paragraph 1.B.(2) in Subtask 70-24-99-990-051, Instructions. CLASS D: High Chromium Superalloys Schantz Reagent (Class C)** Hydrochloric acid** 10 ml 10 ml
NOTE: **NOTE: Shelf life one hour after mixing, mixture must be used immediately. CLASS E: Carbon steels, bearing and gear alloys Distilled Water Nitric acid 95 ml 5 ml
EFFECTIVITY: ALL
70-24-99
STANDARD PRACTICES MANUAL AS907-1-1A CLASS F: Aluminum Alloys CLASS G: Inconel 718 and all other nickel based alloys SUBTASK 70-24-99-990-053 D. Formulas for Dip Tank Etchants. (1) Not applicable. Distilled Water Sodium hydroxide Distilled water to make Cupric chloride Hydrochloric acid Methanol 60 ml 20 grams 100 ml 1 gram 4 ml 4 ml
EFFECTIVITY: ALL
70-24-99
EFFECTIVITY: ALL
70-24-99
INSPECTION METHODS - INSPECTION METHODS TASK 70-30-00-200-001 1. Inspection Methods SUBTASK 70-30-99-99G-001 A. General. (1) Engine parts are inspected for many different problems that can occur during their service. The inspection methods used to find and measure these problems are given in the repair and restoration manuals that apply to these parts. Usually, methods used as standards throughout the aircraft industry are not given in this section. When special methods or changes to standard commercial processes are required, or when special equipment is necessary, the procedures are included here.
SUBTASK 70-30-00-200-011 B. Types of Inspection (1) The types of inspection required for maintenance and restoration operations can be divided into the following categories: (a) (b) Visual, including the use of special lights, dental mirrors, borescopes, magnifying glasses, etc. Dimensional, including the use of micrometers, vernier calipers and height gages, dial indicators, comparators, and special gages. Refer to TASK 7031-00-220-001, Dimensional Inspection, and TASK 70-31-01-220-002, Use Limits for Standard Measuring Instruments. Magnetic Particle. Refer to TASK 70-32-01-240-001, Magnetic-Particle Method. Fluorescent-Penetrant. Refer to TASK 70-32-02-230-001, FluorescentPenetrant Inspection, and TASK 70-32-02-230-001, Spot-FluorescentPenetrant Inspection. Radiographic, including the use of gamma- or X-rays to find internal defects. Refer to TASK 70-32-05-260-001, Radiographic Inspection. Ultrasonic, to find and measure defects below the surface by their reflection or their effect on ultrasonic vibrations. Refer to TASK 70-32-06-270-001, Ultrasonic Inspection, TASK 70-32-09-270-002. Eddy current, to find and measure defects on and below the surface by their effect on an electrical field generated by a calibrated coil instrument. Refer to: TASK 70-32-07-250-001, High Speed and Slow Speed Eddy Current Inspection of Circular Holes in Inconel or Titanium Engine Parts,
EFFECTIVITY: ALL
(c) (d)
(e) (f)
(g)
70-30-00
INSPECTION METHODS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A TASK 70-32-08-250-002, 2 MHz Manual Eddy Current Inspection of Bores in Titanium Alloy Rotating Engine Hardware, TASK 70-32-10-250-003, 2 MHz Manual Eddy Current Inspection of Bores in Rotating Engine Hardware Using Systems Under Computer, Numeric, or Robotic Control, TASK 70-32-12-250-005, Eddy Current Inspection of Bores in Inconel Rotating Engine Hardware, SUBTASK 70-30-00-200-013 C. Marking of Parts. (1) When it is necessary to mark an engine part, use only approved marking methods and materials. Refer to TASK 70-16-00-350-001, Marking Practices.
SUBTASK 70-30-00-200-014 D. Inspection Terms. (1) The terms used throughout this manual to describe defects are listed in the following table. Table 1. Term Bi-monthly Bi-weekly Blister Definition Every two months/60 days Every two weeks/14 days A raised portion of a surface caused by separation of the outer layers of the parent material or of a coating applied to it. Indentation of the surface by concentrated loads or impact. A change in the elasticity or resilience of the parent material, usually caused by aging, extreme cold, chemical action, or cold-working. A large-scale deformation of the original contour of a part, usually caused by pressure or impact from a foreign object, structural stresses, excessive localized heating, highpressure differentials, or any combinations of these. Bubble Flaking Oxide formation Peeling Scale Slag inclusion (weld) Peening Hammering Cold worked hard such as Packing Pre-formed (O-Ring) Associated Terms
Brinelling Brittle
Buckle
Ballooning Bend Bulge Crease Curl Dent (not to be confused with small-area defect in heavy material) Depression
EFFECTIVITY: ALL
70-30-00
Table 1. (Cont) Term Buckle (continued) Definition Associated Terms Distortion Elongation Fold Indentation Kink Protrusion (hollow) Rupture (result of excessive buckling) Uneven Warpage Wrinkle A rapid, destructive, oxidizing action, usually caused by higher temperature than the parent material can withstand. Change in color appearance often indicates this condition. Burn out (missing piece) Erosion Corrosion Guttered Heat-check Heat deterioration Hole (burn) Overheated Oxidation Rub Wear
Burn
Burnishing
Smoothing of a metal surface by mechanical action, but without a loss of material. Generally found on plain bearing surface. Surface discoloration is sometimes visible around the outer edges. Normal burnishing from operational service is not detrimental if the coverage approximates the carrying load and there is not evidence of burns. A rough edge or a sharp protrusion on the edge or surface of the parent material. See "Gall" or "Scratch". Waves or ripples on a machined surface, in the direction of the cut, caused by a loose or dull cutting tool, or a tool that is not rigidly supported. A breaking away of the edge of the parent material, usually caused by heavy impact from a foreign object.
Burr
Chafing Chatter marks
Chip
Break Nick (similar to "Chip" but no parent material is removed). Notched spalling (usually a broken-away flat surface).
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Table 1. (Cont) Term Cold shut Definition A casting defect resulting from metal flowing into an area from 2 directions, thereby forming a discontinuity at the meeting line. A mass of small pits which cumulatively create a large, shallow cavity (usually rough in the surface of the parent material). A parting or discontinuity in the parent material. Associated Terms Seam
Corrosion
Pit
Crack
Break Cold shut (castings) Crater (castings) Fatigue damage Fissure Fracture Lap (forgings) Rupture Seam Separation Slit Tear
Crack (fabrications)
A parting of parent metal, or of the metal in a welded zone. Parent metal crack limits include all cracks in the parent metal beyond the heat-affected zone, as measured 1/8 inch from the weld fusion line. Weld cracks limits include all cracks in the heat-affected zone. A mesh of minute hairline cracks found in glazed or baked-on coated surfaces, generally caused by temperature change or by deformation of parent metal. Cracks do not penetrate into parent metal. Gradual continuous distortion or plastic flow under constant stress. Any alteration or change of shape, dimension or configuration resulting from stress or damage. A completely smooth surface depression caused by pressure or impact from a smooth, rounded foreign object. The parent material is displaced, but is not separated.
Crazing
Creep
Deformation
Bend Creep Distortion Peen
Dent
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Table 1. (Cont) Term Deviation Definition Any condition that causes a part to differ from the manufacturers blueprint. Associated Terms Damage Defect Flaw Imperfection Irregularity Crack Seam Cold shut Lap Bend Deformation
Discontinuity
An interruption in the normal physical structure or configuration of a part. Any twisting, bending or permanent strain that results in misalignment or change of shape. Gradual wearing away of a surface caused by a fluid (gas or liquid) flowing over the surface. Wear is generally caused by fine particles of foreign material entrained in hot engine gases flowing at a high velocity. The progressive fracture of a material under cyclic stress loading. See "Spalling". Wearing away by lowamplitude rubbing against another metal (generally associated with press fit or close fitting parts). A defect caused by the movement of 2 surfaces in contact with each other. In most cases, an accumulation of foreign material is deposited on the parent material. A wide, rough scratch or group of scratches, usually with one or more sharply incised corners, and frequently accompanied by deformation or removal of parent material.
Distortion
Erosion
Fatigue
Crystallization Fretting Flaking Wear Galling
Flaking Fretting
Galling
Pickup
Gouge
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Table 1. (Cont) Term Groove Definition A long, narrow, continuous depression caused by pressure of a moving surface in contact with the parent material. Local distortions. Associated Terms If depression is shallow and smooth, see "Wear"; if depression is sharp, see "Scratch". Blister Buckle Bubble Out-of-round Burr
High spots
High metal
Displaced metal adjacent to a defect such as a scratch, nick or gouge, which is raised above the surrounding surface. The corrosion of unprotected metal (with no coating) that has been exposed to hot gases. When first exposed, the surface becomes rough and appears to be pitted and pockmarked. Also, there is a noticeable difference in the colors of the exposed and unexposed surfaces. Further exposure of surface to hot gases causes it to blister and, in time, flake off in layers. The state of being out-of balance. Unequal distribution of weight about the axis of rotation, which usually results in vibration. Foreign material embedded in metal during solidification, or formed by subsequent reaction of the solid metal. The visible evidence that a material defect exists, even though the defect itself may not be visible to the naked eye.
Hot Gas Corrosion (Sulfidation)
This kind of corrosion differs from that normally found on surfaces attacked only by salt in the atmosphere. In hot gas corrosion, the hot gases convert sulphur to sulfide in the presence of salt. The metal is attacked by the resulting deposits.
Imbalance
Inclusion
Indication
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Table 1. (Cont) Term Looseness Definition Abnormal movement of a part, or insufficient securing of a part. Associated Terms Backed out Excessive play Excessive back-lash Insufficient torque Shaky Sloppy Unbottomed Unpinned Unwired Eccentric Out-of-round Out-of-square Mismatched Unmatched Chip Dent Notch
Misalignment
A mismatching or malformation of any part which either prevents perfect assembly or results in faulty operation and/or ultimate failure. A surface impression with sharp corners or bottom, usually caused by pressure or impact from a sharp-edged object. The parent material is displaced, but usually none is separated. Term used to describe surface defects that can be seen but not felt with fingernail or scriberpoint. An abnormal sound involving moving parts, usually an increase in volume or a change of pitch.
Nick
No apparent depth
Noise
Bumps (sound) Chatters Clicks Grates (usually gears) Grinds Hums Rattles Rubs Scrapes (sound) Screeches Thumps Whistles Clogged Contaminated Plugged Restricted
Obstruction
Prevention of free flow of fluid (air, oil, fuel, water) because of foreign material in the flowpath or malformation of the part.
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Table 1. (Cont) Term Oil-canning (snapping action) Definition Snapping or popping displacement of sheet metal when restrained at its edges like a diaphragm, wall, or bottom of an oil can. All material in a single part except the weld, braze filler, or heat-affected zone (within 1/8 inch [3.2 mm] of the fusion line). Transfer of one material into or onto the surface of another in contact with it, usually as a result of friction-heating. Burr Gall Embedment Inclusion Pile-up Protrusion Metallization Bound Compressed Flattened Seized Smashed (without separation into pieces) Squashed Squeezed Porosity Pits Associated Terms Buckling
Parent metal
Pickup
Pinched
Distortion of one or more surfaces of the parent material, caused by pressure.
Pinholes
Very small pits or holes caused by the evolution of gas from a metal during solidification or after chemical treatment. A minute depression or cavity having no sharp, high-stress corners in the surface of the material. Pits are usually caused by chemical reaction (rusting, chemical corrosion).
Pit
Corrosion Crater Electrolytic Cavity Inclusion Perforation Pinholes Pock-marked Pit Pinholes If impression is shallow and smooth, see "Wear". If impression is sharp, see "Scratch".
Porosity Rub
Areas containing numerous pits or pinholes A surface depression or displacement caused by 2 surfaces moving while in contact with each other.
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Table 1. (Cont) Term Scale Definition A layer of metallic oxides formed by chemical action of oxygen on the exposed surface of the metal, usually while hot. See "Scratch". A long, narrow, sharpcornered impression caused by the movement of a sharp object across the surface of the parent material. A welding or binding of faces which prevent further movement. Abrasion Chafe Furrow Groove Score Bound up Frozen Tight Wedged Welded (without external heating) Associated Terms Burn
Scoring Scratch
Seizure
Semi-monthly Semi-weekly Sheet-metal dent
Twice a month at equally spaced intervals Twice a week at equally spaced intervals A smooth, large-area depression in the parent material. Cracking off or flaking off of small particles of metal from the surface, usually in thin layers or localized spots. A crack-like separation caused by too much tensile shear force, usually the result of abusive machining or metal removal. The act of putting a balanced component out-of-balance. Usually "Imbalance" is meant. A hard surface-film of partially carbonized hydro-carbon, such as oil, which is built up when the part is heated to or above the breakdown point of the fluid. Banded Discolored Oxidized Stained Buckle
Spalling
Flaking Fretting Galling
Tear
Unbalance
Varnish film
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Table 1. (Cont) Term Wear Definition Relatively slow removal of parent material in the process of operation (not always visible to the naked eye). Associated Terms Abrasion Attrition Brinnelled Chafed Chattering Erosion Fraying Fretting Friction Galling Glazing Groove Interference Oxidation Roughness Rubbed Scarfed Scuffed Uneven Weak
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DIMENSIONAL INSPECTION - DIMENSIONAL INSPECTION TASK 70-31-00-220-001 1. Dimensional Inspection SUBTASK 70-31-00-99G-001 A. General. (1) The tolerancing of form and positional characteristics is indicated on drawings by means of either a written note or a feature control symbol (see Figure 1, Page 2). The definition and use of these symbols is illustrated in Figure 2 (Sheet 1 of 2), Page 3 and Figure 3 (Sheet 1 of 8), Page 8.
SUBTASK 70-31-00-220-011 B. Definitions. (1) Datum. The reference surface, line or point with respect to which other geometric characteristics are located and measured. (2) Condition of Size. See Figure 1, Page 2. Two conditions of size are recognized in positioning and form tolerancing: "Maximum Material Condition" (MMC) which is the condition least favorable for assembly with a mating part, and "Regardless of Feature Size" (RFS) in which form and positional tolerances apply regardless of the size of the feature specified.
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DIMENSIONAL INSPECTION Page 1 Dec 01/03
Feature Control Symbols and Condition of Size Figure 1
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Dimensional Practices Figure 2 (Sheet 1 of 2)
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Dimensional Practices Figure 2 (Sheet 2)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-31-00-220-012 C. General Rules - MMC and RFS. (1) Rule I: When the material condition ( Figure 1, Page 2) of a specific positional or form tolerance is not stipulated on a drawing, the following rules apply: Maximum Material Condition (MMC). When no modifier is specified, true position applies at MMC. Maximum material condition also applies to datum references other than plane surfaces. Regardless of Feature Size (RFS). When no modifier is specified, concentricity tolerances and tolerances of form apply regardless of feature size. RFS also applies to datum references. Where tolerances of form or position, or of datum references, apply to a screw thread, the tolerances apply to the pitch diameter.
Rule II:
Rule III:
SUBTASK 70-31-00-220-013 D. Glossary of Dimensional Inspection Terms. (1) The following glossary provides interpretation and explanation of the dimensional system and practices used in the repair and restoration manuals. Definition Clearance measured in a direction parallel to the engine centerline. Movement of a part in a direction parallel to the engine centerline. The bevel machined or formed at an edge to eliminate a sharp corner. The relationship between 2 circumferences having radii of different lengths, but the same center and direction. NOTE: Does not include total indentations or out-of-roundness. A line across a circle, which intersects and is perpendicular to the centerline. The total indicator reading (TIR) shown when an indicator contacts a cylindrical or conical surface, and the piece is rotated 360 degrees about an established axis. The reading includes both the eccentricity and out-of-roundness.
Term Axial clearance Axial movement Chamfer (Refer to Detail B, Figure 3 (Sheet 1 of 8), Page 8) Concentricity (Refer to Detail E, Figure 3 (Sheet 3 of 8), Page 10)
Diameter (Diametral) Diametral runout (Refer to Detail C, Figure 3 (Sheet 2 of 8), Page 9)
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Term Drop (Refer to Detail D, Figure 3 (Sheet 2 of 8), Page 9) Eccentricity (Refer to Detail E, Figure 3 (Sheet 3 of 8), Page 10)
Definition The relative distance between 2 or more planes, measured from a common reference surface. The distance between the axis of rotation and parallel axis through the geometric center of a part. NOTE: This condition does not include out-ofroundness or local imperfections. The total indicator reading shown when the indicator contacts the face of a workpiece at a fixed distance from an established axis, while the workpiece is rotated 360 degrees about that axis. NOTE: This method does not measure concavity or convexity, which are related to the term "flatness". The total deviation of a surface of a part from a true plane or straight edge. Free from all external forces or constraints. Refer to "total indicator reading" (TIR). Two or more straight lines or flat planes extending in the same direction, which are equidistant at all points. Clearance measured in a direction perpendicular to the engine centerline. The total indicator reading shown when an indicator is removed radially across the face of a part at 90 degrees to an established axis. This measurement will show any existing concavity/ convexity. Movement of a part in a direction perpendicular to the engine centerline. The distance from the center to the circumference of a circle or arc. The opposite of "free-state". The holding or clamping of a flexible part to a specified shape or configuration. Total radial variation from a true circle or cylinder; may be measured as the total indicator reading when the part is rotated 360 degrees about its own geometric center, or onehalf the difference between the maximum and minimum diameters.
Face runout (Refer to Detail F, Figure 3 (Sheet 3 of 8), Page 10)
Flatness (Refer to Detail G, Figure 3 (Sheet 4 of 8), Page 11) Free-state Full indicator reading (FIR) Parallelism (Refer to Detail J, Figure 3 (Sheet 5 of 8), Page 12) Radial clearance Radial flatness (Refer to Detail K, Figure 3 (Sheet 6 of 8), Page 13)
Radial movement Radius Restrained
Roundness cylindricity (Refer to Detail L, Figure 3 (Sheet 6 of 8), Page 13)
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Term Sharp edge
Definition An outside corner formed by the intersection of 2 flat surfaces or by the intersection of a concave radius and another surface, which form an abrupt angle. Burrs may extend from the surface machined last, and thus increase the sharpness of the edge. The intersection of 2 lines, axes, planes or surfaces forming an angle of 90 degrees.
Squareness perpendicularity (Refer to Detail A, Figure 3 (Sheet 1 of 8), Page 8) Straightness (Refer to Detail H, Figure 3 (Sheet 4 of 8), Page 11) Total indicator reading (TIR)
A tolerance zone of uniform width along a line that does not deviate in direction. The mathematical difference between maximum and minimum readings of an indicator as it traverses one or more typical or specified lines on the surface being inspected. The exact location, which can be calculated with known data, of a point or series of points on a part. True position may be stated either as degrees of arc from an established point, or as coordinate dimensions from horizontal and vertical centerlines or other features.
True position (Refer to Details M and N, Figure 3 (Sheet 8), Page 15)
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Inspection Terms Figure 3 (Sheet 1 of 8)
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Inspection Terms Figure 3 (Sheet 8)
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USE LIMITS FOR INSTRUMENTS - USE LIMITS FOR STANDARD MEASURING INSTRUMENTS TASK 70-31-01-220-002 1. Use Limits for Standard Measuring Instruments SUBTASK 70-31-01-99G-002 A. General. (1) The internal accuracy of measuring instruments decreases with increasing size; therefore, the tolerance of a part dimension may be less than the internal tolerance of the instrument used to measure that dimension. The tolerance limitations tabulated in this section are to be observed when special inspection tooling is not specified or is not available. Whenever the total part tolerance for a specific size is closer than the tolerance limit shown for a specific size and type of measuring instrument, a more precise checking device must be used.
SUBTASK 70-31-01-220-021 B. Error in Measurement. (1) The design, manufacture and operation of all inspection devices must be controlled so that, with 95 percent assurance, the total error of measurement resulting from any combination of lack of repeatability and accuracy shall not exceed 25 percent of the total tolerance. (Ninety-five percent assurance means that 95 out of 100 readings will be within the allowable error in measurement.) EXAMPLE: If the dimensional limits of a given part are 1.200-1.202 inches (30.4830.53 mm), the estimated total error in measurement of the inspection device, as determined by tests, shall not exceed 0.0005 inch (0.013 mm) [with 95 percent assurance] that is, 1.200 - 1.202 inch (30.48-30.53 mm) x 0.25 = 0.0005 inch (0.013 mm). (2) Temperature effects should be considered when performing critical, small tolerance inspections. Parts should be as close as possible to the same temperature, 58F (2.78C), as the inspection tooling. This will minimize the effects that variation in temperature may have on measurement accuracy. If there is a significant variation in temperature, allow time for the component and the tooling to reach the same temperature. NOTE: The concern is for the variation in temperature between the inspection tooling and component, not the temperature changes of the component itself that may occur because of normal shop environmental changes. Consideration should also be given to sources of localized heating or cooling, radiant heaters, skylights, air conditioner outlets, etc. that may cause a component or a portion of a component to be heated or cooled resulting in a temperature variation between the component and the inspection tooling. Hand held inspection tooling used for critical, small tolerance inspections, should be fitted with thermal pads to prevent heating of the tooling that could effect measurement accuracy.
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USE LIMITS FOR STANDARD MEASURING INSTRUMENTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-31-01-220-022 C. Effect of Measurement Error on Dimensional Limit. (1) The allowable error of measurement does not in any way affect the measured value obtained by the inspector, which he must compare directly with the dimensional limits stated in the repair manual. EXAMPLE: If the dimensional limit is 1.202 inches (30.53 mm) as above, and the inspection reading (using the applicable measuring device) is 1.2021 inches (30.533 mm), the dimension is out-of-limits. SUBTASK 70-31-01-220-023 D. Limits of Measuring Devices. (1) The types and sizes of measuring devices listed below may be used to measure dimensions whose tolerance range is no closer than those shown. Table 1. Standard Outside Micrometer Size of Standard Outside Micrometer, (inches) 0-1 (0.0001 graduations) 0-1 (0.001 graduations) 1-2 through 5-6 (0.0001 graduations) (0.001 graduations) 6-7 through 8-9 9-10 through 11-12 12-13 through 14-15 15-16 through 17-18 18-19 through 23-24 24-25 through 32-33 33-34 through 35-36 36-37 through 41-42 42-43 through 45-46 46-47 through 47-48 0.0012 0.002 0.002 0.002 0.003 0.0035 0.004 0.0045 0.004 0.005 0.006 0.010 Maximum Total Part Tolerance (inch) 0.0008 0.002
For dimensions greater than 48 inches (1219 mm), having a total tolerance range of 0.010 inch (0.25 mm) or less, an indicator gage and master must be used unless otherwise specified by the repair manual.
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Table 2. Standard Inside Micrometer Size of Standard Inside Micrometer, (inches) 3-4 through 11-12 12-13 through 23-24 24-25 through 35-36 36-37 through 42-43 43-44 through 47-48 48-49 through 52-53 53-54 through 57-58 58-59 through 62-63 63-64 through 67-68 Maximum Total Part Tolerance (inch) 0.002 0.003 0.004 0.005 0.006 0.007 0.008 0.009 0.010
Table 3. Vernier Calipers Vernier Calipers (Size being measured inches) 0-6 6-12 12-24 24-36 36-48 48-60 60-72 Maximum Total Part Tolerance (inch) 0.004 0.005 0.007 0.010 0.013 0.017 0.020
Table 4. Standard Vernier Height Gage Size of Standard Vernier Height Gage (inches) 12 24 36 48 Maximum Total Part Tolerance (inch) 0.003 0.004 0.005 0.006
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Table 5. Miscellaneous Measuring Instruments Miscellaneous Measuring Instruments Depth micrometers Decimal scale Radius gage Dial bore gage Dial caliper (0.001 inch graduations) Dial indicators (electronic) under (0.0001 inch graduations) (0.0005 inch graduations) (0.001 inch graduations) Periphery tape Telescopic hole gage Small hole gage Bevel protractor Maximum Total Part Tolerance (inch) 0.002 0.030 0.010 0.001 0.005 0.001 0.001 0.005 0.010 0.010 0.004 0.004 15 minutes
When it is necessary to measure to the fourth decimal place, optical collimators, optical or mechanical electro-limit gages or equivalent must be used.
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ACCEPTABILITY LIMITS - ACCEPTABILITY LIMITS FOR FLUORESCENT-PENETRANT INSPECTION TASK 70-31-02-220-003 1. Acceptability Limits for Fluorescent-Penetrant Inspection SUBTASK 70-31-02-99G-003 A. General. (1) This procedure defines acceptance limits for parts subject to fluorescent-penetrant inspection. Acceptable defects for most major components are defined in applicable sections of the applicable manual. Where these limits are not defined in the applicable manual the following apply.
SUBTASK 70-31-02-220-031 B. Inspection Classes. (1) (2) (3) (4) (5) The following classes apply: Class A: Nonwelded Parts. Class B: Fusion Welded Parts. Class C: Nonwelded Parts (No Spacing Required). Class D: Fusion Welded Parts (No Spacing Required).
SUBTASK 70-31-02-220-032 C. Acceptability Limits. NOTE: Following are the acceptable defects listed for each of the above classes. (1) Class A (Nonwelded Parts). (a) Only the following indications are acceptable, and they should not be closer than 0.50 inch (12.7 mm). 1 2 (2) All indications less than 0.03 inch (0.8 mm) long. Indications 0.03-0.06 inch (0.8-1.5 mm) long not interpreted as cracks.
Class B (Fusion Welded Parts). (a) Indications no longer than 0.06 inch (1.5 mm) when viewed under black light shall be allowed if the following conditions are met. 1 The indication is confined to the weld, or to the heat affected zone of the parent metal within 0.09 inch (2.3 mm) of the weld line. See Figure 1, Page 3.
ACCEPTABILITY LIMITS FOR FLUORESCENT-PENETRANT INSPECTION Page 1 Dec 01/03
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STANDARD PRACTICES MANUAL AS907-1-1A 2 The indication, if it is in the heat affected zone, shall be in a transverse direction to the weld. The spacing between indications shall be no less than 0.50 inch (12.7 mm) for indications occurring in the heat affected zone, and no less than 0.25 inch (6.4 mm) for indications occurring in the weld.
(b)
Only the following indications are acceptable outside heat affected zone, and they shall be no closer than 0.50 inch (12.7 mm). 1 2 All indications less than 0.03 inch (0.8 mm) long. Indications 0.03-0.06 inch (0.8-1.5 mm) long not interpreted as cracks.
(3)
Class C (Nonwelded Parts, No Spacing Required). (a) Only the following indications are acceptable. 1 2 All indications less than 0.03 inch (0.8 mm) long. Indications 0.03-0.06 inch (0.8-1.5 mm) long not interpreted as cracks.
(4)
Class D (Fusion Welded Parts, No Spacing Required). (a) Indication no longer than 0.06 inch (1.5 mm) shall be allowed if the following conditions are met. 1 The indication is confined to the weld, or to the heat affected zone of the parent metal within 0.09 inch (2.3 mm) of the weld line. See Figure 1, Page 3. The indication, if it is in the heat affected zone shall be in a transverse direction to the weld.
2 (b)
Only the following indications are acceptable outside the heat affected zone. 1 2 All indications less than 0.03 inch (0.8 mm) long. Indications 0.03-0.06 inch (0.8-1.5 mm) long not interpreted as cracks.
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Weld Area and Heat Affected Zone Figure 1
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TUBE FORMING LIMITS - TUBE FORMING REQUIREMENTS FOR SECTION REPLACEMENT REPAIRS TASK 70-31-03-220-013 1. Tube Forming Requirements for Section Replacement Repairs SUBTASK 70-31-03-99G-013 A. General. (1) This procedure gives the necessary requirements to form tubing stock for use in section replacement repairs on external tubing.
SUBTASK 70-31-03-220-131 B. Bending Requirements. (1) Ovality The cross section in the area of a tube bend shall not have ovality more than 5 percent for tube working pressures of 1000 psi (6900 kPa) and over, or 10 percent for tube working pressures under 1000 psi (6900 kPa). The percent ovality is defined by Figure 1, Page 4 and the following formula: Percent ovality = (Actual Maximum OD - Actual Minimum OD) x 100 divided by Specified Nominal OD (a) Tube working pressures shall be interpreted as 50 percent of the hydrostatic test pressure requirements as specified in the applicable engine manual. If no hydrostatic test pressure requirements are specified, the ovality shall not exceed 10 percent. Reduced Wall Thickness, caused by bending or sizing, must be within the limits given in table 1. Min Wall Thickness Remaining (Percent of Nominal) 85 70
(b)
Nominal Wall Thickness 0.020 in. (0.51 mm) or less 0.020 in. (0.51 mm) or more (2) Surface Characteristics - Tubes (a) (b)
Cracks and sharp corners are not acceptable. Sharp edges and burrs must be removed to facilitate safe handling and to prevent mating parts from being cut and scarred. Sharp corners and burrs may be removed by any process, but the radius or equivalent must not exceed 0.030 in. (0.76 mm) for aluminum alloys or 0.015 in. (0.38 mm) for all other materials. Inspection may be made by sight or feel. Gages may be used to verify acceptance or rejection of this characteristic.
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TUBE FORMING REQUIREMENTS FOR SECTION REPLACEMENT REPAIRS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (c) (d) (e) Wrinkles and kinks when measured as defined in Figure 2, Page 5 shall not exceed the values shown in table 2, Page 2. Scratches, Nicks, Cuts Shall Not Exceed the Value Shown in table 3, Page 3. Dents shall not exceed a depth of 10 percent of the nominal tube OD. No radius within the dent or between the dent and its adjacent tube surface shall be less than three times the nominal tube wall thickness. More than two dents in any three consecutive 8.0 in. (203 mm) of tube length is not permitted. For high pressure tubing, 500 psi (3450 kPa) and over, wall thickness more than 0.020 in. (0.51 mm): scratches, nicks, and cuts including those superimposed in dents that are in excess of five percent of the tube wall thickness must be removed by burnishing or by blending per TASK 70-42-00350-002, Blending Procedures, (etching and FPI not required). In this operation, the wall thickness shall not be reduced by more than 10 percent of the nominal wall thickness. In the bent portion of a tube this maybe in addition to the thinning caused by bending. The surface finish in the reworked area shall be as good or better than the original, and the surface protective treatment shall be restored by the same or equivalent process of the original. See table 3, Page 3. Tube Working Pressure (See Paragraph X) Less than 500 psi Depth of Wrinkles and Kinks (Max A) Wall Wall Thickness 0.020 Thickness Greater In. or Less Than 0.020 In. 2 percent of nominal tube OD or 2 percent of nominal tube OD or 0.040 in. (1.02 mm) whichever is 0.040 in. (1.02 mm) whichever is smaller smaller 1 percent of nominal tube OD or 2 percent of nominal tube OD or 0.020 in. (0.51 mm) whichever is 0.040 in. (1.02) whichever is smaller smaller For low pressure tubing, under 500 psi (3450 kPa), wall thickness, 0.020 in. (0.51 mm) or less: any scratches, nicks, or cuts on the tube with edges raised above the surrounding surface will not be acceptable. Scratches, nicks, or nuts which can be felt with an 0.040 in. (1.02 mm) radius scriber using a light finger pressure shall be removed by burnishing or blending per TASK 70-4200-350-002, Blending Procedures, (etching and FPI not required) providing the final wall thickness is not reduced by more than an additional 10 percent of the nominal wall thickness. See table 3. For high pressure tubing, 500 psi (3450 kPa) and over, wall thickness 0.020 in. (0.51 mm) or less: no scratches, nicks, or cuts which can be felt with an 0.040 in. (1.02 mm) radius scriber using a light finger pressure are permitted in the bends. Such scratches nicks, or cuts in straight portions of the tube shall be removed by burnishing or blending per TASK 70-42-00-350-002, Blending Procedures, (etching and FPI not required) providing the final wall thickness is not reduced by more than an additional 10 percent of the nominal wall thickness. See table 3, Page 3.
(f)
500 psi or more
(g)
(h)
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Depth of Scratches, Nicks, and Cuts (Max) Tube Working Pressure Wall Thickness (See Engine Manual) 0.020 in. (0.51 mm) Or Less Less than 500 psi (3450 kPa) Per Step (g) 500 psi (3450 kPa) or more Per Step (h)
Wall Thickness Greater Than 0.020 in. (0.51 mm) 10 percent of nominal tube wall thickness Per Step (f)
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Ovality Figure 1
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Wrinkles and Kinks Figure 2
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ACCEPTABILITY LIMITS - ACCEPTABILITY LIMITS FOR OPEN-FACE HONEYCOMB TASK 70-31-04-220-001 1. Acceptability Limits for Open-Face Honeycomb SUBTASK 70-31-04-99G-001 A. General. (1) This standard practice defines the allowable acceptability limits for asmanufactured, open-face honeycomb only. After the open-faced honeycomb is brazed to the inseparable assembly, the limits in the applicable manual apply.
SUBTASK 70-31-04-220-051 B. Classification. (1) (2) (3) (4) This standard practice provides for the identification and requirements for the following classes. CLASS A: Recommended for 0.125 in. (3.18 mm) honeycomb cell size. CLASS B: Recommended for 0.062 in. (1.59 mm) honeycomb cell size. CLASS C: Recommended for 0.031 in. (0.79 mm) honeycomb cell size.
SUBTASK 70-31-04-220-052 C. Honeycomb Definitions. (1) Nomenclature Cell The following definitions apply to this standard practice. Definition A single enclosed opening in a honeycomb core formed by attaching rows of ribbons at positioned nodes. The dimension from the cell bottom to the top of the cell ( see Figure 2, Page 4). The inside distance between the two opposite and parallel sides of a cell. Nodes flats shall not be considered cell sides when measuring for cell size. Cell size is measured with the raw honeycomb in a flat state before the formation into a ring ( see Figure 1, Page 3). A pattern of metal ribbons formed and joined that results in multiple open adjacent cells.
Cell Height Cell Size
Honeycomb Core
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ACCEPTABILITY LIMITS FOR OPEN-FACE HONEYCOMB Page 1 Dec 01/03
Nomenclature Honeycomb Core Width
Definition A point-to-point dimension of the honeycomb core measured transverse to the ribbon direction ( see Figure 2, Page 4). Any area in which two edges of honeycomb core are joined ( see Figure 3, Page 5). The ribbon surface that contacts an adjacent ribbon surface area. A cell not completely enclosed resulting from a machining operation. A cell not completely enclosed by the honeycomb ribbon by its position at the outer edge of the formed structure. Holes less than 0.015 in. (0.38 mm) in diameter. A single strip of metal that forms the cell wall. The joining of multiple ribbons in rows result in a honeycomb core. The connection (spot tacking or resistance welding) of two formed ribbons at points of contact. The direction parallel to the ribbon node as assembled in the honeycomb core.
Honeycomb Core Splice Node Open Cell Partial Cell
Pin Holes Ribbon
Ribbon Connection
Ribbon Direction
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Honeycomb Cell Figure 1
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Honeycomb Core Figure 2
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Honeycomb Core Splice Figure 3
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-31-04-220-053 D. Honeycomb Cell Requirements. NOTE: The following tolerances shall apply unless otherwise noted in the engine shop manual. (1) Honeycomb Cell Size. NOTE: Honeycomb cell size is the dimension as measured between the cell inside surfaces across the flats (see Figure 1, Page 3). (a) The average cell size shall be within plus or minus 6 percent (6%) from nominal cell size as specified per table 1. Table 1. Average Cell Size Variation (6% from nominal) Class-Cell Size (across flats) A 0.125 in. (3.175 mm) B 0.062 in. (1.575 mm) C 0.031 in. (0.787 mm) (b) Variation (across flats) 0.118 to 0.113 in. - (2.997 to 3.378 mm) 0.058 to 0.066 in. - (1.473 to 1.680 mm) 0.029 to 0.033 in. - (0.736 to 0.838 mm) No single cell shall vary from the nominal cell size by more than plus or minus 12 percent (12%) as specified per table 2. Table 2. Single Cell Size Variation (12% from nominal) Class-Cell Size (across flats) A 0.125 in. (3.175 mm) B 0.062 in. (1.575 mm) C 0.031 in. (0.787 mm) (2) Ribbon Connections. (a) The following limits shall not be exceeded when ribbons are attached at the nodes by spot tacking or resistance welding: 1 2 Each 0.25 in. (6.35 mm) of cell height in one node shall contain not more than two spot tacks. Pin holes (holes less than 0.015 in. (0.38 mm) in diameter) through nuggets in more than 10 percent of the nodes. Any hole larger than 0.015 in. (0.38 mm) in diameter through any one nugget is not allowed. Inspect the ribbon ends for mismatch at the core splice. A maximum mismatch of 0.003 in. (0.076 mm) is allowed (see Figure 3, Page 5). Variation (across flats) 0.110 to 0.140 in. - (2.794 to 3.556 mm) 0.055 to 0.069 in. - (1.397 to 1.752 mm) 0.027 to 0.035 in. - (0.686 to 0.889 mm)
3 (3)
Open Cells for Class A, B, and C.
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STANDARD PRACTICES MANUAL AS907-1-1A (a) (b) (4) Open cells at either edge of the honeycomb core resulting from machining or other processing shall not be allowed. Open cells at either end of the honeycomb core segment is allowed (see Figure 2, Page 4).
Finished Dimensions. (a) Finished dimensions of open faced honeycomb shall apply to the total core configuration. Width measurements shall be taken at the extreme edges of the honeycomb core.
(5)
Honeycomb Core Splices. (a) Core splices shall conform to the following: 1 2 3 Splices shall be joined on a diagonal. Splices shall not be closer than 2 inches (51 mm) to another splice (no point in the diagonal line). Specific splice geometry/configuration shall be defined in the applicable manual.
(6)
Non-Conventional Machining. (a) Non-conventional machining of the honeycomb core is permitted provided the surfaces meet the following requirements: 1 2 3 4 5 Average recast not to exceed 0.002 in. (0.051 mm). Maximum recast layer not to exceed 0.004 in. (0.102 mm). Microcracks are allowed in recast layer only. Surface finish requirements of non-conventional machined surfaces do not apply. Maximum intergranular attach not to exceed 0.0015 in. (0.038 mm).
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ACCEPTABILITY LIMITS - ENGINE PART SURFACE INTEGRITY ACCEPTABILITY LIMITS FOR NONTRADITIONAL MACHINED SURFACES TASK 70-31-05-220-001 1. Engine Part Surface Integrity Acceptability Limits for Non-Traditional Machined Surfaces SUBTASK 70-31-05-99G-001 A. General. (1) This Standard Practice presents requirements applicable to localized surface areas of repaired parts, as defined by the part-specific repair procedure, that are subjected to nontraditional machining. The use of nontraditional machining can cause significant surface integrity changes to localized areas resulting in alteration of the material or chemical properties of the part. (a) Classification 1 This Standard Practices contains the following classes. Unless otherwise specified, the requirements herein apply to all classes: CLASS A: Static Components - General applications. CLASS B: Static Components - Other part specific applications where previous experience with increased metallurgical limits on similar parts/materials/features exists (for example: laser drilled holes). CLASS C: Turbine Airfoil Components - Airfoil trailing edge holes/slots and all other features (tip cap, airfoil cutouts, and spoolie holes). CLASS D: Turbine Airfoil Components - Non-hole features such as seal slots, and scallops. CLASS E: Turbine Airfoil Components - Airfoil/band cooling holes. CLASS F: Rotating parts-disks, spools, shafts. CLASS G: Rotating parts other than disks, spools or shafts. CLASS H: Open-faced honeycomb seals. SUBTASK 70-31-05-220-051 B. Tools, Equipment, and Materials. (1) (2) As specified in each process reference. Consumable Materials: None.
SUBTASK 70-31-05-220-052 C. Referenced Publications. (1) The following documents form a part of this Standard Practice to the extent specified herein. Unless otherwise indicated, the latest issue shall apply.
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ENGINE PART SURFACE INTEGRITY ACCEPTABILITY LIMITS FOR NONTRADITIONAL MACHINED SURFACES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (a) American Society for Testing and Materials NOTE: In case of conflict between ASTM E 140, ASTM E 384, ASTM E 407, or ASTM E 915 and this manual, the requirements of this manual shall apply. ASTM E 140 - Standard Hardness Conversion Table for Metals. ASTM E 384 - Standard Test Method for Microhardness of Materials. ASTM E 407 - Standard Practice for Microetching Metals and Alloys. ASTM E 915 - Standard Test Method for Verifying the Alignment of X-Ray Diffraction Instrumentation for Residual Stress Measurement. (b) (c) TASK 70-30-00-200-001, Inspection Methods. TASK 70-34-00-200-003, Hardness Measurement - General.
SUBTASK 70-31-05-220-053 D. Definitions. (1) Nomenclature Alloy Depletion For purposes of this Standard Practice, the following definitions shall apply: Definition A condition at or near the AD surface where the material is deficient in one or more elements of its normal composition. AD is normally associated with intergranular oxidation (IGO). A continuous flow of electricity between the electrode and the part. If an arc occurs, both the part and the electrode will be damaged. An arithmetic average of 10 individual measurements, which do not include redeposited material or globules, taken at approximately equal distances. An example of Average Recast material measurement is shown in Figure 4, Page 12 Associated Terms AD
Arc
Spark out
Average Recast
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Nomenclature Chemical Milling (CHM)
Definition The controlled dissolution of metal through the action of acid or alkaline solutions, without the application of electric current, to obtain weight reduction and specification design. The amount of metal removed is a function of the composition of the solution, temperature of the solution, and the time immersed in the solution. A material removal process using a series of electric sparks to erode material from a workpiece under carefully controlled conditions. A material removal process using a conductive, noncontacting, rotating wheel that removes conductive material by traversing over the work. This is achieved by the anodic dissolution of a positive workpiece, separated from a shaped, negative electrode (grinding wheel) by a moving conductive electrolyte. This process removes conductive material by the anodic dissolution of a positively charged workpiece separated from a shaped, negatively charged electrode by a moving conductive electrolyte. Changes in hardness of a surface layer as a result of heat, mechanical working, or a chemical change during processing.
Associated Terms CHM
Electrical Discharge Machining (EDM)
EDM
Electro-chemical Grinding (ECG)
ECG
Electro-chemical Machining (ECM)
ECM
Hardness Alteration
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Nomenclature Intergranular Attack (IGA)
Definition A form of corrosion or oxidation attack in which preferential reactions are concentrated at the surface grain boundaries, usually in the form of sharp notches or discontinuities. Intergranular oxidation (IGO) is a subset of IGA. Intergranular oxidation is a form of intergranular attack derived from exposure to elevated temperatures in which there is a depletion in one or more elements of its normal composition of elements, concentrated at the grain boundaries. A machining process that uses a series of coherent light pulses to vaporize material from a workpiece. The largest reading of recast material that does not include redeposited material. The largest reading shall include all local swells protruding from normal surface of the recast layer and which exhibit flow lines or structure similar to the continuous recast layer. Examples of Maximum Recast material are shown in Figure 1 (Sheet 1 of 2), Page 8, Figure 2, Page 10, and Figure 3, Page 113 A separation, rupture or fissure altering the continuity of a surface; usually narrow or tight and characterized by sharp edges or abrupt changes in direction. Microcracks can only be detected by metallographic evaluation. Examples of microcracks are shown in Figure 5, Page 13.
Associated Terms IGA
Intergranular Oxidation (IGO)
IGO
Laser Machining
Maximum Recast
Microcrack
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Nomenclature Node
Definition The surface of a formed honeycomb ribbon which contacts an adjacent formed honeycomb ribbon. Any material removal method where tool-to-workpiece contact is non-existent or minimal and that changes the inherent physical, chemical, or metallurgical properties of the surface. These property changes cannot be fully evaluated by nondestructive methods. A shallow depression resembling a small crater caused by corrosion or impingement of foreign particles against the surface. Material that was removed and rejoined to the surface. Redeposited material normally exhibits the following characteristics: (1) Not tightly adherent to the continuous recast layer with indications of detachment. (2) An interface layer may be present between the redeposited material and the continuous recast layer. Note: Examples of Redeposited Material are shown in Figure 1 (Sheet 1 of 2), Page 8. Magnification greater than 200x may be needed to determine the difference between maximum recast and redeposited material. Redeposited material may be reported for information purposes but shall not be a criterion for acceptance except for openfaced honeycomb as shown in Figure 6, Page 14..
Associated Terms
Nontraditional Machining Processes
Noncon-ventional Machining Special Processes
Pit
Redeposited Material
Spatter
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Nomenclature Recast Burr or Burr
Definition Recast material which extends over an open honeycomb cell from smearing when machining honeycomb. Example is shown in Figure 6, Page 14.. The portion of the surface which during the metal removal process becomes molten and resolidifies in place. Globules are local swells in the recast layer protruding from the normal surface of the recast layer whose occurrence does not repeat at regular intervals. Globules are usually defined as having a height-towidth ratio greater than 1, and do not show evidence of detachment or an oxide layer between the globule and a continuous recast layer. Globules exhibit flow lines or structure continuous with the recast layer. Those stresses which remain in a material after all external influences have been removed. Source who provides material, parts, or services for incorporation into specified parts. Surface roughness (Ra) expressed in microinches or micrometers. The surface condition or properties of a material resulting from a controlled manufacturing process. Any machining method involving substantial tool/ workpiece contact.
Associated Terms
Recast Layer
Remelted Material/Continuous Recast Layer
Recast/Globules
Globular Recast
Residual Stresses
Supplier
Surface Finish
Ra
Surface Integrity
Traditional Processes
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Nomenclature Thermal Machining
Definition Material removal processes that remove material by the selective application of thermal energy. Examples of Thermal Machining are Electro-Discharge Machining and Laser Machining.
Associated Terms
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Maximum Recast Example Sheet 1 Figure 1 (Sheet 1 of 2)
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Maximum Recast Example Sheet 2 Figure 1 (Sheet 2)
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Correct Measurement of Recast Layer with a Void Figure 2
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Incorrect Measurement of Recast Layer with a Void Figure 3
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Average Recast Thickness Figure 4
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Microcrack Depth Figure 5
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Open Faced Honeycomb Examination Figure 6
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-31-05-220-054 E. Requirements. (1) Surface Integrity Identification. Each surface that requires assured surface integrity shall be identified in the specific repair procedure. (2) Surface Integrity. The maximum acceptable limits for designated surface integrity areas are in accordance with the table of acceptability limits, and as follows. NOTE: The table of acceptability limits is divided into two tables. Table 1, Page 16 is for classes A thru D and table 2, Page 16 is for classes E thru H. (a) Surface Stress Measurements. If the repair procedure requires shot peening of the designated Surface Integrity areas, tables 1, Page 16 and 2, Page 16apply before shot peen, except residual tensile stress measurements shall not be required on surfaces subject to shot peening. Diffusion Coated Surface Stress Measurement. For diffusion coated surfaces, tables 1, Page 16 and 2, Page 16 apply before coating, except residual tensile stress measurements shall not be required on surfaces subject to diffusion coating.
(b)
(3)
Residual Stress Conformance Exceptions. It is not necessary to verify conformance to the residual tensile stress requirements of tables 1, Page 16 and 2, Page 16, if one of the following processing sequences is used: (a) (b) (c) (d) (e) Shot peening surfaces generated by any traditional or nontraditional method except a thermal method. Shot peening of a thermal machined surface if a minimum of 0.010 inch (0.25 mm) is removed by a non-thermal method before peening. Low stress grinding after any nontraditional machining method if a minimum of 0.010 inch (0.25 mm) is removed. Machining of titanium alloys if a minimum of 0.010 inch (0.25 mm) is removed by any chemical or electrochemical method. Nitriding, carburizing or induction hardening of steel alloys.
(4)
Surface Finish Conformance Exception. (a) It is not necessary to verify conformance to the surface finish requirements of tables 1, Page 16 and 2, Page 16 if the nontraditional machined feature cannot be measured using a surface profilometer. Finished dimensions of open-faced honeycomb shall apply to the total core configuration. Width measurements shall be taken at the extreme edges of the honeycomb core.
(b)
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Table 1. Acceptability Limits - Class A thru Class D Characteristic Microcracks Class A Recast layer only Class B 0.0015 inch (0.038 mm) parent metal cracking permitted 0.0015 in. (0.038 mm) depth max Class C Recast layer only Class D Recast layer only
Intergranu-lar Attack, Intergranular Oxidation Alloy Depletion, Carbide Depletion Recast Layer
0.0015 in. (0.038 mm) depth max
0.0015 in. (0.038 mm) depth max
0.0015 in. (0.038 mm) depth max
0.0015 in. (0.038 mm) depth max 0.002 in. (0.01 mm) depth max
0.0015 in. (0.038 mm) depth max 0.004 in. (0.10 mm) average depth 0.008 in. (0.20 mm) depth max NA
Burrs, Recast Burrs, Redeposited Material 1 Hardness Alteration Rehardening Hardness Alteration Softening Residual Tensile Stress Pitting Surface Finish NOTE:
1
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA 0.001 in. (0.03 mm) depth max 250 max
Examples shown in Figure 6, Page 14. Redeposited material must be contained within the top 25 percent of the finish machined cell height.
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Table 2. Acceptability Limits - Class E thru Class H Characteristic Microcracks Class E 0.002 in. (0.05 mm) parent metal cracking permitted 0.0015 in. (0.038 mm) depth max Class F None Allowed Class G Recast layer only Class H Recast layer only
Intergranular Attack, Intergranular Oxidation Alloy Depletion, Carbide Depletion Recast Layer
0.0005 in. (0.013 mm) depth max
0.0005 in. (0.013 mm) depth max
NA
0.0015 in. (0.038 mm) depth max 0.004 in. (0.10 mm) ave. depth 0.008 inch (0.20 mm) depth maximum NA
0.001 in. (0.03 mm) depth max None Allowed
0.001 in. (0.03 mm) depth max 0.0005 in. (0.013 mm) depth max
NA
0.003 in. (0.08 mm) depth max
Burrs, Recast Burrs, Redeposited Material 1 Hardness Alteration Rehardening
NA
NA
0.003 in. (0.08 mm) depth max
NA
0.002 in. (0.05 mm) max. depth. 3HRc max or equivalent2, specified for the part. 0.002 in. (0.05 mm) max depth. 3HRc max. or equivalent2, specified for the part. 20 ksi (138 Mpa) max at more than 0.001 in. (0.03 mm) below surface 0.001 in. (0.03 mm) depth max 250 max
0.002 in. (0.05 mm) max. depth. 3HRc max or equivalent2, specified for the part. 0.002 in. (0.05 mm) max depth. 3HRc max. or equivalent2, specified for the part. 20 ksi (138 Mpa) max at more than 0.001 in. (0.03 mm) below surface 0.001 in. (0.03 mm) depth max 250 max
NA
Hardness Alteration Softening
NA
NA
Residual Tensile Stress
NA
NA
Pitting Surface Finish NOTE:

1
0.001 in. (0.03 mm) depth max 250 max
NA NA
Examples shown in Figure 6, Page 14. Redeposited material must be contained within the top 25 percent of the finish machined cell height. Equivalent hardness shall be in accordance with ASTM E 140.
NOTE:
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-31-05-220-055 F. Procedure. (1) Residual Stress Measurement Procedure. To be determined as specified through repair procedure or selection of method from ASTM E 915 X-Ray Diffraction specification. (2) Surface Finish Measurement Procedure. (a) (b) (3) Surface Finish is to be measured using a surface profilometer with a mechanical (stylus) contact. For Class C, D, and E, surface finish is to be measured in a direction parallel to airflow.
Metalographic Specimen Preparation. (a) Methods should be selected which will result in good edge retention since the characteristics being evaluated may measure from 0.0001 to 0.0005 inch (0.003 to 0.013 mm). This procedure cannot and does not attempt to describe all the variations in technique used successfully by individuals in various laboratories, but is restricted to the preparation of specimens for most recast and IGA evaluations. 1 Sectioning. a The specimen should be cut slowly, with an adequate supply of coolant directed onto the cutting area. Direction of the cut and rotation of the wheel should be through the surface to be evaluated, moving toward the parent material. Always cut with the surface to be evaluated in compression. Thus, if using a cutting wheel, the wheel must enter the surface to be evaluated first, then the parent material. Open-faced honeycomb must be sectioned perpendicular to the ribbon direction and through the nodes. Example shown in Figure 6, Page 14.
(b)
Mounting Specimens. a b Mounting materials that require extensive pressure for bonding or curing should not be used. Epoxy mounting materials work very well, and the use of vacuum degassing techniques during the mounting process is also recommended. A good bond between the mounting medium and the specimen is essential for good edge retention. The use of backup materials, such as Nickel plate, on the surface to be evaluated is also helpful.
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STANDARD PRACTICES MANUAL AS907-1-1A 3 Grinding and Polishing Many techniques exist for preparation via either automatic or manual methods. For reproducibility and consistency, automated grinding/ polishing is recommended. Techniques must be chosen with flatness and edge retention as primary goals since the surface alteration layer may be on the order of 0.0003 inch (0.008 mm) or less. Guidelines/ procedure for the preparation process should include control of the following parameters: NOTE: Monitoring and control of the referenced process characteristics will produce samples suitable for recast evaluation. a b c Lubrication Frequency. Time. Grinding Format. Disc. Papers. d Type of Polishing Cloth. Nap. No nap. e f Pressure (per mount). Type of Abrasive. Size. Manufacturing Method. g Speed. Head. Table. h Rotation of Head compared to Table. Complimentary. Counter. i Control of Solutions. pH. Concentration.
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STANDARD PRACTICES MANUAL AS907-1-1A 4 Marking Mark all metallographic sections so that they can be cross-referenced to the required part/lot. 5 Etching. Etching of micrographic samples when required is to be determined as specified through repair procedure or selection of method from ASTM E 407, Microetching Metals and Alloys. (4) Microcrack Evaluation Procedure. The presence of cracks should be evaluated at 200 - 500x magnification in the unetched condition. Care should be taken to distinguish between actual cracks and metallographic scratches ( Figure 5, Page 13). (5) Intergranular Attack Evaluation Procedure. (a) The presence of intergranular attack should be evaluated after etching at a magnification of 400 - 500x. Higher magnification may be used/required to determine depth. The depth if IGA is determined by the maximum individual occurrence/ observation perpendicular to the surrounding surface.
(b) (6)
Alloy Depletion. Alloy depletion analysis is done through metallurgical examination after etching at a minimum of 500x magnification. The alloy depletion (AD) shows the difference between intergranular attack (IGA) and intergranular oxidation (IGO). IGA does not have AD.
(7)
Recast Layer Thickness Measurement. (a) Recast analysis through metallurgical examination after etching should be done at a minimum of 200x magnification. The micro is to be an actual representative part (scrap part is acceptable), or a coupon of the same alloy in the same heat treated condition. Average recast thickness measurement is to be the average of 10 thickness readings, equally spaced, perpendicular to the adjacent parent material surface. Maximum recast is to be reported as the largest individual reading from step F.(7)(b) above ( Figure 1 (Sheet 1 of 2), Page 8 through Figure 4, Page 12).
(b)
(c) (8)
Hardness Alteration Measurement. (a) Refer to TASK 70-34-00-200-003, Hardness Measurement - General. Microhardness should be used as the preferred method due to the minimal thickness of the altered area. Microhardness is to be as specified through repair procedure or selection of method from ASTM E 384, Standard Test Method for Microhardness of Materials.
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STANDARD PRACTICES MANUAL AS907-1-1A (b) Report converted hardness measurements as follows: the original measurement is to be reported first with the converted number in parentheses. For example: 353HB (38HRC).
SUBTASK 70-31-05-220-056 G. Quality Assurance Provisions. (1) Conformance Processing. The methods used to verify conformance with paragraph E.(2) shall be as approved by the purchaser. (2) Specimen Testing. Specimens processed at the same time, and under the same conditions as the parts they represent, can be used in lieu of testing processed parts. (3) Recast Layer Determination. The average and maximum recast layer thickness shall be determined by metallographic examination at a magnification of 200x minimum. Where multiple recast layers exist, the recast layer reading shall be determined by measuring the sum of the recast layers. (4) Nontraditional Machined Finish Qualification. When the repair procedure permits a part to be finish machined by a nontraditional machining process (for example: EDM) without subsequent metal removal by a traditional process, a specimen representative of the part (same material), shall be processed in accordance with a quality plan.
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MACHINED TOLERANCES - MACHINED FEATURES SHOP-RUN TOLERANCES TASK 70-31-06-220-001 1. Machined Features Shop-Run Tolerances SUBTASK 70-31-06-99G-001 A. General. (1) This Standard Practice gives the general instructions and shop-run tolerances for machined features produced by the document referring to this Standard Practice. The data given in this Standard Practice applies to machined features when: (a) (b) The tolerances on form and position are not specified, and The repair document or other approved document references this Standard Practice. NOTE: This Standard Practice is to be used in conjunction with TASK 70-3100-220-001, Dimensional Inspection, and TASK 70-31-07-220-001, Sheet Metal Parts And Fabricated Assemblies Shop-Run Tolerances. SUBTASK 70-31-06-220-002 B. Definitions (1) Datum. The reference surface, line, or point from which other geometric characteristics are located and measured. (2) Nominal Thickness. The value midway between the minimum and the maximum stock limits specified in the document or drawing. (3) Surface Roughness. Measured surface profile characteristics. Often referred to as the surface texture or surface finish. (4) Edgebreak. An edgebreak is the treatment necessary to a corner or intersection of two machined surfaces or a machined surface and any other surface. SUBTASK 70-31-06-220-003 C. Requirements. (1) Applicability.
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MACHINED FEATURES SHOP-RUN TOLERANCES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A The requirements of this Standard Practice are applicable to all machined features. For form and position tolerances of sheet metal parts not specified in the applicable manual, refer to TASK 70-31-07-220-001, Sheet Metal Parts and Fabricated Assemblies Shop-Run Tolerances. (2) Dimension Requirements. Machined features must be to applicable manual limits. If the applicable manual does not specify the variations permitted for the conditions of form and position, the values specified here apply if this Standard Practice is referenced. (3) Tolerance of Form and Position. (a) Run-Out. The circular run-out of any diameter shown concentric about an axis must not be more than 0.005 inch (0.13 mm) full indicator movement (FIM) to other diameters shown concentric to that same axis. If a datum is in the figures, the run-out must be to that datum axis. 1 Other Regular Features. The axis of other regular features must be concentric with each other and with other coaxial diameters to 0.005 inch (0.13 mm) dia. 2 Flatness, Straightness, True Contour. Variation in flatness, straightness, and true contour must not be more than the values shown in Table 1, Page 2. Table 1. Variation From Flatness, Straightness, and True Contour Surface Roughness 63 microinches (1.6 micrometers) and smoother Coarser than 63 microinches (1.6 micrometers 3 Unit Variation In Any Direction in./in. (mm/25.4 mm) 0.002 in. (0.05 mm) 0.004 in. (0.10 mm) Maximum Total Variation 0.004 in. (0.10 mm) 0.006 in. (0.15 mm)
Parallelism and Perpendicularity. The elements of flat machined surfaces shown parallel or perpendicular and dimensioned from a common datum must be parallel or perpendicular to each other within the tolerance that follows: For elements with a length of 20 inches (508 mm) and less: the total tolerance is 0.002 inch (0.05 mm) times the length, with a maximum of 0.015 inch (0.38 mm) total. For elements with a length of more than 20 inches (508 mm): the total tolerance is 0.002 inch (0.05 mm) times the length with a maximum of 0.030 inch (0.76 mm) total. For perpedicularity of threaded features, refer to Step C.(9)(b).
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STANDARD PRACTICES MANUAL AS907-1-1A 4 Run-Out - Circular (Face Run-Out). The maximum circular run-out of circular element at right angles to its axis must not be more than the values shown in Table 2, Page 3. Table 2. Circular Run-Out Diameter 0 to 1.0 in. (25 mm) included over 1.0 in. (25 mm) to 2.0 in. (51 mm) included over 2.0 in. (51 mm) to 3.0 in. (76 mm) included over 3.0 in. (76 mm) to 4.0 in. (102 mm) included over 4.0 in. (102 mm) to 5.0 in. (127 mm) included over 5.0 in. (127 mm) to 12.0 in. (305 mm) included over 12.0 in. (305 mm) to 20.0 in. (508 mm) included over 20.0 in. (508 mm) WARNING: (4) Circular Run-Out Full Indicator Movement (FIM) 0.001 in. (0.03 mm) 0.002 in. (0.05 mm) 0.003 in. (0.08 mm) 0.004 in. (0.10 mm) 0.005 in. (0.13 mm) 0.007 in. (0.18 mm) 0.010 in. (0.25 mm) 0.020 in. (0.51 mm) USE PROTECTIVE GLOVES TO PREVENT INJURY FROM SHARP EDGES AND ROUGH SURFACES.
Edgebreak Sharp Edges On Machined Surfaces. Sharp edges, high metal, and burrs must be removed to prevent stress concentrations, to help safe handling, and to prevent mating parts from being cut and scored. After removal, the requirements of Figure 1 (Sheet 1 of 4), Page 6 must be met. An inspection can be made by looking at visual standards. WARNING: DO NOT BREATHE THE PARTICLES FROM THE SHOT PEENING OR LET THE PARTICLES TOUCH YOU. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
(a)
Shot Peened External Corners. For areas that you will shot peen, the edgebreak on all the external corners must be 0.015-0.030 inch (0.38-0.76 mm). Minimum or corner radius less than 0.015 inch (0.38 mm) is permitted if both of the conditions that follow are met: 1 2 Minimum edgebreak is greater than or equal to 0.005 inch (0.13 mm). It is shown that corner rollover during shot peening does not occur at the minimum edgebreak condition.
(b)
Life-Limited Part Edgebreaks.
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STANDARD PRACTICES MANUAL AS907-1-1A For life-limited parts the edgebreak requirements should be fully specified by the text or figure in the applicable manual. Do not use the edgebreak requirements in this paragraph unless instructed by the applicable manual. (5) Blended Surfaces. All connecting curved surfaces or curved and plane surfaces shown as tangent must be blended smoothly. (6) Center Hole. Center holes are permitted in flat end shafts and must be proportional in measure with the shaft end diameter. They are not shown on figures unless it is necessary to limit their size. (7) Surface Roughness. The surface roughness values listed in Table 3, Page 4 apply as follows: (a) (b) When the text or figures of the document referring to this Standard Practice do not specify a roughness height rating for these specific surfaces. When these values specify a smaller roughness than the general roughness value specified in the document referencing this Standard Practice or if none is specified. Table 3. Surface Roughness Values Surface or Feature Holes with a tolerance equal to or less than 0.003 in. (0.08 mm) Threaded surfaces Flat surface of spotface or counterbore Chamfers up to 0.06 in. (1.5 mm) Holes with a tolerance greater than 0.003 in. (0.08 mm) (8) Spotface Instructions. The diameter of spotface is given as the diameter of the flat, cleaned surface with the full-corner radius. Where the depth of the spotface is less than the corner radius, the full spotface diameter will not exist on the part. The minimum depth of a spotface shall be sufficient to cleanup at least 90 percent of the surface. The maximum depth of a spotface must not violate the minimum part thickness and must not be more than 0.02 inch (0.5 mm) deeper than the depth required for 90 percent cleanup. Refer to Figure 2, Page 10 and to Step C.(10)(b) for positional tolerance requirements. (9) Screw Threads. (a) Thread Length. Roughness Height Rating 63 microinches (1.6 micrometers) 63 microinches (1.6 micrometers) 125 microinches (3.2 micrometers) 125 microinches (3.2 micrometers) 250 microinches (6.4 micrometers)
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STANDARD PRACTICES MANUAL AS907-1-1A Thread length indicated in the text or figure is for minimum gage fit; incomplete threads beyond this point (for lead of tap or die) must conform to the applicable thread standard or specification. (b) Pitch Diameter. The axis of both internal and external threaded features, as established by the pitch diameter, must be perpendicular to the face or shoulder within 30 minutes in any direction. (c) Threaded Inserts. Threaded inserts must be installed with precision that will make the internal thread perpendicular to the face or shoulder of the parent material, within 1 degree in any direction. (10) Holes. (a) Hole Centerline. When a hole is dimensioned by other than the true position tolerancing method, (except as approved in Step C.(10)(b)), the hole centerline must be perpendicular to the face or the shoulder, within 1 degree in any direction. (b) Counterbores, Countersinks, Counterdrills. Counterbores, countersinks, and counterdrills must be within a limit of 0.005 multiplied by the radius of the hole from the true position of the related hole. (c) Drill Point Depth. The drill point depth must not exceed 0.5 times the normal hole diameter.
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Edgebreak Sharp Edges on Machined Surfaces Sheet 1 Figure 1 (Sheet 1 of 4)
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Edgebreak Sharp Edges on Machined Surfaces Sheet 4 Figure 1 (Sheet 4)
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Interpretation Figure 2
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-31-06-220-004 D. Visual Indications. (1) Static (Non-Rotating) Metallic Items. Visual flaws in machined surfaces of static (non-rotating) metallic items are acceptable, provided they are within the following limits and conditions. Do not reduce the basic size (nominal) as stated within the text or figures, by more than 5 percent after any adjacent high metal has been removed. Verification of the requirements may be made by any practical means including visual standards or aids. (a) Superficial Imperfections. Superficial imperfections of no measurable depth such as burnish marks and evidence of contact with gages and fixtures are permitted. (b) Chatter Marks. Tool chatter marks are permitted provided the surface roughness requirements are met. (c) Scratches. Scratches are permitted within the following depth, surface roughness, and drawing characteristic limits, with the exception that scratches are not permitted on fuel and oil sealing surfaces. 1 2 Scratches up to 0.001 inch (0.03 mm) in depth are permitted. Scratches up to 0.003 inch (0.08 mm) in depth are permitted where a surface roughness of 63 microinches (1.6 micrometers) or greater is permitted. Scratches up to 0.005 inch (0.13 mm) in depth are permitted where a surface roughness of 125 microinches (3.2 micrometers) or greater is permitted.
(d)
Nicks. Nicks are permitted within the following depths and conditions: 1 2 Nicks up to 0.001 inch (0.03 mm) in depth are permitted. Nicks up to 0.005 inch (0.13 mm) in depth are permitted where a surface roughness of 63 microinches (1.6 micrometers) or greater is permitted.
(e)
Dents. Dents or imperfections resembling dents are permitted as long as the diameter is no greater than 10 times the depth. 1 2 Dents up to 0.002 inch (0.05 mm) in depth are permitted. Dents up to 0.005 inch (0.13 mm) deep are permitted where a surface roughness of 63 microinches (1.6 micrometers) or greater is permitted.
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STANDARD PRACTICES MANUAL AS907-1-1A (f) Spiral Tool Marks. Spiral or circular tool marks less than 0.003 inch (0.08 mm) in depth are permitted in drilled holes. (2) Rotating Metallic Items. Visual flaws in machined surfaces of rotating metallic items are acceptable provided they are within the following limits and conditions. A rotating item is defined as an item that rotates about its own axis, coincident with the engine centerline. Airfoils (and the airfoil portion of blisks) are not rotating metallic items. (a) Superficial Imperfections. Superficial imperfections of no measurable depth, such as burnish marks and evidence of contact with gages and fixtures, are permitted. (b) Excluded Features. With the exception of superficial imperfections as defined in Step D.(2)(a), visual flaws are not permitted on the following features: 1 2 3 4 5 6 7 (c) All features with a radius less than 0.500 inch (12.70 mm) in any direction, such as holes and fillets. All features with a surface roughness of 32 microinches (0.8 micrometers) or less. All axial and circumferential dovetail forms including load and lock slots. Splines. Both the large and small radii in compound fillets and shaped holes having at least one of the radii less than 0.500 inch (12.70 mm). Bearing journal surfaces. Disk bores and seal teeth.
Scratches. Scratches in areas other than those defined in Step D.(2)(b) up to 0.001 inch (0.03 mm) in depth are permitted after any adjacent high metal has been removed.
(d)
Nicks. Nicks in areas other than those defined in Step D.(2)(b) up to 0.001 inch (0.03 mm) in depth are permitted after any adjacent high metal has been removed.
(e)
Dents. Dents in areas other than those defined in Step D.(2)(b) up to 0.001 inch (0.03 mm) in depth are permitted after any adjacent high metal has been removed.
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STANDARD PRACTICES MANUAL AS907-1-1A WARNING: TITANIUM DUST IS FLAMMABLE. DO NOT ALLOW THE DUST TO COLLECT. DO NOT USE WATER TO EXTINGUISH A TITANIUM FIRE. EXTINGUISH WITH AN APPROVED CHEMICAL FOR METAL FIRES.
(f)
Titanium alloy material removed by machining can bond back onto the machined surface. If you can see the material without magnification, the condition is unacceptable.
(3)
Contamination. None is permitted. All heat-treated parts must be clean and free from foreign material before any heat treatment operation. All cavities must be cleared of all chemical agents used during a repair of refurbishment immediately following each process.
(4)
Discoloration. Discoloration due to processing is acceptable, unless unapproved by the applicable manuals. Discoloration due to other causes is not acceptable.
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SHEET METAL TOLERANCES - SHEET METAL PART AND FABRICATED ASSEMBLIES SHOP-RUN TOLERANCES TASK 70-31-07-220-001 1. Sheet Metal Part And Fabricated Assemblies Shop-Run Tolerances SUBTASK 70-31-07-99G-001 A. General. (1) This Standard Practice gives the general instructions and shop-run tolerances for sheet metal and fabricated tools and applicable parts. The data given in this Standard Practice applies when the tolerances on form and position are not specified and the repair document or other approved document reference this Standard Practice. NOTE: This Standard Practice is to be used in conjunction with TASK 70-31-00220-001, Dimensional Inspection, and TASK 70-31-06-220-001, Machined Features Shop-Run Tolerances. SUBTASK 70-31-07-220-002 B. Definitions (1) Datum. The reference surface, line, or point from which other geometric characteristics are located and measured. (2) Fabricated Assemblies. Welded, brazed, cemented, bonded, and riveted assemblies fabricated from metal and designed to be permanent. (3) Forming. Making a change, with the exception of shearing or blanking, in the shape or contour of a metal part without intentionally changing the thickness. (4) Nominal Stock Thickness. The value midway between the minimum and the maximum stock limits specified in the repair. (5) Non-Traditional Thermal Material Removal Process. Any material removal method where metal is removed by melting. (6) Oxide Layer. A dispersion of oxides that occurs because of melting metal in the presence of oxygen. (7) Recast.
SHEET METAL PART AND FABRICATED ASSEMBLIES SHOP-RUN TOLERANCES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A That portion of the surface which during the metal removal process becomes molten and hardens again in place (remelted material). (8) Sheet Metal. Sheet stock that has a nominal stock thickness less than 0.250 inch (6.35 mm). SUBTASK 70-31-07-220-003 C. Requirements. (1) Applicability. The requirements of this Standard Practice apply to all surfaces and features (and their inter-relationships) of sheet metal parts and fabricated assemblies. For obvious machined features such as spotfaces, chamfers, screw threads, and drilled and reamed holes, refer to TASK 70-31-06-220-001, Machined Features Shop-Run Tolerances. (2) Dimensional Requirements. All features and surfaces must be within applicable manual limits. If the applicable manual does not specify allowable variations for the conditions of form and position, the values specified here apply if this Standard Practice is referenced. (3) Breaking Sharp Edges. (a) Sheared Edges. Sheared edges are acceptable provided that sharp edges are broken. Sharp edges and loose or adhering burrs must be removed to permit safe handling and to prevent mating items from being cut and scored. They may be removed by any process provided the radius, chamfer, or equivalent does not remove more than 0.005 inch (0.13 mm) on stock through 0.025 inch (0.64 mm) nominal thickness, 0.010 inch (0.25 mm) on stock between 0.025 inch and 0.062 inch (0.64 and 1.57 mm), and 0.015 inch (0.38 mm) on stock 0.062 inch (1.57 mm) and over. (b) Sharp Corners. Sharp outside corners must be removed. They may be removed by any process provided the radius, chamfer, or equivalent is not more than a value equal to the nominal stock thickness or 0.125 inch (3.18 mm), whichever is smaller. For nominal stock thickness of 0.015 inch (0.38 mm) or less, the radius, chamfer, or equivalent shall not exceed 0.015 inch (0.38 mm). Refer to Figure 1, Page 8. (c) Breakaway. The maximum breakaway of punched openings, holes, and sheared edges must be a maximum of one-third of the nominal stock thickness that meets the specified limits of size. This requirement must be met exclusive of countersinks, breakedges, and chamfers, but may include breakaway that falls within the limits of size. Refer to Figure 2, Page 9. (d) Blended Surfaces.
STANDARD PRACTICES MANUAL AS907-1-1A Blended surfaces are connecting curved surfaces or curved and plane surfaces, including convolutions, beads, dimples, and eyelets, and must be blended smoothly. (e) Flares. A flare made by a bending procedure is acceptable if there are no cracks in the flare. Refer to Figure 3, Page 10. (f) Mating Parts. Parts that mate to other parts must conform to the same contour within the maximum gap tolerance permitted by the forming requirement. If the maximum gap is not given, the limits of Figure 4, Page 11 apply. Refer to Figure 4, Page 11. (g) Holes. Holes in sheet metal parts and fabricated assemblies can be punched unless the surface through which the hole passes is identified as a machined surface. In this case, the requirements of TASK 70-31-06-220-001, Machined Features Shop-Run Tolerances, are applicable. Punched holes are measured at their smallest diameter. The surface roughness on punched holes up to 0.500 inch (12.70 mm) diameter must not be more than 250 microinches (6.35 micrometers) and must not be more than 500 microinches (12.70 micrometers) for larger diameters. (4) Thickness After Forming. (a) Stock Thickness Reduction. Sheet metal thickness, when specified, must be interpreted as the thickness of the sheet metal before it is formed. This is the starting stock thickness. 1 A decrease in sheet metal thickness caused from forming is only permitted if the remaining thickness is not less than 75 percent of the nominal thickness. This reduction allowance does not apply to thickness dimensions that are shown directly as a thickness requirement. This reduction allowance does not allow the use of material with a starting stock thickness less than specified.
(b)
Stock Thickening. A 15 percent increase in stock thickness over maximum is permitted in localized areas from forming operations.
(c)
Runout. The circular runout of any diameter shown concentric about an axis must not be more than the value shown in Table 1, Page 4 full indicator movement (FIM) to other diameters shown concentric to that same axis. If a datum is in the figures, the runout must be to that datum axis.
Table 1. Circular Runout of Diameters Diameter Thru 6.00 in. (152.4 mm) Over 6.00 thru 20.00 in. (152.4 thru 508.0 mm) Over 20.00 thru 36.00 in. (508.0 thru 914.4 mm) Over 36.00 in. (914.4 mm) 1 Tolerance (FIM) 0.040 in. (1.02 mm) 0.060 in. (1.52 mm) 0.100 in. (2.54 mm) 0.120 in. (3.05 mm) The center hole of washer type punchings must be located within true position tolerance shown in Table 2, Page 4 in relation to the outside diameter. Table 2. True Position of Washer Type Punchings Inside Diameter Thru 1.00 in. (25.4 mm) Over 1.00 thru 3.00 in. (25.4 thru 76.2 mm) Over 3.00 in. (76.2 mm) Tolerance 0.015 in. (0.38 mm) multiplied by the radius of the hole 0.030 in. (0.762 mm) multiplied by the radius of the hole 0.050 in. (1.27 mm) multiplied by the radius of the hole
(d)
Flatness, Straightness, True Contour. Variations in flatness, straightness, and true contour must not exceed the values shown in Table 3, Page 4 and Table 4, Page 4 except as indicated in Step C.(5) and its sub-steps. The variations are determined on the surface of the sheet metal to which the dimensions apply.
Table 3. Variation for Non-Welded and Non-Brazed Surfaces Nominal Stock Thickness Thru 0.090 in. (2.29 mm) Over 0.090 thru 0.250 in. (2.29 thru 6.35 mm) Unit Variation in./in. (mm/25.4 mm) 0.015 in. (0.38 mm) 0.010 in (0.25 mm) Max Total Variation 0.050 in. (1.27 mm) 0.030 in. (0.76 mm)
Table 4. Variations for Welded and Brazed Surfaces Nominal Stock Thickness Thru 0.032 in. (0.81 mm) Over 0.032 thru 0.060 in. (0.81 thru 1.52 mm) Over 0.060 thru 0.125 in. (1.52 thru 3.18 mm) Over 0.125 thru 0.250 in. (3.18 thru 6.35 mm) (e) Unit Variation in./in. (mm/25.4 mm) 0.025 in. (0.64 mm) 0.020 in. (0.51 mm) 0.015 in. (0.38 mm) 0.005 in. (0.13 mm) Max Total for Surface 3.0 thru 6.0 in. (76 thru 152 mm) Long 0.075 in. (1.91 mm) 0.060 in. (1.52 mm) 0.045 in. (1.14 mm) 0.015 in. (0.38 mm) Max Total for Surface 6.0 (152 mm) and Longer 0.100 in. (2.54 mm) 0.080 in (2.03 mm) 0.060 in. (1.52 mm) 0.030 in. (0.76 mm)
Parallelism and Perpendicularity. The elements of flat sheet metal surfaces shown parallel or perpendicular and dimensioned from a common datum must be parallel or perpendicular to each other and the common datum within 2 degrees.
(5)
Visual Flaws. (a) Sheet Metal Surfaces. The following paragraphs provide the acceptability limits for visual surface flaws on sheet metal. These limits apply to all sheet metal surfaces and edges and to all machined edges. They do not apply to items attached to sheet metal surfaces or to any surface where the surface finish is designated. Verification of these requirements may be made by any practical means including visual standards or aids. 1 Significant Areas. Any area of the sheet metal surface that is 0.060 inches (1.52 mm) or nearer to any edge, weld, or bend tangent where the bend radius is less than 1.0 inch (25 mm). Areas of bends (within bend tangents) whose radius is less than 1.0 inch (25 mm) are also significant. Refer to Figure 5, Page 12. 2 Acceptability Limits. a Flaws with Discernible Depth. Table 5 provides the acceptability limits for flaws with a discernible depth. Connecting flaws are to be interpreted as a single flaw. These limits apply only to the depth and length of the flaws and there are no limits for quantity and spacing of the flaws. Indications of 0.001 inch (0.03 mm) or less in depth cannot be interpreted.
Table 5. Acceptability Limits for Flaws with Discernible Depth Area (Refer to Figure 5, Page 12) Significant Area Significant Area Depth 0.002 in. (0.05 mm) or less Over 0.002 in. (0.05 mm) thru 5% of nominal thickness with a max allowable depth of 0.005 in. (0.13 mm) 0.004 in. (0.10 mm) or less Over 0.004 in (0.10 mm) thru 10% of nominal thickness with a max allowable depth of 0.010 in. (0.25 mm) b Formed Depressions and Dents. Formed depressions and dents are acceptable provided they are without sharp creasing, and: They do not exceed 0.005 inch (0.13 mm) in depth or height. The width is no greater than 10 times the depth. They blend smoothly with adjacent surfaces without sharp creasing. Far-side of formed/depressions and data not to be interpreted as high metal. c Discoloration. Discoloration due to processing is acceptable, if not disallowed by other Standard Practices. Discoloration due to other causes is not acceptable. d High Metal. High metal is not acceptable. e Corrosion. Corrosion is not acceptable. f Superficial Imperfections. Superficial imperfections of no measurable depth such as burnish marks and evidence of contact with gauges and fixtures are not considered dangerous and are permitted on any sheet metal surface. g Contamination. Max Length 1.50 in. (38.1 mm) 0.10 in. (2.5 mm)
Non-Significant Area Non-Significant Area
6.0 in. (152 mm) 0.15 in. (3.8 mm)
STANDARD PRACTICES MANUAL AS907-1-1A None permitted. All heat-treated parts shall be clean and free from foreign material prior to any heat treatment operations. All cavities must be cleared of all chemical agents used during manufacturing, immediately following such processing. (6) Sheet Metal Brackets. Non-traditional material removal process limits (laser cutting and electrical discharge machining) for 321 Stainless Steel and Inco 625. The following limits apply to the cut edges of parts after all processing. Microcracks are allowed in the recast layer only. Max Oxide Layer 0.0005 in. (0.013 mm) Max Taper 0.003 in. (0.08 mm) Max Local Recast 0.003 in (0.08 mm) Max Average Continuous Recast 0.0015 in. (0.038 mm)
Outside Corner Sharpness Figure 1
Breakaway Figure 2
Bending Flare Figure 3
Maximum Gap Figure 4
Bracket Significant Areas Figure 5
INDIRECT INSPECTION - INDIRECT INSPECTION METHODS TASK 70-32-00-200-002 1. Indirect Inspection Methods SUBTASK 70-32-00-99G-002 A. General. (1) Indirect inspection consists of a variety of methods of disclosing defects that are invisible to the naked eye. These defects may be inclusions, voids or other subsurface defects, or they may be surface discontinuities too small to be distinguished from the adjacent material.
SUBTASK 70-32-00-200-021 B. Qualification of Inspectors. (1) Indirect inspection methods require specialized training and knowledge of techniques, and experience in the interpretation of indications. It is essential that inspectors be able to distinguish between indications of defects and spurious or irrelevant indications in order to evaluate the flaw correctly. For that reason, only qualified inspectors shall be permitted to use these methods.
SUBTASK 70-32-00-200-022 C. Applications of Indirect Inspection. (1) Appropriate methods of inspection must be chosen on the basis of the material from which the part is made, of the type of defect to be investigated, and whether it is a surface or sub-surface defect. Magnetic materials, such as iron and ferrous alloys, nickel and cobalt can be reliably inspected for surface defects by the magnetic-particle method. Nonmagnetic materials, such as aluminum, magnesium, brass, copper, bronze, most stainless steels, titanium, ceramics and nonmetallic materials must be inspected by the fluorescent-penetrant method for surface defects. Voids, inclusions, and subsurface discontinuities in any type of material can be disclosed by either ultrasonic or radiograph (X-ray) inspection. In magnetic material, some subsurface defects are indicated by the magnetic-particle method.
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INDIRECT INSPECTION METHODS Page 2 Dec 01/03
MAGNETIC PARTICLE - MAGNETIC-PARTICLE METHOD TASK 70-32-01-240-001 1. MAGNETIC-PARTICLE METHOD MAGNETIC-PARTICLE INSPECTION EQUIPMENT PRODUCES A HEAVY ELECTROMAGNETIC FIELD. IF YOU HAVE A PACEMAKER, DO NOT STAND CLOSER THAN 10 FEET FROM THE EQUIPMENT WHILE IN OPERATION. CONTACT THE MANUFACTURER OF YOUR PACEMAKER FOR ALL PRECAUTIONS. FAILURE TO DO SO COULD AFFECT THE OPERATION OF YOUR PACEMAKER AND CREATE A HEALTH CONCERN.
WARNING:
SUBTASK 70-32-01-240-011 A. Theory. (1) Magnetic-particle inspection basically consists of subjecting the parts to a magnetic field, which sets up magnetic lines of force in the part. Discontinuities cause the lines of force to be distorted and form new magnetic poles. Ferromagnetic particles, in suspension in a liquid flowing over the part, will be attracted to the new magnetic poles or discontinuities and adhere to the part as long as the magnetic force is maintained. The direction and intensity of the magnetic field must be chosen to create strong magnetic leaks around the discontinuities, which act as an air gap. The defects are then made visible by the application of a liquid suspension of ferromagnetic particles to the surface of the part. See Figure 1, Page 2. The ferromagnetic particles are coated with a material which fluoresces when subjected to ultraviolet light. The fluorescent particles effectively outline the discontinuity enabling the inspector to measure and evaluate the extent of the discontinuity. The detection of defects is most effective when their plane is perpendicular to the magnetic field. Detection remains possible as long as the angle between the defect and the field remains greater than 45 degrees. See Figure 2, Page 3. Detection becomes increasingly difficult as the angle is reduced from 45 degrees and becomes impossible when the defect is in-line (zero degrees) with the magnetic force lines. It is, therefore, necessary to inspect the part using at least 2 directional fields, either by changing the position of the part relative to the field, or by using a different magnetization technique. The choice of technique to be used is determined by the shape and size of the part to be inspected.
(2)
(3)
(4)
(5)
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Flux Lines at Discontinuity Figure 1
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Angel of Defect to Magnetic Field Figure 2
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-01-240-012 B. Preparation of Parts for Magnetic-Particle Inspection. (1) (2) Parts should be free of oil, dirt, or other surface contamination before inspection. If necessary, scratches or pitting due to contact corrosion may be removed by stoning. When the specified inspection method consists of passing the current through the part, the contact faces should be cleaned of any coating and polished to ensure good electrical conduction. It is not necessary to systematically remove protective coatings from parts purely for the magnetic-particle inspection. Prior to inspection, the part must be checked to assure the residual field strength is less than 240 A/m (3 oersted). If the maximum allowable field strength is exceeded, demagnetization is required per Subtask 70-32-01-240-014, Demagnetization.
(3)
SUBTASK 70-32-01-240-013 C. Magnetization Techniques. (1) (2) The techniques used to create the magnetic field vary according to the desired field direction relative to the part. These different techniques allow generation of: (a) (b) (3) Longitudinal fields, when the part to be inspected channels the lines of force. See Figure 3, Page 5. Circular fields created by the passage of an electric current in the part (see Figure 4, Page 6) according to the principle stated below.
Basic Principle. (a) Any current flowing through a conductor creates a circular magnetic field, formed by closed loops, lying in a plane perpendicular to the conductor. A strong field exists as long as the current flows, and a residual field remains after the current is cut off.
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Longitudinal Field Figure 3
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Circular Field Figure 4
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-01-240-014 D. Demagnetization. (1) Principle of Demagnetization. (a) Demagnetization is carried out by subjecting the part to magnetic fields of successively reversing polarity, and of rapidly decreasing strength. This result can be achieved either with the magnetization equipment or with supplementary apparatus. The phenomenon can be shown graphically. See Figure 5. Due to the hysteresis effect, and the action of the Earths magnetic field, demagnetization is never perfect from a theoretical viewpoint. For practical purposes, however, it is sufficient to demagnetize the parts to the limits imposed by the operating characteristics of the part, and of the equipment available to check the demagnetization.
(b)
(2)
Using a Demagnetizer. (a) (b) (c) (d) (e) This method consists of subjecting the parts to an alternating magnetic field, formed inside a solenoid (demagnetizing tunnel). Turn on the demagnetizer before introducing the parts. Do not cut off the current while the parts are in, or close to, the demagnetizer. Pass parts, which have a small diameter relative to the solenoid opening, close to a wall or in a corner of the solenoid opening. Do not allow parts to remain stationary in the demagnetizer during operation in order to avoid the risk of heating the part.
(3)
Demagnetization is Produced: (a) By gradually withdrawing the parts to approximately 4 feet (1.2 meters) from the demagnetizer, which effectively reduces the induced magnetism in the part. By leaving the part in the solenoids, but reducing the current.
(b) (4)
Checking the Demagnetization. (a) The effectiveness of demagnetization must be checked by measuring the field strength. Unless otherwise indicated, a residual field of less than 240 A/ m (3 oersted) is acceptable. Checking for demagnetization is only possible if the part presents two distinct poles. If the part is cylindrical (without grooves, slots, etc.), the magnetic field is circular, therefore, it has no poles and the inspection will give no result. See Figure 6. Parts which are magnetized in this way (notably cylindrical parts), either by passage of a current or on a concentric central conductor, must be very carefully demagnetized, since no check is possible.
(b)
(5)
Demagnetization Between Circular and Longitudinal.
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STANDARD PRACTICES MANUAL AS907-1-1A (6) All parts are magnetized in 2 directions, one circular and the other longitudinal relative to the geometry of the part. Demagnetization between these opposing fields is not required providing the circular magnetization is first and the longitudinal field strength is greater than the circumferential field. However, demagnetization after circumferential magnetization is usually accomplished for added insurance.
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Demagnitization Figure 5
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Checking Demagnitization Figure 6
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-01-240-015 E. Equipment Variables. (1) Several types of current are used (alternating, half- or full-wave rectified) as well as several types of magnetizing current indicators on the machine ammeters (effective or RMS current, mean current, etc.). The current values given in the manuals are peak values, and the user must correct the values given according to his type of equipment. The table in Figure 7, Page 13 describes how these corrections are to be made. Current values should be maintained within 5 percent of the specified values. Checking the readings given by magnetic generator equipment. Having studied the tables given, it is necessary to know the type of magnetizing current, and the type of indication given by the ammeter on the machine. The type of magnetizing current may be determined by examining the circuit diagram of the machine, and can be confirmed with an oscilloscope. The type of current reading is indicated by symbols on the ammeter dial. See Figure 8, Page 14. (a) (b) (c) (d) (e) The moving-iron instrument gives reading direct in RMS values. The moving-coil meter gives mean currents. This type of instrument can only be used on direct or rectified current. The moving-coil ammeter, with built-in rectifier indicates mean current values, whatever the type of magnetizing current. It is essential to check the accuracy of these ammeters with a master ammeter. Some magnetic inspection equipment is supplied by the manufacturer with the ammeter calibrated in peak values, twice mean value, etc. Take the corresponding change of scale, which must be clearly indicated on the instrument dial into account.
(2)
(3)
Example of correction covered in Figure 7, Page 13. (a) The magnetizing current is full-wave rectified, and the ammeter indicates mean current. For 100 A peak value, a current of 63.7 A must be indicated (refer to Figure 7, Page 13). If the value required in the manual is 1000 A, the inspector should read 637 A on his ammeter to fall within the correct inspection conditions. Refer to Figure 9, Page 15 for typical inspection symbol.
(b)
(4)
Example of correction not covered by the relationship table. See Figure 7, Page 13. (a) The magnetizing current is half-wave rectified (pulsed), and the ammeter indicates mean current. For a pulsed current we have: I Peak = I Mean (refer to the type of current column) Therefore, for a 100 A peak value, the ammeter should show a mean current of: I Mean = I Peak / pi = 100 / pi = 31.9 A
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STANDARD PRACTICES MANUAL AS907-1-1A (b) If the value required in the manual is 1000 A, the inspector should read 319 A on the ammeter. A typical inspection symbol is shown in Figure 9, Page 15.
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Peak Amperage Versus Amperage Indicated Figure 7
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Ammeter Symbols Figure 8
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Typical Magnetic-Particle Inspection Symbol Figure 9
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-01-240-016 F. Process Control. (1) (2) To control the quality of the magnetic-particle inspection processes, it is necessary to control the quality of the process, the materials, and the equipment. It is recommended that a quality assurance plan be established to check the process and materials on a regular schedule. (a) Process either the Known Defect Test Part (KDTP) or the Test Ring daily before any parts are processed. Reference TASK 70-32-80-700-010, Test of Magnetic-Particle Inspection Process. The solution tests are recommended daily before any parts are processed. Black ultraviolet light intensity checks are recommended weekly before any parts are processed or when ever a bulb or filter is changed in the lamp. Refer to TASK 70-32-80-700-010, Test of Magnetic-Particle Inspection Process. Background white light in the inspection booth should be checked on a weekly basis. Refer to TASK 70-32-80-700-010, Test of Magnetic-Particle Inspection Process.
(b) (c)
(d)
(3)
It is also recommended that a quality assurance plan be developed to check the equipment on a regular basis as follows: (a) Use a calibrated ammeter to check the equipment ammeter at three points in the range through which the equipment is used. NOTE: The readings of the equipment ammeter should not vary by more than 10 percent of the readings from the calibrated ammeter. The accuracy of the ammeter should be checked every six months. (b) On equipment that uses a timer to control current duration, check the timer to within 0.1 second with an electronic timer. NOTE: This check should be performed every six months. (c) On equipment that uses a quick-break feature, use an oscilloscope or equipment recommended by the manufacturer to ensure the proper functioning of this feature. NOTE: This check should be performed every six months. (d) Dead weight test yokes and permanent magnets every six months. NOTE: Alternating current yoke should have a lifting force of 10.00 lbs (4.5 kg) minimum with a 2.00-4.00 inch (50.8-101.6 mm) spacing between the legs. Direct current yokes and permanent magnets should have a lifting force of 30 lbs (13.6 kg) minimum with a 2.00-4.00 inch (50.8101.6 mm) spacing between the legs.
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STANDARD PRACTICES MANUAL AS907-1-1A (4) If the process is not performed daily, and the process is determined to be out-ofcontrol by the process test standard practice, all engine parts inspected since the last in-control point should be reprocessed.
SUBTASK 70-32-01-240-017 G. Symbols. (1) There is a particular magnetic-particle inspection procedure for each part. To simplify these procedures, a system of symbols indicating the methods of inspection and the critical parameters has been established. applicable manual and process documents use these symbols to identify the recommended procedures. This standard practice defines the symbols and the procedures indicated by each symbol. Passing Current Through the Part. See Figure 10, Page 22. (a) Theory. This procedure creates a circular magnetic field in the part, and allows longitudinal defects in the external surface to be detected. (b) Procedure. WARNING: USE CARE WHEN WORKING WITH ELECTRICITY. DO NOT ATTEMPT TO ADJUST ELECTRICAL CONNECTIONS WHILE THE EQUIPMENT IS OPERATING.
(2)
CAUTION: KEEP GOOD CONTACT BETWEEN JAWS AND PART. ARCING AND BURNING OF PART COULD OCCUR. 1 2 3 4 (3) Check the condition of braided copper jaws (or possibly lead jaws) to ensure good contact between jaws and part. Apply indicated current (1600 A), 2-3 pulses, for 0.5-1.0 second duration. Stop flow of suspension solution before the last pulse. Inspect part for defects.
Using a Concentric Central Conductor. See Figure 11, Page 23. (a) Theory. This procedure creates a circular magnetic field in the part and allows detection of longitudinal defects in the internal and external surfaces, and radial defects in the end surfaces. (b) Procedure. 1 2 Position the part correctly, using a support of insulating material, if necessary, if the bar is horizontal. Apply indicated current (1000 A), 2-3 pulses for 0.5-2.0 seconds duration through the central conductor bar.
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STANDARD PRACTICES MANUAL AS907-1-1A 3 4 (4) Stop flow of suspension solution before the last pulse. Inspect part for defects.
Using an Eccentric Central Conductor. See Figure 12, Page 24. (a) Theory. This procedure creates a circular magnetic field in the part and allows detection of longitudinal defects on internal and external surfaces, and radial defects on end surfaces. (b) Procedure. CAUTION: USE INSULATING MATERIAL (SUCH AS A PLASTIC SLEEVE OVER THE CONDUCTOR) BETWEEN CONDUCTOR AND PART. SCRATCHING OF PART AND ELECTRIC ARCING DAMAGE TO THE PART COULD OCCUR. 1 Apply indicated current (1000 A), one pulse for 0.5-2.0 seconds duration, at each position of the part with the suspension solution flowing continuously. Rotate the part to reposition at 45 degrees or 6 inches (150 mm) of peripheral length for each pulse of current. After complete rotation with suspension solution flowing, repeat magnetizing at all positions with no flow of suspension solution. Inspect part after total magnetization of the part by complete rotation. Inspect large parts, requiring more than eight positions to complete the rotation, after each magnetization: one pulse with suspension solution flowing followed by one without.
2 3 4 5
(5)
Using a Split Coil Conductor (Knife Switch). See Figure 13, Page 25. (a) Theory. This procedure creates a circular magnetic field in the part and permits detection of radial defects on the face of the part, and longitudinal defects on the outer surfaces. (b) Procedure. 1 Fixed table method. a b c Determine current by dividing the ampere-turns (AT) by the number of turns in the coil being used. Apply current, 2-3 pulses, for 0.5-2.0 seconds duration, with "quick break" current decay at each position of part. Stop flow of suspension solution before the last pulse.
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STANDARD PRACTICES MANUAL AS907-1-1A d e f 2 Restrict the flow of suspension solution to the quadrant being magnetized at each position. Inspect part after complete rotation and magnetization (four positions). Repeat procedure if part is to be turned over as indicated by symbol. See Figure 18, Page 30.
Rotating table method. a b Determine current by dividing the ampere-turns (AT) by the number of turns in the coil being used. Apply current, one pulse of 2-4 seconds duration, with "quick break" current decay while slowly rotating the part with suspension solution flowing. Apply as many pulses, as needed, for 360 degrees rotation with current on. Stop flow of suspension solution and repeat magnetization. Inspect part after complete rotation and magnetization of part. Repeat procedure if part is to be turned over as indicated by symbol. See Figure 18, Page 30 through Figure 20, Page 32.
d e (6)
Using a Coil into Which Part is Positioned. See Figure 14, Page 26. (a) Theory. 1 2 3 4 5 6 This procedure creates a longitudinal magnetic field in the part and permits detection of circumferential defects. This procedure is used for long circular parts and for parts where access is difficult. A magnetic field is induced into the part when the part is placed into the current carrying coil. The long axis is pointed through the opening of the coil and the part is held near the inside edge of the coil. This procedure is used on parts which have a length to diameter ratio of one or more. The magnetic field is effective approximately 4-5 inches (100-125 mm) on each side of the centerline of the coil. On long parts, magnetization must be carried out in several stages. Each stage is carried out on the section of the part which is inside the coil where the magnetic field is properly distributed.
(b)
Procedure.
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STANDARD PRACTICES MANUAL AS907-1-1A 1 2 3 4 (7) Determine current by dividing the ampere-turns (AT) by the number of turns in the coil being used. Apply current, 2-3 pulses for 0.5-2.0 seconds duration, with "quick break" current decay at each position of the part. Stop the flow of suspension solution before the last pulse. Inspect after complete magnetization of the part.
Using Induced Current Technique. See Figure 15, Page 27. (a) Theory. 1 2 3 This procedure induces a toroidal magnetic field in the part and allows detection of circumferential defects. This procedure is used for hollow parts with small length to diameter ratios. The part is placed inside and concentric with the coil. The axis of the part is parallel to that of the coil. A soft iron laminated core is placed inside and concentric with the part. The rapid collapse of current in the coil induces circulating eddy currents in the part. This, in turn, induces a toroidal magnetic field in the part.
(b)
Procedure. 1 2 3 4 Determine current by dividing the ampere-turns (AT) by the number of turns in the coil being used. Apply current, 2-3 pulses for 0.5-1.0 second duration, with "quick break" current decay. Stop the flow of suspension solution before the last pulse. Inspect the part for defects.
(8)
Using Pole Pieces. See Figure 16, Page 28. (a) Theory. 1 2 This procedure induces a longitudinal magnetic field in the part, and permits detection of circumferential defects. The part being inspected is held between the pole pieces of the electromagnetic machine. The part completes the magnetic circuit and channels the lines of force. On occasion, an accumulation of excess magnetic-particle forms at the end of the parts which are in contact with the pole pieces. These areas can be subsequently inspected using the residual magnetism.
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STANDARD PRACTICES MANUAL AS907-1-1A (b) Procedure. 1 2 3 Determine current by dividing the ampere-turns (AT) by the number of turns in the coil being used. Apply current, 2-3 pulses for 0.5-2.0 seconds duration. Stop the flow of suspension solution before the last pulse. NOTE: It may be necessary to use support fixtures to ensure a correct distribution of the lines of force emanating from the pole pieces. The part should be in contact with the pole pieces. 4 (9) Inspect part for defects.
Using a Flat Coil. See Figure 17, Page 29. (a) Theory. 1 This procedure is used to detect circumferential defects. It is particularly suitable for short parts having large cross sections. The maximum diameter of a part must not exceed the diameter of the coil. The coil uses a spirally rolled cable and a soft iron core. The part being inspected is positioned on the coil. When a continuous current flows, a magnetic field is generated. The intensity of this field is strengthened, in part, by a current induced when the secondary circuit is interrupted with "quick break" current decay. The face on which the part rests must be turned up and inspected upon completion of inspection of other face. This procedure creates a toroidal field in the part, allowing detection of circumferential defects.
2 3
4 5 (b)
Procedure. 1 2 3 4 5 Determine the current by dividing the ampere-turns (AT) by the number of turns in coil being used. Apply current, 2-3 pulses for 0.5-2.0 seconds duration with "quick break" current decay. Stop the flow of suspension solution before the last pulse. Inspect part for defects. Turn the part over and repeat magnetization and inspection of other side as indicated by symbol.
(10) Additional Symbols. See Figure 18, Page 30. These additional symbols are used in conjunction with the process symbols and have the shown meanings.
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Passing Current Through the Part Figure 10
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Concentric Central Conductor Figure 11
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Eccentric Central Conductor Figure 12
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Split Coil (Knife Switch) Conductor Figure 13
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Part Passed Through Coil Figure 14
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Concentric Coil with Iron Core Figure 15
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Pole Pieces Figure 16
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Flat Coil Figure 17
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Process Symbols Figure 18
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-01-240-018 H. Inspection. (1) General. (a) (b) Fluorescent-penetrant inspection shall always precede magnetic-particle inspection if both inspections are required. Each part must be magnetized in 2 directions to locate all defects. Circular magnetization and inspection must always precede longitudinal magnetization and inspection. Parts on which a coating is to be replaced because of deterioration (peeling, flaking, cracking, etc.) should not be inspected until after the coating is removed. Normally, protective coatings less than 0.004 inch (0.10 mm) thick are not removed from parts for inspection purposes. However, coatings which do not allow the suspension solution to wet the part surface must be removed to achieve a reliable inspection. The process document will specify when coatings must be removed. The specified values of current for each part are based on 3-phase, full-wave, rectified current. If the equipment in use has a different power supply, adjustments to these current values may be necessary. The specified values of current are based upon the equipment specified in the equipment list. If such equipment is not used, equivalent magnetization can be verified by using a gauss meter capable of determining the peak values of the tangential field using a Hall-effect probe. The tangential applied field strength levels shall be in the range of 30-60 gauss (2.4-4.8 kAm1) and shall be present in all areas of the part to be inspected.
(c)
(d)
(2)
Equipment. (a) Magnetic-particle inspection equipment rated 6000 amp, 3-phase, full-wave rectified, alternating current with "quick break" current decay such as: 1 2 3 4 5 6 7 Magnaflux ARQ 966: Magnaflux Corporation. (Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003.) SREM 6022R: SREM. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. For pole piece inspection, use two coils mounted in parallel 1122 turns per coil, 22 amp rating. For vertical coil inspection, use one coil, 5 turns, 14 inches (360 mm) diameter, 2700 amp rating. Split coil conductor, use SREM 6000 with rotating table, 4 turn coil, 24 inches (600 mm) diameter, 6000 amp rating. Flat coil, use SREM, 9 turns, 2700 amp rating. Various diameter coils:
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STANDARD PRACTICES MANUAL AS907-1-1A a b c d e 8 9 (b) Magnaflux, P/N 74610, 2 inches (50 mm) diameter, 6 turns. Magnaflux, P/N 74615, 4 inches (100 mm) diameter, 5 turns. Magnaflux, P/N 74620, 6 inches (150 mm) diameter, 8 turns. Magnaflux, P/N 74630, 10 inches (250 mm) diameter, 12 turns. Magnaflux, P/N 74635, 12 inches (305 mm) diameter, 12 turns.
Demagnetization equipment using alternating current. Demagnetization equipment using reversing DC coil with a 30-point step-down current decay.
Auxiliary equipment. 1 Assortment of non-magnetic central conductors such as brass or copper in different diameters ranging from 0.25 inch to 2 inches (6 to 50 mm) and 18 inches (460 mm) in length. Laminated soft iron cores. Flexible electrical cables. Shunt test meter. Black light borescope. "Quick break" test instrument such as Magnaflux Corporation, P/N 148335, or equivalent. Inspection booth or darkroom which prevents excessive admission of white light. White light lamp for visual inspection of parts. Assortment of adjustable mirrors. Black light to detect fluorescent indications.
2 3 4 5 6 7 8 9 10 (3) Materials.
NOTE: All materials are used at ambient temperatures. Material Magnetic-Particle Suspension Solution Product/Solution Number S1041
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STANDARD PRACTICES MANUAL AS907-1-1A WARNING: WEAR PROTECTIVE GLOVES TO KEEP HANDS FROM DRYING OUT FROM CONTACT WITH THE SOLUTION. DO NOT SMOKE OR EAT WHILE USING THE SOLUTION. WASH HANDS THOROUGHLY AFTER USE.
(4)
Procedure. NOTE: Parts must be thoroughly cleaned before magnetic-particle inspection. Use solvent or vapor degreasing methods to remove any protective oil coating immediately before magnetizing. NOTE: Follow the sequence of magnetization/inspection specified by the circled number in the part inspection illustration. Demagnetize part between each inspection process. NOTE: Before starting the MPI process, you should verify that you complied with Subtask 70-32-01-240-016, Process Control. NOTE: Prior to inspection the part must be checked to assure the residual field strength is less than 240 A/m (3 oersted). If the maximum allowable field strength is exceeded, demagnetization is required per Subtask 70-32-01240-016, Demagnetization. (a) Magnetization of parts. 1 2 3 4 (b) Position part and equipment according to the recommended procedure specified in the process document. Apply magnetic-particle suspension solution to part (wet continuous method). Magnetize part for specified time and current. Discontinue suspension solution flow immediately preceding last current pulse.
Inspection of parts. 1 2 3 4 Allow suspension solution to remain on part for 1 minute before inspection. Inspect part, to limits specified in process document, in a darkened room under ultraviolet light. Inspect all areas of part. Inside surfaces such as shafts or holes may require use of a mirror or borescope. Verify all indications. a False indications. An accumulation of magnetic particles not held magnetically, but present due to: Foreign substance adhering to part.
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STANDARD PRACTICES MANUAL AS907-1-1A Foreign fluorescent substance adhering to part. Suspension drainage flowpaths. Handling, fixture, or equipment smudges. Foreign particles such as lint fibers in suspension solution. NOTE: False indications may be verified by wiping area with a clean cloth or fine grit abrasive cloth with oil; cleaning, and remagnetizing in the appropriate direction. If indication does not reappear, it was false. b Irrelevant indications. These are true indications caused by magnetic leakage fields, and are generally acceptable. Some examples are: Scratches, dents, and burrs. Machine tool marks. Brazed joint. Sharp fillets. Dissimilar permeabilities. Heat treat scale. NOTE: Irrelevant indications may be verified by examining area with a magnifying glass and white light or reviewing the part design. c Relevant or true indications. Actual magnetic leakage fields judged acceptable or rejectionable per specified allowable limits. Some examples are: Cracks. Stringers. Inclusions. Laps/folds. Lack of weld fusion/penetration.
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STANDARD PRACTICES MANUAL AS907-1-1A Seams. NOTE: Relevant indications may be verified by wiping area with a clean cloth or fine grit abrasive cloth with oil; cleaning, and remagnetizing in the appropriate direction. If indications reappear, it is a defect. 5 (c) Identify relevant defect indications and record required information. Mark or tag parts as necessary.
Demagnetization of parts. 1 2 Various methods of demagnetization may be used depending upon equipment and/or size and shape of part. Demagnetize as follows: a b c d Pass parts through entire length of demagnetizer coil with current on. Parts should be held close to top or sides of coil. Rotate circular parts while withdrawing from coil. Withdraw parts in a straight line from coil, and do not turn off power until part is 4 feet (1.2 meters) from coil. NOTE: If parts are difficult to demagnetize, try tapping them with a rubber mallet while in or close to coil. Repeat demagnetization cycles until magnetic field is depleted.
(d)
Test for demagnetization. 1 2 3 Place probe of magnetic field test instrument in contact with part. Move probe over all areas of parts, especially top and bottom rims of flanges, and all projections from main body. Observe indicator. It should not deflect more than 3 oersteds from its point of reference.
(e)
Cleaning. 1 2 Clean part with petroleum solvent C04-002. Coat part with corrosion protective oil C02-025, as required.
(f)
Quality assurance. 1 Check part with magnetic field indicator to assure magnetic field is 3 oersteds or less.
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STANDARD PRACTICES MANUAL AS907-1-1A 2 3 Inspect part under ultraviolet lamp to assure all fluorescent material has been removed. Make sure the following process and material tests have been met. a b Process Test TASK 70-32-80-700-010, Test of Magnetic-Particle Inspection Process. Magnetic-Particle Suspension Solution Test per Solution Sheet S1041.
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FLUORESCENT PENETRANT - FLUORESCENT PENETRANT INSPECTION TASK 70-32-02-230-001 1. Fluorescent Penetrant Inspection SUBTASK 70-32-02-99G-001 A. General. (1) The fluorescent penetrant inspection (FPI) process is a visual inspection used for detection of small surface defects that may not be visible under normal white-light visual inspection. These defects may be cracks, inclusions, voids, or other types of defects which are inherent or which are a result of in-service use. NOTE: Large surface defects which are easily visible to the naked eye may not retain penetrants and consequently will not reveal indications under ultraviolet light. These defects require white-light visual inspection for detection. (a) Fluorescent-penetrant inspection referenced in this manual shall be performed in accordance with Specifications ASTM E1417 or AMS 2647 which detail the minimum requirements. Refer to the component section of the manual for specific instruction and/or acceptance criteria. Where no specific process has been specified, the following Table 1, Page 2 shall be used as a guide. Inspection to a higher sensitivity level than specified is acceptable provided the process yields a satisfactory indication to a background contrast. Type II and Type III processes shall not be used on engine components. The examination of critical components shall be performed with Type I, Method D, Sensitivity Level 4, process. Critical components are defined as any part that by design experiences rotary motion when in operation (e.g., blades, disks, wheels, impellers, seal plates, spacers, couplings, tie bolts, spinners, shafts, and gears, etc.). For critical components, penetrant dwell time shall be 30 minutes minimum. Otherwise, dwell time shall be a minimum of 10 minutes. For dwell time greater than two hours, the penetrant must be reapplied every two hours to prevent drying. Rotate part as necessary to prevent pooling. Developer is required. Dry powder developer is the preferred developer for routine inspection. The component shall be dry before applying the developer. Dry developer dwell time shall be 10 minutes minimum, to four hours maximum. Method D may be substituted for Method A (unless water contact is prohibited).
(b)
(c)
(d)
(e)
(f)
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FLUORESCENT PENETRANT INSPECTION Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (g) Inspection aids such as mirrors and borescopes shall be used to inspect features such as bores or holes where the line of sight is greater than 45 degrees or the visual access is restricted. All relevant indications shall be evaluated, using ultraviolet light, against the appropriate accept/reject criteria. Linear indications shall be defined as those with at least a three to one ratio of length to width. Templates or flat wire gauges are recommended for defect size determination. Magnification (10x maximum) and/or white light may be used to determine discontinuity type or to aid in evaluation. Indications on parts may be evaluated as follows: 1 Lightly wipe the area, in one direction, with a soft brush or cotton tipped applicator dampened with solvent. Do not permit solvent to flood the surface. After the solvent evaporates from the surface, re-inspect. If an indication reappears, evaluate it immediately. If a relevant indication does not reappear, evaluate it after redevelopment. The redevelopment time shall be a minimum of 10 minutes (3 minutes for nonaqueous developer).
(h)
(i)
The component or area of the component being inspected shall be free of any contaminants that may inhibit the penetrant from entering discontinuities, suppress dye performance, or produce unacceptable background. Such contaminants shall include, but not be limited to, coatings, paint, varnish, oil, grease, oxides, corrosion products, scale, smeared metal, visible dye remains, chemical or other residue. The cleaning methods selected shall be consistent with contaminants to be removed, and shall not be detrimental to the component. After examination, the components shall be cleaned to remove developers and penetrant residues. Table 1. Penetrant Inspection Guidelines
Component Critical Rotation Components Blades Fan Compressor Turbine Discs Fan Axial compressor Impeller Turbine Miscellaneous Seal plates, rotating seals
Type
Method
Sensitivity
1 1 1 1 1 1 1 1
D D D D D D D D
4 4 4 4 4 4 4 4
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Table 1. Penetrant Inspection Guidelines (Cont) Component Spacers Couplings Fan spinner Bearings Gear, Shafts Tie rod, Lock nut Type 1 1 1 1 1 1 Method D D D D D D Sensitivity 4 4 4 4 4 4
Non-Rotating Components Structural Components Front frame Inlet housing Compressor/turbine cases Combustion case/ backwall Combustion liner and details Mount flanges and bosses Shrouds Diffuser vanes Stator assemblies, nozzles Windage shields Miscellaneous Anti-rotation keys Sheet metal details Casting details Fuel Manifolds Tubing/Piping Bolts, Bushings 1 1 1 1 1 1 A/D A/D A/D A/D A/D A/D 3 2 2 3 3 3 1 1 1 1 1 1 1 1 1 1 A/D A/D A/D A/D A/D A/D A/D A/D A/D A/D 2 3 3 3 3 3 3 2 2 2
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SPOT-FLUORESCENT PENETRANT - SPOT-FLUORESCENT-PENETRANT INSPECTION TASK 70-32-03-230-002 1. Spot-Fluorescent-Penetrant Inspection SUBTASK 70-32-03-99G-002 A. General. (1) The spot-fluorescent-penetrant inspection process is intended for inspections at remote locations or as a localized process limited to small specific areas for inspection. The spot-fluorescent-penetrant inspection process is not intended as a substitute for normal inspection. It is convenient to use for inspection of welded or other localized repair areas. (a) Spot-fluorescent-penetrant inspection referenced in this manual shall be performed in accordance with Specifications ASTM E1417 or AMS 2547 which detail the minimum requirements. Refer to the component section of the manual for specific instruction and/or acceptance criteria. Where no specific process has been identified, Table 1, Page 2, SPM, SUBTASK 70-32-02-99G-001, Fluorescent-Penetrant Inspection, shall be used as a guide with the exception that Method C may be substituted for Method A or D. Inspection to a higher sensitivity level than specified is acceptable provided the process yields a satisfactory indication to a background contrast. Type II and Type III processes shall not be used on engine components. The examination of critical components shall be performed with Type I, Method C or D, Sensitivity Level 4, process. Critical components are defined as any part that by design experiences rotary motion when in operation (e.g., blades, disks, wheels, impellers, seal plates, spacers, couplings, tie bolts, spinners, shafts, and gears, etc.). For critical components, penetrant dwell time shall be 30 minutes minimum. Otherwise, dwell time shall be a minimum of 10 minutes. For dwell time greater than two hours, the penetrant must be reapplied every two hours to prevent drying. Rotate part as necessary to prevent polling. Developer is required. For Method C, nonaqueous developer (NAD) is recommended. Apply NAD as a uniform this coating over the inspection surface. If the developer coating thickness is to heavy and the metallic surface is not visible, the part shall be cleaned and reprocessed. The component shall be dry before applying the developer. NAD dwell time shall be 10 minutes minimum, to one hour maximum. Inspection aids such as mirrors and borescopes shall be used to inspect features such as bores or holes where the line of sight is greater than 45 degrees or the visual access is restricted.
(b)
(c)
(d)
(e)
(f)
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STANDARD PRACTICES MANUAL AS907-1-1A (g) All relevant indications shall be evaluated, using ultraviolet light, against the appropriated accept/reject criteria. Linear indications shall be defined as those with at least a three to one ratio of length to width. Templates or flat wire gauges are re commended for defect size determination. Magnification (10x maximum) and/or white light may be used to determine discontinuity type or to aid in evaluation. Indications on parts may be evaluated as follows: 1 Lightly wipe the area in one direction, with a soft brush or cotton tipped applicator dampened with solvent. Do not permit solvent to flood the surface. After the solvent evaporates from the surface, re-inspect. If an indication reappears, evaluate it immediately. If a relevant indication does not reappear, evaluate it after redevelopment. The redevelopment time shall be a minimum of 3 minutes for nonaqueous developer or 10 minutes if other developers are used.
(h)
The component or area of the component being inspected shall be free of any contaminants that may inhibit the penetrant from entering discontinuities, suppress dye performance, or produce unacceptable background. Such contaminants shall include, but not be limited to, coatings, paint, varnish, oil, grease, oxides, corrosion products, scale, smeared metal, visible dye remains, chemical or other residue. The cleaning methods selected shall be consistent with contaminants to be removed, and shall not be detrimental to the component. After examination, the components shall be cleaned to remove developers and penetrant residues.
EFFECTIVITY: ALL
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SPOT-FLUORESCENT-PENETRANT INSPECTION Page 2 Dec 01/03
RADIOGRAPHIC INSPECTION - RADIOGRAPHIC INSPECTION TASK 70-32-05-260-001 1. Radiographic Inspection SUBTASK 70-32-05-99G-001 A. General. (1) The radiographic inspection process is a nondestructive method of detecting flaws, cracks, corrosion, defects, wear, deformation, relative position, and presence of foreign bodies in an inspected part. The radiographic process employs X-rays, which are projected through the inspection part, forming an image on photographic film (radiograph) or captured as an image on filmless electronic imaging equipment which will show defects, etc. Radiographic inspection complements other methods of nondestructive inspection but does not replace them. Only experienced, certified inspectors shall be authorized to accept or reject parts on the basis of radiographic inspection. Personnel Requirements. (a) Personnel performing this inspection must be certified in accordance with National Aerospace Standard (NAS-410), American Society of Non Destructive Testing (ASNT-TC-1A), Air Transport Association Specification No. 105 (ATA 105), or locally approved certification program. Personnel performing this inspection should receive practical training in the use of this procedure and must demonstrate proficiency in calibration of the inspection equipment, inspection of hardware, and evaluation of indications before the authority to accept and reject hardware is delegated. Any training which may be provided regarding the performance of this inspection does not imply that the personnel who receive that training have met the requirements for inspector certification in accordance with NAS-410, ASNT-TC-1A, or ATA 105.
(2) (3) (4)
(b)
(c)
SUBTASK 70-32-05-260-011 B. Equipment. (1) Because of the hazardous nature of X-rays, all equipment must be approved and certified by an approved agency for radiographic inspection. Maintenance and replacement of parts must be performed in accordance with instructions provided by the equipment manufacturer. Equipment that requires calibration or safety
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STANDARD PRACTICES MANUAL AS907-1-1A checks shall not be used when the calibration or safety tag is exposed, illegible or missing. NOTE: Filmless electronic imaging equipment may be used in place of film provided that you meet all requirements in Subtask 70-32-05-260-013, Quality Assurance. (a) An X-ray generating unit of 300 KVCP (Kilo Volt Constant Potential) is required to inspect 1.25 inch (31.8 mm) thick steel. Greater thicknesses will require more powerful equipment. Lead cones and filters made of various materials are used to vary X-ray exposure to produce the sharpest radiographic image under a variety of conditions. The film holder holds a piece of film and protects it from light exposure. The film holder also holds optional lead screens in uniform contact with the film when specified. The film viewer is used to examine the processed radiograph. The developed film is mounted on a translucent lighted surface which projects light through the film allowing it to be examined. The light intensity is adjustable and evenly diffused over the viewing surface. The densitometer, the radiographic density step tablet, and the radiographic density comparator are used to establish the density of the inspection part and consequently help to determine accurate exposure and development time. Penetrameters, image quality indicators (IQI), and wire gages are used to measure image quality of radiographs. The material designated for the penetrameters, IQI, and wire gages are radiographically similar to the material being inspected and have approximately the same densities. Radiographically similar material refers to materials or alloys which have approximately the same radiation absorption. The identical alloy is not required. 1 2 Penetrameters and IQI are blocks of specified materials and thicknesses containing holes of specified sizes. Penetrameters are manufactured to the requirements shown in Figure 1 (Sheet 1 of 2), Page 3. The IQI are manufactured to the requirements of Figure 2, Page 5. The wire gage contains 7 wires of specified material and sizes and is manufactured to the requirements of Figure 3, Page 6.
(b)
(c)
(d)
(e)
(f)
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Penetrameters (Inches) Sheet 1 Figure 1 (Sheet 1 of 2)
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Penetrameters (Inches) Sheet 2 Figure 1 (Sheet 2)
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Image Quality Indicator Figure 2
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Wire Gage Figure 3
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-05-260-012 C. Procedure. (1) Film must be stored in a cool, dry area which is free from penetrating radiation.
CAUTION: DO NOT SUBJECT FILM TO TEMPERATURES HIGHER THAN 858F (298C) BEFORE PROCESSING. PROCESSED FILM SHOULD BE KEPT IN AN AREA IN WHICH THE TEMPERATURE DOES NOT EXCEED 1008F (388C), BUT IT DOES NOT HAVE TO BE PROTECTED FROM PENETRATING RADIATION. (2) Film must be handled by its edges, with clean, dry hands to avoid finger marks. Unexposed and unprocessed film shall be handled only in a dust-free photographic darkroom. An approved safelight may be used if desired. X-RAYS ARE HAZARDOUS AND THEIR EFFECT IS CUMULATIVE. THEY CANNOT BE DETECTED BY ANY OF THE HUMAN SENSES. MAKE SURE THAT PROPER SHIELDING IS USED AND THAT EQUIPMENT IS OPERATED ONLY IN ACCORDANCE WITH APPROVED SAFETY PRACTICES AND PERSONNEL PROTECTION DEVICES.
WARNING:
(3)
Film Exposure. (a) Settings for parts are obtained by estimate, trial, and correction until a satisfactory radiograph is obtained. These particulars are recorded on technique charts and filed by part identification for future reference. The technique chart should include the following information: Part number X-ray unit identification Milliamperage Film exposure time Cone Angle Filter Screen remarks, sketches, etc. Kilovoltage Film size Film type Film focal distance: at least 36 inches (914 mm) Focal spot size Setup (cutting of film for separate exposures) Cassette Number of film frame Identification of the film for part number and location of film on part
(b)
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STANDARD PRACTICES MANUAL AS907-1-1A Penetrameter, IQI, or wire gage used (identity, size, and material) Film processing time - temperature Distance of film from inspection surface: must not exceed 1.5 inch (38 mm) Specific remarks, sketches, etc. (c) Select the proper penetrameter, IQI, or wire gage based upon the material and thickness of area of part to be inspected. The penetrameter, IQI, or wire gage is then placed on the X-ray source side of the part to be inspected at the outer edge of the cone of radiation. X-RAYS ARE HAZARDOUS, AND THEIR EFFECT IS CUMULATIVE. MAKE SURE THAT PROPER SHIELDING AND MASKING ARE USED, AND THAT EQUIPMENT IS OPERATED ONLY IN ACCORDANCE WITH APPROVED SAFETY PRACTICES AND PERSONNEL PROTECTION DEVICES.
WARNING:
(4)
Film Processing. Following exposure, the film is developed, fixed, and washed in accordance with the manufacturers instruction sheet. Accurate control of time and temperature is essential and all solution temperatures, including that of the wash-water, should be as near equal as practical. After removal of excess water, the film is dried rapidly in a well ventilated dust-free area.
(5)
Density. The H and D densities of the radiograph should be within a range of 1.5 - 4.0 in the area being interpreted, as read on the densitometer for radiographic density comparator.
(6)
Interpretation. Processed radiographic films are examined in a viewing room in which the light is subdued and shielded so that glare or reflections are not cast on the radiograph being examined. The screen of the viewer is shaded or masked so that direct light cannot shine around the radiograph and into the inspectors eyes. Films with a density of 2.2 or greater should be interpreted under high-intensity viewing illumination. Radiographs that show handling marks in the area of the part image should be discarded and remade.
SUBTASK 70-32-05-260-013 D. Quality Assurance. (1) The penetrameter thickness and hole size defines the sensitivity or quality of the radiograph. The penetrameter used must have a thickness no greater than 2 percent of the thickness of the part being radiographed to a minimum penetrameter thickness of 0.005 inch (0.13 mm). The quality level of inspection must be 2-2T which means that the image of the hole of 2T (twice the thickness of the penetrameter) and the outer edge of the penetrameter panel with a thickness of 2 percent of the part must be visible on the radiograph. The 2 percent refers to the first number in the quality level designation. The IQI is used in a similar method to define radiographic quality. The determination of the visibility index is obtained by counting the number of holes (a)
(2)
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STANDARD PRACTICES MANUAL AS907-1-1A visible on the radiograph, and by using the formula N = a-b. In this formula, b represents the number of holes which would be visible in all the steps with a thickness equal to or greater than 5 percent of the thickness being examined. The value of N can be negative, zero or positive. The sensitivity improves as the positive value of N increases. It should be noted that each group of small holes counts as only one unit in determining (a) and (b). N = value of 1.25 is approximately equivalent to a quality level of 2-2T when penetrameters are used. (3) For the inspection of welds, it is sometimes preferable to use wire gages. The image quality is given by the thinnest wire still distinguishable on the radiograph, assuming that the indicator was placed during the exposure, between the source of radiation and the object being inspected and in close contact with the latter. The number of this wire is the measure of the image quality, which is preceded by the letters BZ. For inspection of electronic beam welds, the X-ray techniques shall recognize the weld preparation angles and have the capability to accurately control that angle during inspection. To establish the best possible angle for exposure during X-ray inspection, a part tacked, clamped, or similarly assembled and ready to weld shall be X-rayed to determine what angle shows the non-fused joint the sharpest, commonly referred to as "Black Line" X-ray. This angle 2 degrees shall then be used after welding for inspection. If filmless imaging equipment is used in place of conventional film, the results of the two methods must correlate. Record retention of the correlation must be maintained. Image processing capabilities such as frame averaging, subtraction, summing, filtering, etc. may be used. When permanent records are required, a back-up copy saved on a different system or media shall be maintained. Unless otherwise instructed by the process document, penetrameters are not required for the inspection of braze joints where the purpose of the inspection is to find whether material is present or absent.
(4)
(5)
(6)
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ULTRASONIC INSPECTION - ULTRASONIC INSPECTION TASK 70-32-06-270-001 1. Ultrasonic Inspection SUBTASK 70-32-06-99G-001 A. General. (1) The ultrasonic methods of nondestructive testing are used to inspect engine components to determine if the parts contain discontinuities or defects which could affect the life or use of the part or to validate repairs such as various bonding procedures. There are 2 basic types of ultrasonic testing; the pulse-echo A scan test and the through-transmission or pitch-catch test. (a) In pulse-echo A scan testing, specific test apparatus converts electrical energy into short pulses of high frequency sound waves. These sound waves are then transmitted to the hardware to be inspected by means of coupling medium or couplant. After passing through this couplant the sound waves continue into or through the hardware and are altered or reflected by sonic reflectors (flaws or back surfaces) back through the couplant and into the ultrasonic receiving element. This sound wave pattern is then processed by the ultrasonic instrument and is observed by the inspector through the use of a cathode ray tube (CRT). Recording equipment or other monitoring facilities may be used to modify this basic system and to provide permanent documentation of inspection results. See Figure 1. In through-transmission or pitch-catch type of testing 2 transducers are used. Accurate positioning of the receiving transducer is required to assure the proper capture of transmitted energy. See Figure 2, Page 6.
(2)
(b)
(3)
Contact testing and immersion testing are the 2 basic ultrasonic testing techniques. (a) Immersion testing is the generally applied inspection process. During immersion testing a waterproof transducer is used at a distance from the test part. The ultrasonic waves are then transmitted into the material through the liquid medium (couplant). The distance between the transducer and the part surface now appears on the CRT display as a wide space between the initial sonic pulse and the front surface reflection. In standard immersion testing both the transducer and the hardware are immersed in the couplant, usually water. This permits easy changes in sonic incident angles and allows mode changes by angulating either the hardware or the transducer holder (manipulator). However, a disadvantage to this system is the need for a tank sufficiently large enough to submerge both the transducer and hardware. See Figure 3, Page 7. In contact testing the transducer is used with a very thin film of couplant between the transducer assembly and the test part. The CRT display from a contact system usually shows the initial sound pulse from the transducer and
(b)
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STANDARD PRACTICES MANUAL AS907-1-1A the front surface reflection as superimposed or very close together. Contact testing can be complicated by the inability to maintain a constant and uniform coupling between the transducer assembly and the test part. Different test part contours and/or sonic propagation directions or modes usually require different transducer assemblies to ensure contact with test part surface. Contact testing is limited to those components and tasks where the specific test method, equipment, transducers, etc., have been judged to be suited for this inspection task. (4) The 3 primary modes of sonic wave propagation used during ultrasonic inspection are: longitudinal, shear, and surface wave. Longitudinal or compression waves have particle vibrations in the same direction as the sound motion. Shear or transverse wave particle vibrations are at right angles to the sound motion. Surface or Rayleigh waves produce an elliptical shear wave form that moves along the free boundary or surface of a solid and is normally confined to a penetration depth of approximately 25 percent of a wave length. See Figure 4, Page 8. The following equation, an adaptation of Snells Law, is used to calculate incident angles, refracted angles, and modes: Sin Angle1 divide by V1 = Sin Angle2 divided by V2 Where: Angle1 = the incident angle of the beam from normal Angle2 = the refracted beam angle in the test material V1 = the velocity of sound in the first medium V2 = the velocity of sound in the second medium Maximum reflection from a sonic reflector is achieved when the reflector surface is 90 percent or perpendicular to the sound propagation direction. (6) When an ultrasonic wave that is traveling through one medium reaches a boundary between it and a second medium, part of the energy continues through the second medium while the remainder is reflected back into the first. The characteristics of each material that determines the amount of reflection is known as the acoustic impedance (z) of the material and is a product of the density of the material (p) and velocity of sound in the material (v), (z = pv). In a pulse-echo system the ultrasonic waves pass through an interface twice, once in each direction. If the second medium is air almost 100 percent of the sound energy will be reflected back into the first medium. If the second medium is not air a different percentage of sound energy will be reflected back toward the first medium. Acoustic impedance may be matched and reflection reduced by keeping the impedances the same, however, it is normally necessary in ultrasonic testing to transmit sound energy between mediums of greatly different acoustic impedances and some method must be available to accomplish this. The best method of reducing impedance mismatch is the liquid couplants. (7) The couplant couples the sound energy transmitted from the transducer to the test part. There is a wide range of couplants including liquids, pastes, and semi-liquids that fulfill the following requirements:
(5)
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STANDARD PRACTICES MANUAL AS907-1-1A (a) (b) The couplant should have an acoustic impedance between that of the transducer face and the test specimen. The couplant should be harmless to the part, easily applied, viscous, easily removed, free of air bubbles and homogeneous and should theoretically wet both the transducer face and specimen surfaces. Water, tap or with a wetting agent added, is commonly used for immersion testing and the more viscous oils, glycerine or other commercially available products, are used during contact testing.
(8)
Only experienced, qualified operators designated and approved to perform this specific ultrasonic inspection shall perform the test. Operator must be capable of performing equipment calibrations, carry out the intended inspection and be capable of correctly interpreting test data before accepting or rejecting inspected parts. Personnel Requirements. (a) Personnel performing this inspection must be certified in accordance with National Aerospace Standard (NAS-410), American Society of Non Destructive Testing (ASNT-TC-1A), Air Transport Association Specification No. 105 (ATA 105), or locally approved certification program. Personnel performing this inspection should receive practical training in the use of this procedure and must demonstrate proficiency in calibration of the inspection equipment, inspection of hardware, and evaluation of indications before the authority to accept and reject hardware is delegated. Any training which may be provided regarding the performance of this inspection does not imply that the personnel who receive that training have met the requirements for inspector certification in accordance with NAS-410, ASNT-TC-1A, or ATA 105.
(9)
(b)
(c)
SUBTASK 70-32-06-270-011 B. Equipment. (1) Ultrasonic test equipment generally consists of the following items. Manufacturers instructions should be consulted for specific equipment being used. (a) The ultrasonic instrument generates electrical pulses, receives return information in the form of small amplitude voltages, amplifies the signals, and displays the signal as vertical deflections on the CRT. It contains the power supply to furnish the proper current requirements and the timing mechanism which controls and synchronizes the pulse rate, sweep, and time delay circuits. The transducer is the pulsing and sensing portion of the system. It is the unit that makes generation and detection of sound energy possible. It consists of a piezoelectric crystal mounted in a housing assembly, with an electrode connecting the crystal to the housing cable connector. The majority of piezoelectric crystals in use are made of lithium sulfate.
(b)
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STANDARD PRACTICES MANUAL AS907-1-1A (c) Quartz and barium titanate are 2 other crystal materials commonly used. The frequency range of ultrasonic transducers used for flaw detection is 500,000 cycles per second to 25,000,000 cycles per second. Manipulators for parts or transducers are incorporated in most ultrasonic test systems to change the angular orientation of the ultrasonic beam with respect to the test specimen. This orientation is required to achieve proper introduction of the sound into the part being tested, and is dependent upon the part geometry, the nature of the defect, and the expected defect orientation in order to obtain the maximum sound energy reflected to the transducer for greatest defect detectability. Recording equipment may be used to provide permanent records of inspection results. Calibration standards are used in ultrasonic testing for calibrating equipment by providing reproducible references for establishing system sensitivity and by verifying that the test system is functioning properly. Calibration standards are normally fabricated from material that is acoustically similar to the part to be inspected. Typical sonic reflectors used for calibration standards are: back surfaces, side of a hole, end of a flat-bottom hole, or notches. See Figure 5 (Sheet 2), Page 10.
(d)
(e) (f)
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Pulse-Echo Testing Figure 1
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Through Transmission Testion Figure 2
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Test Methods Figure 3
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Ultrasonic Wave Propagation Directions Figure 4
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Ultrasonic Calibration Block Inches Sheet 1 Figure 5 (Sheet 1 of 2)
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Ultrasonic Calibration Block Inches Sheet 2 Figure 5 (Sheet 2)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-06-270-012 C. Procedure. (1) Inspection plans or operation sheets should be prepared that define inspection parameters and procedures, including rejection criteria, part disposition, calibration requirements, etc., prior to the inspection of the part. Records should be kept and maintained that reflect compliance with the test requirements and this practice. Normally inspection calibrations are performed before and after the inspection of each part. If a series of inspections are performed, calibration may be performed at the beginning or end of the series, but should not be greater than 8 hours between calibrations. (a) Generally if calibration signals vary by greater than 10 percent full scale, all material inspected during the interim period should be reinspected. However, if the calibration response has increased by more than 10 percent full scale, the hardware need not be reinspected as the system would have been more sensitive than required. During the immersion inspection of forging and certain other applications, calibration is achieved by setting the response signal from one or more 0.020 inch (0.51 mm) side drilled holes to 80 percent full scale amplitude. The distance of the hole(s) below the surface being inspected should correspond to the depth of material to be inspected and allow the necessary resolution. In other tests the calibration standard normally represents the condition in which the test is being conducted. When specific flaw standards are used as a base for calibration, they should represent the approximate limiting condition to be used for part acceptance.
(2)
(b)
(c)
(3)
Part surfaces must be clean and free of any oxides, scales, loose foreign material, or machining grooves which could interfere with the intended inspection. Reference points or other techniques for identifying and marking ultrasonic conditions of interest with respect to part position must be identified and used. Maximum scanning index and speeds shall be no greater than that established for specific technique and shall assure acceptable inspection coverage and detectability. In most inspections the maximum scanning index intervals shall be 75 percent of the effective beam width. With positioning accuracy of 0.01 inch/feet (0.25/304.8 mm) and a spiral index, the scanning index may be increased to 100 percent of the effective beam width. Without a spiral index, it shall be no more than 90 percent. Lineal surface speed during visual inspection shall be no more than 6 inches (15.24 cm) per second. Lineal surface speed during recording shall be determined by the operating characteristics of the equipment. During surface wave contact testing the transducer is normally indexed and simultaneously rotated about its axis to conduct a thorough search of the inspection area.
(4)
(5)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-06-270-013 D. Quality Assurance. (1) Calibrations and calibration checks shall be performed at intervals that assure any part inspected to an improper calibration can be reinspected before any additional processing of the part that would limit or compromise its reinspection.
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EDDY CURRENT INSPECTION - HIGH SPEED AND SLOW SPEED EDDY CURRENT INSPECTION TASK 70-32-07-250-001 1. High Speed and Slow Speed Eddy Current Inspection of Circular Holes in Inconel or Titanium Engine Parts NOTE: SAE Aerospace Standard AS4787 can be used in conjunction with this procedure. AS4787 is considered equivalent to this procedure, but lacks specific inspection requirements for Honeywell products. Therefore both documents will be necessary if inspecting the parts per AS4787. SUBTASK 70-32-07-99G-001 A. General. (1) This practice describes the equipment and processes used for eddy current inspection of circular holes in engine parts. These techniques are used to detect flaws or discontinuities at, or near, the surface of metallic parts which may be detrimental to the part life or limit its intended use. Only qualified operators specifically designated, trained and approved to perform a specified inspection shall perform that test. Operators must be capable of performing equipment calibrations, carrying out the intended inspection and be capable of acceptable interpretation of output test data before his acceptance or rejection of hardware in accordance with an inspection procedure. There are three inspection methods: Method A (High Speed) is in Subtask 70-32-07-250-011, High Speed Eddy Current Inspection (Method A). Method B (Slow Speed) is in Subtask 70-32-07-250-012, Slow Speed Eddy Current Inspection (Method B). Method C (High Speed with Electronic Data Acquisition) is in Subtask 70-32-07-250013, High Speed Eddy Current Inspection with Electronic Data Acquisition and Storage (Method C). SUBTASK 70-32-07-250-011 B. High Speed Eddy Current Inspection (Method A). (1) Method A: High Speed Eddy Current Inspection. (a) Scope. 1 This document describes the equipment, technique and procedure necessary to do a 2 MHz high speed eddy current inspections of circular holes in aircraft engines hardware for the detection of cracking. A Service Bulletin or applicable manual procedure is required for the detailed information needed for inspection of specific parts.
HIGH SPEED AND SLOW SPEED EDDY CURRENT INSPECTION Page 1 Dec 01/03
(2)
(3)
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STANDARD PRACTICES MANUAL AS907-1-1A 2 This document describes the general procedure and equipment which have been approved for the performance of high speed eddy current hole inspections. Exceptions to this procedure may be required for specific cases where the procedure or equipment described in this procedure cannot be used or is not appropriate. Such exceptions should be obtained in writing from Honeywell.
(b)
Applicable Documents. 1 2 3 Instruction manuals or other information provided by equipment manufacturers. The appropriate Service Bulletin or applicable manual inspection for the hardware inspection. Kit preparation and quality assurance plan, M&FQT Procedure 1480 (applies to Honeywell,/QTC only).
(c)
Personnel Requirements. 1 Personnel performing this inspection shall be certified in accordance with one of the following: a b c d e 2 National Aerospace Standard 410 (NAS 410), which replaces MILSTD 410 American Society of Nondestructive Testing specification ASNTTC-1A (ASNT-TC-1A) Air Transport Association Specification No. 105 (ATA 105) Comite Sectoriel Aeronautique Cofrend (COSAC) A locally approved certification program.
Personnel performing this inspection should receive practical training in the use of this procedure and must demonstrate proficiency in calibration of the inspection equipment, inspection of hardware, and evaluation of indications before the authority to accept and reject hardware is delegated. Any training which may be provided regarding the performance of this inspection does not imply that the personnel who receive that training have met the requirements for inspector certification in accordance with Step (c) 1.
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STANDARD PRACTICES MANUAL AS907-1-1A (d) Equipment Requirements. NOTE: Items 1 through 2 are to be supplied by the inspection site. NOTE: Items 3 through 9 can be obtained from Honeywell. The correct service bulletin or applicable manual inspection procedure will specify the necessary tooling requirements. NOTE: Get items 3 through 9 from: Honeywell, QTC. Refer to the List of Suppliers in Step D. of 70-80-00. 1 The eddy current instruments listed in Table 1 are approved for use with this procedure. NOTE: Nortec NDT 19 Instruments having serial numbers 314 and below will not function correctly with the high speed rotor and cannot be used. Instruments having serial numbers 315 and higher may be used if an internal adjustment is made. NOTE: This is to be done by the manufacturer. All NDT 19E models should function without internal adjustments. NOTE: The Hocking Phasec 1.1 must have the appropriate software to ensure that the correct filtering is available to perform high speed bolthole inspections at the appropriate inspection sensitivity and noise levels. To determine if the unit has the correct software, the filter display must show actual frequency values (in Hz). Highlighting the High Pass (HP) filter field on the instrument and advancing through all the frequency settings, should show the following HP filters: DC, 2 Hz, 25 Hz, 100 Hz, and 500 Hz. If these values cannot be displayed, and instead, STD, 1, 2, 3, 4, and 5 are displayed, then the instrument does not have the software needed to perform this inspection. Table 1. Initial Instrument Control Settings Control Description Rohmann Elotest B1: X Axis Gain Y Axis Gain Preamplifier Bandwidth Phase Dot position Filter type Filter frequency Rohmann Elotest B1V3 and B1V4: Frequency
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Setting 0 dB 0 dB Maximum value possible HF 08 0/0 BP (Band pass) 800 Hz 2.0 MHz
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Table 1. Initial Instrument Control Settings (Cont) Control Description Bandwidth Gain Y-Spread X-Spread Phase Filter: High Pass Filter: Low Pass Rohmann Elotest B2: Sweep: Display (Switch) Sweep: Fine Sweep: Coarse HP Filter: Hz HP Filter: Range HP Filter: BP HP Filter: Switch Sensitivity: Y x 2 Sensitivity: dB Phase Frequency: Switch Frequency: Fine Frequency: Range Filter LPF Driver circuit Receiver pre-amp Forster Defectoscope SD 2.832: Power (1/0) Filter (TP/HP) Sensitivity Frequency Phase 1p U1 Yo (Y Position) Xo (X Position)
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Setting HF 58/58 dB 0 0 3288 400 Hz 1.25 kHz X-Y N/A N/A 33 X10 0 On 0 05 4.0 Display Adjust as required to get 2000 kHz 5 HF 1 kHz -12 30 dB 1 (On) 5 (160 Hz High Pass) 26.5 dB 200 kHz (Use Exp. button) 184 1 0 50 0
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Table 1. Initial Instrument Control Settings (Cont) Control Description Intense XY (dB Spread) Store time Display Signal display X1, X10 Switch I/O Switch on motor Forster Defectoscope SD 2.833: Drive Att. Frequency Phase Gain Y Spread X Spread HP Filter LP Filter Time Hocking 2200: RPM Display Persist CH 1 Frequency CH 1 Gain CH 1 X:Y Angle Low Pass Filter High Pass Filter IMP Gain X-Pos 1 Y-Pos 1 Hocking Phasec 1.1: Power Frequency Gain
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Setting As needed 0 1 Impedance mode (TR) Off (0) X10 As desired 25 Ohms 0 dB 2 MHz 218 66 dB 0 dB 0 dB 150 Hz 1 kHz 0.1s 3000 XY 1S 2 MHz 50 dB 0.0 dB 83 2000 Hz 200 Hz +20 dB 0 0 On 2 MHz 30 dB
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Table 1. Initial Instrument Control Settings (Cont) Control Description Phase Store Hi-Pass Filter Lo-Pass Filter I/P Horizontal position Vertical position V/H Ratio Sweep RPM Staveley Nortec 19/19e/19ell: Power Display Sweep Program Memory 2 Latch Frequency Gain (Horizontal and Vertical) Position Angle High Pass Filter Low Pass Filter SP 02 (Probe drive) SP 03 SP 01, 04, 05, 07 Continuous null Display erase Null F1/F2 (Frequency) C/F (Coarse/Fine) Staveley Nortec 24: Frequency Gain H Gain
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Setting 300 250 1500 0 0 1:1 Off 1500 On Frequency 1 Off 01 Off Off 2000 kHz 60.000 128 (50%) 00 200 500 Mid Off Optional Off As required As required Frequency 1 As required 2 MHz 60 dB 72.0
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Table 1. Initial Instrument Control Settings (Cont) Control Description V Gain HP Filter LP Filter Display Sweep V Position H Position Screen Persist Sweep Erase Display Erase Graticule Scanner Sweep Scan RPM Staveley Nortec 2000/2000S: Frequency Angle H Gain V Gain Probe Drive LP Filter HP Filter HPF Pole Sweep V Position H Position Persist Sweep Erase Display Erase Graticule Scan RPM 2 2.0 MHz 1878 60 dB 60 dB Mid 500 200 2-Pole Off 50% 50% Off As required As required On 1500 Probe rotors, associated cables, and adapters are listed in Table 2, Page 8.
Setting 72.0 200 500 60.000 Off 50% 50% Off On 1s On Off 1200
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STANDARD PRACTICES MANUAL AS907-1-1A 3 Eddy Current Probe: SPO-5000 series or a Honeywell approved probe. The probe to be used will be specified in the appropriate approved applicable manual or Service Bulletin for the specific hardware to be inspected.
Table 2. Probe Rotors, Associated Cables, and Adapters Instrument Maker Elotest B1 Rohmann Elotest B2 Rohmann Elotest B1V3/V4 Rohmann NDT 19/19e/19ell Staveley or Nortec 24 Nortec 2000/2000S Staveley NDT 19ell Nortec Staveley 24 Nortec 2000/2000S Staveley Phasec 1.1 Hocking 2200 Hocking Defectoscope SD Forster 2.832 AF 2.833 Defectoscope SD Forster 2.832 AF 2.833 NOTE: * - an approved alternate Rotor HF or STD HF or STD HF or STD 19/RA 19/RA Spitfire 2000 Spitfire 2000 33A022 33A106 HRo 1500 HRo 860T Adapter ARM-1* ARM-1* ARM-1* SPO-5201 SPO-5201 Not Req. Not Not Not Not Req. Req. Req. Req. Cable RK-2N RK-2N RK-2N 9113660 9122084 9122091 9122090 33A023 33R103 Fixed 140-639-6 Guide Fixture GE-FQAP-302 GE-FQAP-302 GE-FQAP-302 GE-FQAP-302A GE-FQAP-302A GE-FQAP-302D GE-FQAP-302D GE-FQAP-302B GE-FQAP-302B GE-FQAP-302C GE-FQAP-302C
Not Req.
is the RB1 M1 adapter (GK Engineering).
Guide Fixture: An approved guide fixture must be used for all inspections to provide mechanical control of the probe angle. The guide fixtures are listed in Table 2, Page 8 will be specified by Honeywell in the appropriate Service Bulletin or applicable manual procedure. Refer to Figure 1, Page 14. Calibration Standard: Calibration standards will be specified in the appropriate Service Bulletin or applicable manual procedure for the part to be inspected. Refer to Figure 2, Page 15. Mineral Oil: A small amount of mineral oil or other lubricant may be used to reduce friction for smoother probe rotation, reduced probe and standard wear, and less noise. It is important that the lubricant be a relatively inert material to avoid chemical reactions which may affect probe performance or reduce its useful life. The use of mineral oil or another lubricant is not required but is left to the discretion of the user. Cleaning Materials: Approved cleaning materials and solvents should be used to make sure the part is clean before inspection. Flex-Hones: Flex-Hones may be used when more aggressive cleaning is required and shall be specified in the appropriate Service Bulletin or applicable manual procedure.
7 8
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STANDARD PRACTICES MANUAL AS907-1-1A 9 (e) Marking Materials: Action Marker Q404, black, or equivalent, shall be used to perform any marking of hardware.
Pre-inspection Part Preparation. 1 Clean the holes to be inspected in accordance with TASK 70-22-06-110043, Special Cleaning Procedure No. 6, Bolthole Cleaning for Eddy Current Inspection. Number the holes for reference. The reference location for numbering is the / in the designation S/N where the part serial number is located. Hole number 1 is the first hole clockwise from the /, aft looking forward (ALF). If the S/N mark does not exist, the number 1 hole will be the first hole clockwise from the initial digit of the serial number. All remaining holes are then numbered in sequence moving clockwise, aft looking forward. Visually inspect the holes under white light. Clean the holes again, as required, to remove any remaining dirt or foreign material. TASK 7022-06-110-043, Special Cleaning Procedure No. 6, Bolthole Cleaning for Eddy Current Inspection.
(f)
Initial Equipment Setup. 1 Select the appropriate inspection kit, as specified in the Service Bulletin or applicable manual procedure for the hardware to be inspected. NOTE: Refer to Table 2, Page 8 for instrument and tooling compatibility. 2 3 4 Install the eddy current probe rotor into the appropriate guide fixture. Refer to Figure 3, Page 16. Connect the cable from the probe rotor to the eddy current instrument. Insert the probe in the calibration standard hole to check the probe fit. Refer to Figure 2, Page 15 and Figure 4, Page 17. It is necessary that the probe contacts the surface of the hole but there should be no interference or binding. Significant probe drag may slow or stop the rotor. If the difference between the probe and hole diameters is too great, either too large or too small, it may be necessary to use a slightly larger or smaller probe. NOTE: It is not recommended to alter the probe ball diameter by any means. 6 7 Insert the probe into the probe rotor or probe adapter, as appropriate for the type of rotor being used. Refer to Figure 3, Page 16. Adjust the eddy current instrument to the initial settings, as specified in Table 1, Page 3.
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STANDARD PRACTICES MANUAL AS907-1-1A (g) Equipment Calibration. 1 Turn on the probe rotor and apply a very small amount of mineral oil to the tip of the probe, if desired. NOTE: Spraying of oil from the spinning probe can be avoided by placing a small drop of oil on a fingertip and then briefly holding the finger against the probe tip. 2 3 Place the guide fixture on the calibration standard, center it over the calibration hole, and translate the probe carefully into the hole. With the probe placed well into the calibration hole but away from the electric-discharge machined (EDM) notch, null (compensate) the instrument. Translate the probe through the hole until the notch signal is located. Refer to Figure 5, Page 18. Scan the length of the EDM notch and observe the response on the CRT. Hold the rotor at the position where the largest notch signal response is obtained. Adjust the instrument phase (rotation) control to orient the notch signal vertically. Refer to Figure 5, Page 18. Adjust the gain control to produce a notch signal with a vertical peakto-peak amplitude of four major screen divisions. It may be helpful to offset the dot position from the center of the screen as an aid in setting the correct notch signal amplitude. NOTE: If the selected instrument gain adjustments are in 1 dB steps, it may not be possible to achieve a notch signal amplitude of exactly four major screen divisions. If the exact calibration amplitude cannot be obtained, use the next higher gain setting. 9 Translate the rotor to scan the complete length of the notch to make sure that the calibration was performed at the location of the largest notch signal amplitude. NOTE: Two peaks will be obtained from most notches which have a length that is smaller than the probe sensing coil diameter. Check the amplitude of both peaks to make sure the calibration is performed on the peak which provides the largest response. 10 (h) Record the instrument calibration settings on the inspection data sheet, Form 699-1 ( Figure 6, Page 19).
4 5 6 7 8
Hardware Inspection.
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STANDARD PRACTICES MANUAL AS907-1-1A 1 After completion of the instrument calibration, either the impedance plane (X/Y) or timebase (Y/T) display mode can be used during the inspection of hardware. Refer to Figure 5, Page 18 and Figure 7, Page 20. The gate and alarm may also be used if desired. Remove the probe from the rotor and check the probe fit by inserting the probe into several randomly selected holes around the hardware. a b It is necessary that the probe contacts the surface of the hole but there should be no interference or binding. If the selected probe does not meet the criteria described in the proceeding paragraph, the probe may be worn or the hole may be oversized. Another probe should be selected. NOTE: The eddy current probes used for this procedure are designed to expand and contract over the full range of the specified tolerance of the hole. 3 Return the probe to the rotor and apply a small amount of mineral oil to the probe tip if desired. If required, adjust the leveling block at the bottom of the guide fixture to keep the probe perpendicular to the bolt hole. Carefully center the probe over the first hole to be inspected and translate the rotor until the probe coil is well into the hole. Null the eddy current instrument. Translate the probe slowly down through the hole and back up again while observing the display of the eddy current instrument. The translation speed should be approximately 0.2 inch (5 mm) per second or less. At this speed the inspection of a hole which is 1.0 inch (25 mm) deep should take at least five seconds in each direction. Monitor the eddy current instrument display and record any indications that exceed the inspection threshold requirements given in the appropriate Service Bulletin or applicable manual procedure for the part being inspected. Move to each subsequent hole and repeat the inspection process. Periodically reapply mineral oil to the probe tip, if needed.
4 5 6
8 (i)
Post-inspection Calibration Check. 1 A calibration check shall be performed upon the completion of each inspection, at least every hour, whenever any system component or the inspector is changed, or any time the inspector suspects a change may have occurred in the inspection system. Return the guide fixture to the calibration standard. Center the fixture over the calibration hole, and move the probe carefully into the hole.
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STANDARD PRACTICES MANUAL AS907-1-1A 3 4 5 6 With the probe well into the hole and the coil away from the EDM notch, null the instrument. Scan the length of the EDM notch and hold the rotor at the position where the largest notch signal response is obtained. If the notch response obtained is four major screen divisions, onehalf major division, the test is acceptable. If the notch response has decreased by more than one-half major screen division, the system must be re-calibrated and any hardware inspected since the last acceptable calibration must be re-inspected. If the notch response has increased by more than one-half major screen division, the system must be re-calibrated prior to the inspection of any additional hardware. Hardware inspected and determined to be acceptable since the last acceptable calibration need not be re-inspected.
(j)
Indication Evaluation/Rejection Criteria. 1 Evaluate any hole which, during the initial inspection, produced one or more indications exceeding the indication evaluation/rejection threshold requirements given in the appropriate Service Bulletin or applicable manual procedure for the part being inspected. Perform a calibration check as described in paragraph B.(1)(i), Postinspection Calibration Check. Repeat the inspection of the hole to relocate the indication and confirm that it exceeds the evaluation/rejection threshold requirements. If the indication is confirmed, clean the hole using approved cleaning material. Refer to paragraph B.(1)(k), Cleaning Procedure. Visually inspect the hole and record any unusual conditions which might affect the inspection results on the eddy current inspection data sheet, Form 699-1 ( Figure 6, Page 19). Repeat the inspection of the hole after cleaning. If the indication amplitude has reduced, repeat the cleaning process as necessary until the indication is removed or the amplitude of the eddy current indication is reduced below the evaluation/rejection limit. If the indication cannot be reduced in amplitude to an acceptable level, or increases in amplitude as a result of the cleaning process, refer to paragraph B.(1)(l), Disposition, Documentation, and Records, and the appropriate Service Bulletin or applicalbe manual procedure for the disposition of the hardware.
2 3 4 5
(k)
Cleaning Procedure. 1 Refer to TASK 70-22-06-110-043, Special Cleaning Procedure No. 6, Bolthole Cleaning for Eddy Current Inspection.
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STANDARD PRACTICES MANUAL AS907-1-1A (l) Disposition, Documentation, and Records. 1 Any indication equal to or greater than the criteria specified in the appropriate Service Bulletin or applicable manual procedure for the hardware being inspected shall be evaluated to the requirements of paragraph B.(1)(j), Indication Evaluation/Rejection Criteria. If the amplitude of any indication, after evaluation, is still equal to or greater than the specified requirements, the hardware shall be considered reject and unserviceable. If the inspection produces no indications equal to or greater than the specified requirements, the hardware shall be considered serviceable. As a minimum, record the requested information on Form 699-1 ( Figure 6, Page 19).
3 4
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Guide Fixture Figure 1
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Calibration Standard Drawing Figure 2
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Rotor Installed in Guide Fixture Figure 3
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High Speed Bolthole Probe, SPO-5000 Series Figure 4
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Calibration DRT Display - X/Y Impedance Plane Figure 5
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High Speed Eddy Current Inspection Data Sheet Figure 6
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Calibration CRT Display - X/Y Timebase Figure 7
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-07-250-012 C. Slow Speed Eddy Current Inspection (Method B). (1) Method B: Slow Speed Eddy Current Inspection Method. (a) Scope. 1 This document describes the equipment, technique and procedure required to conduct 2 MHz slow speed eddy current inspections of circular holes in Inconel and titanium alloy engine hardware for the detection of cracking. A service bulletin or applicable manual procedure must provide the detailed information needed for inspection of specific parts. This document describes the general procedure and equipment which have been approved for the performance of slow speed eddy current hole inspections. Exceptions to this procedure may be required for specific cases where the procedure or equipment described here cannot be used or is not appropriate. Such exceptions should be obtained in writing from Honeywell.
(b)
Applicable Documents. 1 2 Instruction manuals or other information provided by equipment manufacturers. National Aerospace Standard 410 (NAS 410), which replaces MIL-STD 410, and/or American Society of Non Destructive Testing specification ASNT-TC-1A (ASNT-TC-1A). The appropriate Service Bulletin or applicable manual procedure.
3 (c)
Personnel Requirements. Personnel performing this inspection must be certified in accordance with NAS 410, ASNT-TC-1A, Air Transport Association Specification No. 105 (ATA 105), or locally approved certification program. 1 Personnel performing this inspection should receive practical training in the use of this procedure and must demonstrate proficiency in calibration of the inspection equipment, inspection of hardware, and evaluation of indications before the authority to accept and reject hardware is delegated. Any training which may be provided by Honeywell for a technique requiring the performance of this inspection method does not imply that the personnel who receive that training have met the requirements for inspector certification in accordance with NAS 410, ASNT-TC-1A, or ATA 105.
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STANDARD PRACTICES MANUAL AS907-1-1A (d) Equipment Requirements NOTE: Items 1 through 6 are to be supplied by the inspection site. NOTE: Items 7 through 12 can be obtained from Honeywell. The correct service bulletin or applicable manual inspection procedure will specify the necessary tooling requirements. 1 Eddy current instrumentation - one of the following types of equipment is required in order to accomplish these inspections or approved equivalent. a b Nortec Model NDT-19/19E Eddyscope. Nortec Model NDT-16 Eddyscope with Model A16-1 amplifier, Model 016-2 oscillator and either a Model F16-1 or Model FS16-1 or FS16-2 filter module. Rohmann Elotest B1 SDM Eddyscope with Probe socket B1NOB3H or B1-ANO2. Nortec Model NDT-25L
c d 2
Strip chart recorder: One of the following types of equipment is required in order to accomplish these inspections, or approved equivalent. (All recorders must have a minimum of 2 channels.) a b c d e Gould 220 recorder. Gould TA240 recorder with two 13-6615-10A signal conditioners. Gould Windowgraf with two 13-6615-10A signal conditioners. Graphtech WR3310 recorder with two AL 3301 signal conditioners. Graphtech WR7500 recorder with two AL3501 signal conditioners.
3 4 5
Strip chart recorder paper as required. Connecting cables as required for Eddy current instrument, strip chart recorder, scanners, and controllers. Bolt hole Scanner: One of the following sets of scanner equipment is required to accomplish a bolt hole inspection. a b Nortec model PS-2M scanner with model PS-2 speed control. Nortec Model PS-3R scanner and PS-3T translator with respective controllers.
A rigid fixture for holding the Nortec bolt hole scanners. Refer to paragraph C.(1)(d) 5, Bolt hole Scanner. The fixture must have provision for positioning the scanner over the bolt or air holes and
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STANDARD PRACTICES MANUAL AS907-1-1A provision for adjustment so that the probe body can be set parallel to the axis of the bolt or air hole. 7 Inspection probe: Honeywell approved 2 MHz hole probe. Refer to Table 3, Page 23. The correct probe size to be used will be given in the service bulletin or applicable manual procedure for the part to be inspected. Table 3. 2 MHz Bolt Hole Probes Probe No. GEC.100-S/2 GEC.105-S/2 GEC.110-S/2 GEC.115-S/2 GEC.120-S/2 GEC.125-S/2 GEC.130-S/2 GEC.135-S/2 GEC.140-S/2 GEC.145-S/2 GEC.150-S/2 GEC.155-S/2 GEC.160-S/2 GEC.169-S/2 GEC.179-S/2 GEC.189-S/2 GEC.200-S/2 GEC.212-S/2 GEC.225-S/2 GEC.239-S/2 GEC.254-S/2 GEC.270-S/2 GEC.288-S/2 GEC.307-S/2 GEC.328-S/2 GEC.350-S/2 GEC.374-S/2 GEC.400-S/2 GEC.428-S/2 GEC.458-S/2 GEC.491-S/2 GEC.526-S/2 GEC.564-S/2 GEC.605-S/2
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Probe Range 0.100 - 0.104 0.105 - 0.109 0.110 - 0.114 0.115 - 0.119 0.120 - 0.124 0.125 - 0.129 0.130 - 0.134 0.135 - 0.139 0.140 - 0.144 0.145 - 0.149 0.150 - 0.154 0.155 - 0.159 0.160 - 0.173 0.169 - 0.183 0.179 - 0.193 0.189 - 0.204 0.200 - 0.216 0.212 - 0.229 0.225 - 0.243 0.239 - 0.258 0.254 - 0.274 0.270 - 0.292 0.288 - 0.311 0.307 - 0.332 0.328 - 0.354 0.350 - 0.378 0.374 - 0.404 0.400 - 0.432 0.428 - 0.462 0.458 - 0.495 0.491 - 0.530 0.526 - 0.568 0.564 - 0.609 0.605 - 0.653
Rotation PS2M PS-3R 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 100 RPM 60 RPM 97 RPM 60 RPM 92 RPM 60 RPM 87 RPM 60 RPM 82 RPM 60 RPM 77 RPM 60 RPM 72 RPM 60 RPM 68 RPM 60 RPM 64 RPM 60 RPM 60 RPM 56 RPM 56 RPM 53 RPM 53 RPM 49 RPM 49 RPM 46 RPM 46 RPM 43 RPM 43 RPM 40 RPM 40 RPM 37 RPM 37 RPM 35 RPM 35 RPM 33 RPM 33 RPM 30 RPM 30 RPM
Translation PS-3T 1.00 in/min 1.00 in/min 1.00 in/min 1.00 in/min 1.00 in/min 1.00 in/min 1.00 in/min 1.00 in/min 1.00 in/min 1.00 in/min 1.00 in/min 1.00 in/min 1.00 in/min 1.00 in/min 1.00 in/min 0.97 in/min 0.92 in/min 0.87 in/min 0.82 in/min 0.77 in/min 0.72 in/min 0.68 in/min 0.64 in/min 0.60 in/min 0.56 in/min 0.53 in/min 0.49 in/min 0.46 in/min 0.43 in/min 0.40 in/min 0.37 in/min 0.35 in/min 0.33 in/min 0.30 in/min
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Table 3. 2 MHz Bolt Hole Probes (Cont) Probe No. GEC.649-S/2 GEC.697-S/2 GEC.749-S/2 GEC.805-S/2 GEC.865-S/2 GEC.930-S/2 GEC1.000-S/2 GEC1.076-S/2 GEC1.158-S/2 GEC1.247-S/2 GEC1.343-S/2 GEC1.445-S/2 Probe Range 0.649 - 0.701 0.697 - 0.753 0.749 - 0.809 0.805 - 0.869 0.865 - 0.934 0.930 - 1.004 1.000 - 1.080 1.076 - 1.162 1.158 - 1.251 1.247 - 1.347 1.343 - 1.450 1.446 - 1.562 8 Rotation PS2M PS-3R 28 RPM 28 RPM 26 RPM 26 RPM 25 RPM 25 RPM 23 RPM 23 RPM 21 RPM 21 RPM 20 RPM 20 RPM 18 RPM 18 RPM 17 RPM 17 RPM 16 RPM 16 RPM 15 RPM 15 RPM 14 RPM 14 RPM 13 RPM 13 RPM Translation PS-3T 0.28 in/min 0.26 in/min 0.25 in/min 0.23 in/min 0.21 in/min 0.20 in/min 0.18 in/min 0.17 in/min 0.16 in/min 0.15 in/min 0.14 in/min 0.13 in/min
Calibration standard: Calibration standards must be made of the same material as the part to be inspected. Standards must have a hole with an electrical-discharge-machined (EDM) notch cut in the side. Specific details about the dimensions of the calibration standard, the diameter of the hole or holes, and the size and location of the EDM notch will be specified in the service bulletin or applicable manual procedure, for the part to be inspected. See Figure 2, Page 15. Marking materials: C05-104 Action Marker 44, black, or equivalent, to mark parts. Rubber wedge material: Parkway Products, . RTV 583, 0.375 in. (9.53 mm) sheet thickness or equivalent such as an eraser. Cleaning materials: Approved cleaning materials and solvents should be used to make sure the part is clean before inspection. Teflon tape: maximum thickness 0.0035 inch (0.089 mm) 3M Company, number 5490, 0.25 in (6.35 mm) wide.
9 10 11 12 (e)
Pre-inspection - Part Preparation. 1 Clean the holes using approved cleaning materials. Refer to TASK 7022-06-110-043, Special Cleaning Procedure No. 6, Bolt hole Cleaning for Eddy Current Inspection. Number the holes for reference. The reference location for numbering is the "/" in the designation "S/N" where the part serial number is located. Hole number 1 is the first hole clockwise from the "/", aft looking forward (ALF). If the "S/N" mark does not exist, the number 1 hole will be the first hole clockwise from the initial digit of the serial
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STANDARD PRACTICES MANUAL AS907-1-1A number. All remaining holes are then numbered in sequence moving clockwise, aft looking forward. 3 Visually inspect the holes under white light. Clean the holes again, as required, to remove any remaining dirt or foreign material. Refer to TASK 70-22-06-110-043, Special Cleaning Procedure No. 6, Bolt hole Cleaning for Eddy Current Inspection. Note on the appropriate inspection data sheet any significant physical conditions in the holes such as evidence of fretting or rubbing.
(f)
Equipment Set-up. 1 2 Set the instrument control settings in accordance with Table 4. Set the Gould model No. 220 to the settings in accordance with Table 4, or alternate recorder in accordance with Figure 8 (Sheet 1 of 2), Page 35. Adjust the rotational speed of the scanner so that it corresponds to the value noted in Table 3, Page 23 for that diameter of bolt hole probe being used. Table 4. Initial Instrument Control Settings
Control Description Elotest B1: Frequency Gain Y Axis Gain X Axis Gain Preamplifier Bandwidth Phase Dot Position Y/X NDT-16: Filter Gate Alarm Power switch Rotation Control Gain Control Frequency Selector X Control R Control Display Sensitivity Null Button Memory Control Features CRT Adjustment Controls (at GRD)
Initial Settings 2.0 MHz 40 dB 0 dB 0 dB 12 dB HF 0 degrees 0/0 Lowpass 100 Hz Off Off On 0.0 2.00 2 MHz Mid Range Mid Range 1V (H&V) Storage Center Spot
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Table 4. Initial Instrument Control Settings (Cont) Control Description Display Selector Filter Out Switch 20 Hz Filter Switch 10 Hz Filter Switch 5 Hz Filter Switch Filter FS16-1 or 2 Modules: Sweep Mode Switch Sweep Range Switch Sweep Speed Switch Sweep Trigger Erase Mode Switch Record Mode Switch Record Control Connector Ext. Trigger Connector Filter Out Switch 20 Hz Filter Switch 10 Hz Filter Switch 5 Hz Filter Switch NDT-19/19E: Power Control Lock Tape In Display Sweep Program Memory 2 Alarm Latch Frequency KHz Gain (Horizontal & Vertical) Position (Horizontal & Vertical) Angle (Rotation) Filter - High Pass Filter - Low Pass SP 01, 03, 04, 05 SP 02 (Probe Drive) Continues Null F1/F2 (Frequency) NDT 25L: Power
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Initial Settings Filter In Out Out Out HV Any Any Free Run Manual Manual In Out Out Out On Off Off Frequency 1 Off 01 Off Off Off 2000 51.0 128 00 0 100 Off 2 or High Off Frequency 1 On
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Table 4. Initial Instrument Control Settings (Cont) Control Description Status Lights Alarm Display: H/T V/T H/V Non Store Alarm Size Alarm Pos Man X Man R Functions: V Read H Read V Sens H Sens Frequency Angle Gain Prog Store Call Prog Filters: High Pass Low Pass (special function) Gould 220 Recorder: Vertical Pen Position Horizontal Pen Position Horizontal Fine Sensitivity Vertical Fine Sensitivity Horizontal Coarse Sensitivity Vertical Coarse Sensitivity Horizontal/Vertical Markers Recorder Power Button Chart Stop Button Chart Speed Selectors 4 Initial Settings On Optional Off/NA Off/NA On Off NA NA As Needed As Needed Off Off 1 1 2000 kHz As Needed 50 dB As Needed As Needed 0 Hz 100 Hz Centered Centered Full CW Full CW 50mv/div 20mv/div Off On In Out
Figure 8 (Sheet 1 of 2), Page 35 provides equivalent settings for times when alternate recorders are used instead of the Gould 220. To use this table, refer to the Gould 220 initial settings in Table 4, Page 25, find that
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STANDARD PRACTICES MANUAL AS907-1-1A setting in Figure 8 (Sheet 1 of 2), Page 35 for the 220 then read across the table for the appropriate setting for the selected recorder. NOTE: Some inspection procedures require long term storage of strip chart recordings in excess of five (5) years. In these cases, the Gould 220 must be used and not the alternates, since the alternates listed in this document use thermal recording paper with a recorded shelf life limited to five (5) years. NOTE: It is the users responsibility to assure that the recording medium complies with the appropriate regulation. 5 For inspections being accomplished with a Nortec PS-3TR scanner, adjust the speed of translation on the PS-3T controller so that it has the value noted in Table 3, Page 23 for the diameter of hole under inspection. NOTE: For smaller diameter bolt hole probes, adjust the rotational speed of the scanner to the maximum if the speed noted on Table 3, Page 23 can not be achieved. 6 Connect the vertical output of the eddy current instrument to Channel No. 1 of the strip chart recorder and the horizontal output of the eddy current instrument to Channel No. 2.
(g)
Probe Preparation. 1 Select the appropriate size probe for the hole to be inspected as specified in the applicable service bulletin or applicable manual procedure. Refer to Table 3, Page 23. Apply teflon tape to completely cover coil face. See Figure 9, Page 37. NOTE: There must be no wrinkles in the tape edges or they will snag on entering the hole. If the tape is wrinkled, it is too wide or was improperly applied. Remove it, cut a narrower piece, and apply the new piece. 3 Manually insert the probe into the calibration hole to determine fit. Proper fit is achieved when the probe tip is snug enough that it will stand alone and supports its own weight. On inserting or withdrawing the probe there should be a light drag. For probes with saw slots, proper fit is obtained by cutting a piece of wedge rubber, at a slight wedge shape. Gross wedge shapes will work themselves out of the probe slot. Insert the rubber wedge into the probe slot and adjust for fit as described in paragraph C.(1)(g) 3. See Figure 10, Page 38. For probes without saw slots, proper fit is obtained by applying teflon tape as required to the probe body opposite the coil. Insert probe into scanner.
5 6
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STANDARD PRACTICES MANUAL AS907-1-1A (h) Equipment Calibration. CAUTION: BEFORE REMOVING ANY MODULE IN A NDT-16, TURN OFF THE INSTRUMENT POWER. MODULE DAMAGE MAY RESULT IF THE POWER IS NOT TURNED OFF. 1 Connect the equipment and set the initial control settings per paragraph C.(1)(f) of this document. a Set up the NDT-16 as follows: Remove the No. F16-1 filter module during set up of the equipment and carefully snap off the left side cover of the module. Move the small slide switch inside the module near the front panel to position X1. Replace the cover and reinsert the filter module. b Set up the Elotest B1 as follows: Determine the maximum possible preamplifier gain by increasing the preamplifier gain until the "PREAMP OVERLOAD" indication appears. NOTE: To minimize instrument produced noise, the preamplifier gain should be increased to the maximum possible value without producing a preamplifier overload condition. Reduce the preamplifier gain just enough to eliminate the overload indication. CAUTION: DO NOT PRESS THE COMPENSATION BUTTON AFTER SWITCHING BACK TO THE LOW-PASS FILTER. To operate at higher preamplifier gain levels, tune the impedance bridge circuitry. Set the filter to 100 Hz highpass and press the compensation (null) button. Change the filter back to 100 Hz low-pass. Place the probe on a test piece or calibration standard. Adjust the two small potentiometers on the adapter to move the dot as close as possible to the null point on the display. NOTE: If the dot position function is set to 0/0 then the null point will be at the center of the display.
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STANDARD PRACTICES MANUAL AS907-1-1A If necessary, reduce the gain to bring the dot on screen so that this adjustment may be made. NOTE: With proper bridge adjustment it is possible to operate at high pre-amplifier gain settings. This adjustment may be different for each probe. After completing this adjustment, the compensation button can be used as needed to null the instrument. c 2 3 4 No special preparation is necessary for the Nortec NDT 19, NDT 19E, or NDT 25L.
Prepare the probe as stated in paragraph C.(1)(g) of this document. Align the probe and scanner for correct entry into the hole with the calibration notch. Refer to C.(a)(d) 8 calibration standard. Turn on the PS-2M or PS-3T and 3R probe scanner and drive the probe down into the calibration hole until the probe coil is completely within the hole. Stop the scanner when the white epoxy line on the probe stem faces away from the EDM slot location. Null the instrument. For NDT-16, null for 5 to 10 seconds or until the spot stabilizes in the center of screen. With the probe still in the calibration hole, turn on the PS-2M (FWD) and put the transmission in R for rotate only. For PS-3T and 3R systems, turn on the PS-3R for probe rotation only. Change the filter on the eddy current instruments: a b c d On the NDT 16, set the filter to 5 Hz (high pass). On the NDT 19 and 19E, leave the low pass filter at 100 Hz, and set the high pass filter to 4 Hz or 5 Hz. On the Elotel B1, change the filter from the low pass 100 Hz to high pass 5 Hz. On the NDT 25L, leave the low pass filter (SP-02) at 100 Hz, and set the high pass filter to 5 Hz.
5 6 7
9 10 11
Turn on the strip chart recorder and check that Channel No. 1 is on 20 mV/Div. and Channel No. 2 is on 50 mV/Div. Translate the probe within the calibration hole until the EDM notch is detected. Manually translate the rotating probe across the entire EDM notch 0.003 in. (0.08 mm) at a time to determine where the maximum amplitudes are achieved on Channel No. 1 and No. 2.
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STANDARD PRACTICES MANUAL AS907-1-1A 12 Observe the EDM notch response on the eddyscope. Adjust the rotation or phase control to obtain an EDM notch response pointing (longest leg) into the upper left quadrant of the CRT for Inconel or into the lower left quadrant of the CRT for Titanium. See Figure 11, Page 39 and Figure 12, Page 40. In both instances the phase angle established by this step should be set to approximately 45 degrees from horizontal. Examine the recorder tracings on Channels No. 1 and No. 2. Alternately adjust the rotation (Phase) and gain controls to achieve calibration amplitudes of 40 percent (400 mV) full scale on Channel No. 1 and 35 percent (875 mV) full scale amplitude in Channel No. 2 (plus or minus 1 percent full scale). Renull is required after any gain adjustment. Assure that the EDM notch response remains in the correct quadrant on the eddyscope. NOTE: For renulling, it is required that the coils face the side of the hole away from the EDM notch. NOTE: For calibration standards with correction factors applied to them, calibrate the equipment to those factors (plus or minus 1 percent full scale). NOTE: Calibration standard correction factors - As a result of differences in notch response resulting from possible variations in the fabrication process, calibration standards may have amplitude correction factors (equivalent responses) applied to them. The Honeywell quality technology laboratory will establish these equivalent responses by comparing the responses from the Honeywell master standard to the response from the subordinate standard. In cases where an equivalent response is required, this equivalent response applies only to the calibration and does not alter the amplitudes specified for indication rejection or evaluation limits. 14 When these amplitudes have been achieved, translate the probe very slowly across the entire notch to assure that the calibration has been performed at the point of maximum response from the notch. If a greater amplitude is obtained on the strip chart Channel No. 1 (vertical), repeat paragraphs C.(1)(h) 13 and 14. If excessive noise is experienced on Channel No. 1 at the calibration settings, check for the following: a b c d e Teflon tape on probe face worn or damaged. Probe not aligned with calibration hole. Probe not wedged properly. Calibration hole dirty. Equipment malfunction (high gain).
13
15
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STANDARD PRACTICES MANUAL AS907-1-1A 16 (i) Record all calibration data onto the strip chart recording and onto an appropriate inspection data sheet. See Figure 13, Page 41.
Part Inspection 1 2 Assure the teflon tape is still covering the coil. Replace if it is worn or wrinkled, and recheck calibration. Examine the probe fit in several holes and make whatever adjustments are necessary to ensure a fit which is equivalent to that obtained for calibration. Holes may be over or undersize and it may be desirable to inspect all the holes of one size before changing the diameter of the probe if it is required. Scan all holes in the upward direction (translation) unless otherwise specified. NOTE: Check the teflon tape on the probe frequently and replace it if it becomes worn or wrinkled. 4 5 6 If any indications exceeding the requirements of paragraph C.(1)(k) of this document are found, mark the hole for evaluation. After all holes have been inspected, evaluate the indications from paragraph C.(1)(i) 4 per paragraph C.(1)(l) of this document. Complete the post-inspection check per paragraph C.(1)(j) of this document.
(j)
Post-inspection Calibration Check. 1 2 3 After completion of the part inspection, or after intervals not to exceed four hours, check the calibration on the calibration standard. If the calibration repeats within 5 percent of full scale at channel No. 1 of the strip chart recorder the test is acceptable. If the amplitude of the response on Channel No. 1 has decreased by 5 percent of full scale amplitude, repeat the calibration procedure and reinspect all parts inspected since the previous calibration. If the amplitude of the response on Channel No. 1 has increased by more than 5 percent, only parts previously found to be rejected to paragraph C.(1)(k) need to be reinspected, repeat the calibration procedure prior to additional inspection.
(k)
Inspection Requirements. 1 Any indication equal to or greater than the criteria specified in the service bulletin or applicable manual procedure for the part being inspected must be evaluated according to the requirements of paragraph C.(1)(l).
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STANDARD PRACTICES MANUAL AS907-1-1A 2 If, after completion of the evaluation procedure, the amplitude of any indication is still equal to or greater than the requirements of the service bulletin or manual procedure, the part must be considered unserviceable.
(l)
Indication Evaluation. NOTE: The optimum time to perform these evaluations is either at the time the indication is found, or immediately after the completion of the inspection of a specific area. 1 Examine the traces on Channel No. 1 of the strip chart for each hole. For each hole with an indication(s) meeting the requirements of paragraph C.(1)(k), reclean the hole with a cotton swab moistened with cleaning fluid, and reinspect the hole. If the indication remains, it is considered repeatable, and should be evaluated as stated below. If not, proceed to next indication. For all repeatable indications record the hole number, Channel No. 1 amplitude on the recorder and the location within the hole on the appropriate inspection data sheet. Carefully examine the area under evaluation with a bright white light, using a glass of 2 to 10 power. Note any unusual conditions, such as discoloration, scratches, score marks, sharp edges, uneven surfaces, etc. Record these conditions on the appropriate inspection data sheet. Carefully reclean the area containing the indication per paragraph C.(1)(e) of this document. Assure that no protruding material exists in the area. Check that the probe fits snugly in the hole, and that the hole has not become elliptical. Assure that the calibration amplitude is 40 percent full scale on Channel No. 1 and 35 percent full scale amplitude on Channel No. 2. Assure that the EDM notch is in the correct quadrant on the eddyscope. Repeat the inspection of the hole. If the indication amplitude has reduced, repeat the cleaning process as necessary until the indication is removed or the amplitude of the eddy current indication is reduced below the evaluation limit. If the indication cannot be reduced in amplitude to an acceptable level, or increases in amplitude, as a result of the cleaning, refer to paragraph C.(1)(k) and the appropriate service bulletin or applicable manual procedure for information regarding the disposition of the part.
5 6
(m)
Records 1 As a minimum, the following information must be permanently written on each strip chart recording and an appropriate inspection data sheet.
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1 Eddyscope:
2 Recorder:
3 Probe: 4 Indications: 5 Part:
Manufacturer Model No. Serial No. Gain level Frequency setting Rotation control setting Filter switch position Manufacturer Serial No. Horizontal channel coarse sensitivity Vertical channel coarse sensitivity Chart speed Model number, frequency designation, and serial number Evaluation of all reportable indications and results Part Name Part Number Part Serial Number Engine Serial Number Type of Inspection and area. Example: Inner Bolt Holes Cycles Since New/Time Since New (CSN/TSN) if available
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Alternate Strip Chart Recorder Settings Sheet 1 Figure 8 (Sheet 1 of 2)
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Alternate Strip Chart Recorder Settings Sheet 2 Figure 8 (Sheet 2)
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Application of Teflon Tape to Probe Figure 9
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Rubber Wedging for Sizing Figure 10
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Inconel Notch Response Figure 11
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Titanium Notch Response Figure 12
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Slow Speed Eddy Current Inspection Data Sheet Figure 13
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-07-250-013 D. High Speed Eddy Current Inspection Method with Electronic Data Acquisition and Storage (Method C). (1) Method C: High Speed Eddy Current Inspection with Electronic Data Acquisition and Storage. (a) Scope. 1 This document describes the equipment, technique, and procedure necessary to perform a 2 MHz high speed eddy current inspection with electronic data acquisition of circular holes in engine hardware. A Service Bulletin or applicable manual procedure shall provide the detailed information needed for inspection of specific parts. Perform the inspection of the hardware in accordance with Subtask 7032-07-250-011, High Speed Eddy Current Inspection (Method A), and the following parameters.
(b)
Applicable Documents. 1 All documents listed in paragraph B.(1)(b), Applicable Documents, are to be followed. Refer to , High Speed Eddy Current Inspection (Method A).
(c)
Personnel Requirements. 1 Personnel performing this inspection must be certified in accordance with one of the requirements listed in paragraph B.(1)(c), Personnel Requirements. Refer to Subtask 70-32-07-250-011, High Speed Eddy Current Inspection (Method A).
(d)
Pre-inspection Part Preparation. 1 Pre-inspection part preparation is to be performed in accordance with Subtask 70-32-07-250-011, High Speed Eddy Current Inspection (Method A).
(e)
Equipment Requirements. CAUTION: THE HOLESCAN SYSTEM IS A HIGH PERFORMANCE, PCBASED EDDY CURRENT ELECTRONIC DATA ACQUISITION SYSTEM. DO NOT INSTALL ANY OTHER SOFTWARE (GAMES, SCREEN SAVERS, ETC.) OR HARDWARE (NETWORK CARDS, GAME CARDS, ETC.) WITHOUT APPROVAL FROM THE SYSTEM MANUFACTURER. 1 HOLESCAN SYSTEM: ROHMANN GMBH SCANALYZER OR A Honeywell-APPROVED EQUIVALENT. THE HOLESCAN/SCANALYZER EDDY CURRENT INSPECTION SYSTEM IS A UNIVERSAL SOFTWARE PROGRAM TO ANALYZE, RECORD AND FILE DATA OF IMAGE GENERATING EDDY CURRENT INSPECTIONS. THE SCANALYZER SYSTEM INCLUDES THE FOLLOWING RECOMMENDED COMPONENTS:
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STANDARD PRACTICES MANUAL AS907-1-1A a Computer - IBM-compatible PC, with Pentium processor > 200 MHz, main memory > 32 MB, monitor - SVGQ graphic card (256 colors > 800 x 600 pixel) 1024 x 786 recommended, operating system - Windows NT operating system with Service Pack 3 or higher, Elotest PC4 digitizing PC-card (type PC4/0, PC4/1, or PC4/ 2) and all associated software, or an approved equivalent. Eddy current instrument - Rohmann Elotest B1/V4 or latest version with model B1-RS probe adapter. Guide fixture - A Honeywell-approved guide fixture, P/N SO16602, to provide mechanical control of the probe angle. Probe rotor - SR1-HF Rohmann ScanAlyzer rotation scanner with analog or digital position identification, or an approved equivalent. Cable - Rohmann GmbH model RK-2N cable, or an approved equivalent. Probe Adapter - ARM1 for Rohmann rotor, or an approved equivalent.
b c d
e f 2
Probe: The correct probe size will be specified in the Service Bulletin or applicable manual procedure for the part to be inspected. Refer to Figure 4, Page 17. Calibration Standard: Calibration standards must be made of the same material as the part to be inspected. Specific details will be specified in the Service Bulletin or applicable manual procedure for the part to be inspected. Refer to Figure 2, Page 15. Mineral Oil: A small amount of mineral oil or other Honeywellapproved lubricant can help produce a smoother probe rotation, reduce probe wear, and reduce incorrect eddy current signals. It is important that the lubricant be a relatively inert material to avoid chemical reactions that may affect probe performance or reduce its useful life. The use of mineral oil or another lubricant is not necessary but can be used at the discretion of the inspector. Cleaning Materials: Use Honeywell approved cleaning materials and solvents to make sure the part is clean before inspection. Marking Materials: Action Marker P/N Q404, black, or a Honeywellapproved equivalent, to mark parts. Flex-Hones: Flex-Hones may be used when more aggressive cleaning is required and shall be specified in the appropriate Service Bulletin or applicable manual. Inspection Shoes: A dedicated inspection fixture (shoe) for each piece of hardware has been designed to help facilitate inspection of the bolt holes. It is recommended that inspection be performed using the
5 6 7
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STANDARD PRACTICES MANUAL AS907-1-1A inspection shoes. A list of approved inspection shoes can be obtained from Honeywell. (f) Initial Equipment Setup. 1 2 3 Make all necessary cable connections for system operation. Select the appropriate eddy current probe and calibration standard for inspection. Insert the probe into the calibration standard hole to check the fit. It is desirable to have the probe lightly touch the surface of the hole but there should be no interference or binding. The motor in the probe rotor is very low torque so any drag will slow or stop the rotor. a If the difference between the probe and hole diameter is too great, either too large or too small, it may be necessary to use a slightly larger or smaller probe.
4 5
Insert the probe into the probe rotor. Turn off the power to the Rohmann eddy current instrument when it is not in use. Damage to the cathode ray tube (CRT) may occur when it is not used for more than one hour. Adjust the Rohmann Elotest B1/V4 controls in accordance with the settings given in Table 5. Adjust the Holescan system controls: a Using the DEVICE SETUP menu in the APPLICATIONS MANAGER menu, adjust the ScanAlyzer controls in accordance with the settings given in Table 7, Page 45, Table 8, Page 45, and Table 9, Page 46.
6 7
Recommended filter settings for certain probe diameters are given in Table 10, Page 46. NOTE: Filter settings are based upon probe diameter. The settings may change over time because of probe wear. The table below is a reference to use as a starting point for filter settings. Because of probe manufacturer, conditions, and diameter, some adjustment to these settings may be necessary to achieve equal lengths of the eddy current signal legs. Table 6. Rohmann Eloted B4V4 Controls
Description Frequency BWL Gain
Initial Setting 2 MHz Off 60 dB
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Table 6. Rohmann Eloted B4V4 Controls (Cont) Initial Setting Increase until probe trouble/overload is detected by the instrument, and then reduce the pre-amp by one setting X Axis Gain 0 dB Y Axis Gain 0 dB Phase 186 Disp Y/X Highpass Filter See Filter Settings Table Lowpass Filter See Filter Settings Table Band Dyn (600-850 Hz band pass) Dot Position 0/0 Timebase SYNC - Auto Gate Optional Alarm Optional NOTE: The initial settings of the MAIN PARAMETERS dialog box in the INSTRUMENT menu can be downloaded to and/or from the Rohmann Elotest B1/V4 instrument. Description Pre-amp
Table 7. Holescam Instrument Settings Description DISPLAY Window: Threshold Type Threshold Level X-Axis (Cross/Box) Threshold Level Y-Axis (Cross/Box) Alarm Mode Timebase X-deflection Single Shot Time Roll Mode Time Setting Cross Threshold (Box) 250/250 100/100 Short (Visible) Auto 25ms/div 0.3 sec 8s
Table 8. Holescan System Controls-Scan Device Menu PC4 SCANNER PARAMETERS Window: X-Axis Y-Axis Meter Mode Rotor Double Meter Mode (rotor checked) Meter Unit Degrees Meter Unit Start Position 0 Start Position Info Data Source
Analog (fixed lines checked) (Inches) 0
Channel 1 (ext)
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Table 8. Holescan System Controls-Scan Device Menu (Cont) PC4 SCANNER PARAMETERS Window: X-Axis Y-Axis Info End Position 360 End Position 2.165354 Scan Resolution 0.5 Scan Resolution 0.015 Physical 0.5 Physical 0.000528651 Resolution Resolution Max Scan Speed 3600 NOTE: AXIS dialog box in the DISPLAY menu is not used for set up of ScanAlyzer.
Table 9. Holescan Systems Controls- Display Menu Standard DISPLAY Configuration Window: Adjust Default Volt/Div. C-Scan Unit 0.5 V/Div. Use Div.
Table 10. Recommended Filter Settings Probe Diameter (Inch) 0.192 0.239 0.244 0.247 0.281 0.294 0.299 0.308 0.314 0.318 0.328 0.334 0.395 0.408 0.435 0.514 Highpass Filter (Hz) 200 200 200 200 400 400 400 400 400 400 400 400 500 500 500 500 Lowpass Filter (Hz) 800 800 800 800 1000 1000 1000 1000 1000 1250 1250 1250 1250 1250 1250 1250
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STANDARD PRACTICES MANUAL AS907-1-1A (g) Equipment Calibration. NOTE: The eddy current instrument displays the peak-to-peak eddy current signal. The ScanAlyzer system captures the peak response of the longest leg of the eddy current signal, not the peak-to-peak value. Any calibration response from the ScanAlyzer system must be doubled for the correct calibration amplitude. 1 (h) Equipment calibration is to be performed in accordance with Subtask 70-32-07-250-011, High Speed Eddy Current Inspection (Method A).
Hardware Inspection. 1 2 Attach the appropriate inspection shoe to the guide fixture for inspection of bolt holes. Hardware inspection is to be performed in accordance with Subtask 70-32-07-250-011, High Speed Eddy Current Inspection (Method A).
(i)
Post-inspection Calibration Check. 1 2 Remove the inspection shoe from the guide fixture before postinspection calibration check. Post-inspection calibration is to be performed in accordance with Subtask 70-32-07-250-011, High Speed Eddy Current Inspection (Method A).
(j)
Indication Evaluation/Rejection Criteria. NOTE: The eddy current instrument displays the peak-to-peak eddy current signal. The ScanAlyzer system captures the peak response of the longest leg of the eddy current signal, not the peak-to-peak value. Any evaluation performed of an eddy current response from the ScanAlyzer system must be doubled for the correct amplitude. 1 Evaluation and rejection of hardware is to be performed in accordance with Subtask 70-32-07-250-011, High Speed Eddy Current Inspection (Method A).
(k)
Cleaning Procedure. 1 Refer to TASK 70-22-06-110-043, Special Cleaning Procedure No. 6, Bolthole Cleaning for Eddy Current Inspection.
(l)
Disposition, Documentation, and Records.
Disposition, documentation, and record keeping are to be performed in accordance with Subtask 70-32-07-250-011, High Speed Eddy Current Inspection (Method A).
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EDDY CURRENT INSPECTION - 2 MHZ MANUAL EDDY CURRENT INSPECTION OF BORES IN TITANIUM ALLOY ROTATING ENGINE HARDWARE TASK 70-32-08-250-002 1. 2 MHz Manual Eddy Current Inspection of Bores in Titanium Alloy Rotating Engine Hardware SUBTASK 70-32-08-99G-002 A. General. (1) This document describes the general equipment, techniques, and procedures required to conduct 2 MHz manual (hand-held) eddy current inspections of bores in rotating engine hardware manufactured from Titanium alloys. A Service Bulletin or applicable manual will be required for specific applications to provide the information necessary to conduct that specific test. This document describes how to accomplish inspections using 2 MHz absolute probes, specific eddy current instruments, hand held fixtures, and Gould strip chart recorders. This document describes the general procedure and equipment approved to accomplish the required inspections. For specific cases where the procedure or equipment described herein cannot be applied as written, approval for specific exceptions should be obtained in writing from the appropriate technical group to cover the deviating items. Personnel Requirements. (a) Personnel performing this inspection must be certified in accordance with National Aerospace Standard (NAS-410), American Society of Non Destructive Testing (ASNT-TC-1A), Air Transport Association Specification No. 105 (ATA 105), or locally approved certification program. Personnel performing this inspection should receive practical training in the use of this procedure and must demonstrate proficiency in calibration of the inspection equipment, inspection of hardware, and evaluation of indications before the authority to accept and reject hardware is delegated. Any training which may be provided by Honeywell for a technique requiring the performance of this inspection method does not imply that the personnel who receive that training have met the requirements for inspector certification in accordance with NAS-410, ASNT-TC-1A, or ATA 105.
(2)
(3)
(4)
(b)
(c)
(5)
The following documents shall form a part of this procedure to the extent specified herein. Unless a specific issue is specified, the latest revision shall apply. (a) (b) Appropriate equipment instruction manuals. National Aerospace Standard (NAS-410), American Society of Non Destructive Testing (ASNT-TC-1A), or ATA 105.
2 MHz MANUAL EDDY CURRENT INSPECTION OF BORES IN TITANIUM ALLOY ROTATING ENGINE HARDWARE Page 1 Dec 01/03
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STANDARD PRACTICES MANUAL AS907-1-1A (c) Appropriate Service Bulletin or applicable manual procedure.
SUBTASK 70-32-08-250-021 B. Equipment. (1) The instrumentation/tooling listed in this section does not include all of the equipment necessary to perform this inspection, but does include all items for which substitution cannot be made without written approval from Honeywell. (a) Instruments. 1 Eddy Current Instruments. a b c 2 Nortec Model NDT-16 Eddyscope. Nortec NDT-19 Eddyscope. Rohmann Elotest B1 SDM Eddy Current Instrument.
Strip Chart Recorder a Gould Brush 2 Channel Model 220
3 (b)
Connecting Cables from eddy current instrument to chart recorder
Tooling. 1 2 Probes and Fixtures: Reference applicable Service Bulletin or applicable manual. See Figure 1, Page 3. Calibration Standard: Eddy current calibration standard shall be manufactured from the same materials as the part to be inspected. Obtain this standard from Honeywell or use an approved equivalent. See Figure 2, Page 4. Applicable Service Bulletin or applicable manual shall define the standard for each application. NOTE: This tooling will be contained in a Honeywell inspection kit. The inspection kit number shall be identified in the applicable Service Bulletin or applicable manual procedure. A complete inspection kit containing all required tooling can be obtained from Honeywell by contacting the following: NOTE: Honeywell. Refer to the List of Suppliers in Step D of Subtask 70-80-00-800-003.
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Typical Inspection Fixture Figure 1
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Typical Calibration Standard Figure 2
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-08-250-022 C. Material. Reference No. C10-040 C10-010
Consumable Teflon tapemaximum thickness 0.0035 inch (0.089 mm) Scotch Brite pads SUBTASK 70-32-08-250-023 D. Equipment Setup. (1)
Connect the selected equipment and allow it to warm up for 15 minutes or as specified by the manufacturer. NOTE: It is important that the cables from the eddy current instrument to the chart recorder be connected correctly. Ensure that the vertical analog output channel from the eddy current instrument is connected to Channel 1 (the left channel) on the chart recorder. The horizontal channel should then be connected to Channel 2 (the right channel) of the chart recorder.
(2)
Set the instrument controls as follows: Table 1. Initial Instrument Control Settings
Parameter Nortec NDT-16 Eddyscope: Frequency Gain Vertical Display Sensitivity Horizontal Display Sensitivity Rotation Filter Nortec NDT-19 Eddyscope: Frequency Vertical Gain Horizontal Gain Phase Vertical Position Horizontal Position Low Pass Filter High Pass Filter Special Function 2 - Probe Drive
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Setting 2 MHz 2.00 1 volt / division 1 volt / division 0.00 "Filter Out" switch depressed 2000 KHz (2 MHz) 60.0 dB 60.0 dB 0 128 128 100 Hz 0 Hz 1.0 (or Medium)
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Table 1. Initial Instrument Control Settings (Cont) Parameter Rohmann Elotest B1 Eddy Current Instrument: Frequency Y Axis Gain X Axis Gain Preamplifier Gain Bandwidth Gain Phase Filter Gould 220 Chart Recorder: Vertical Fine Sensitivity Horizontal Fine Sensitivity Vertical Coarse Sensitivity Horizontal Coarse Sensitivity MM/SEC Switch SUBTASK 70-32-08-250-024 E. Probe Preparation. (1) (2) Select the appropriate probe and fixture for the bore to be inspected (reference applicable Service Bulletin or applicable shope manual). Prepare teflon tape for probe wear face as follows: (a) Lay a strip of tape approximately 1.0 inch (2.54 cm) long on a firm, smooth, clean surface. With a razor blade cut the tape to a square of approximately 0.250 inch (6.35 mm). NOTE: That size of tape should be sufficient to completely cover coil face, plus additional width so that tape edges are slightly off the probe tip. (b) Apply the tape tightly across the coil face and around each side, Refer to Figure 3, Page 8. Smooth all edges back from the coil. NOTE: There must be no wrinkles on the tape face or they will snag on entering the bore. If the tape is wrinkled, it is too large. Remove it, cut a new smaller piece, and apply the new piece. (c) Draw the probe back and forth across some fabric with the coil face in contact with the fabric. Heat from the resulting friction will soften the tape adhesive to provide a tight fit. Ensure unwrinkled edges adhere to the probe tip.
Setting 2.0 MHz 0 dB 0 dB 12 dB High Frequency (HF) 50 dB 0 100 Hz lowpass Full clockwise Full clockwise 20 millivolts / division 50 millivolts / division Depressed
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STANDARD PRACTICES MANUAL AS907-1-1A (3) (4) Assemble the taped probe onto the inspection fixture using the indexing screw. Ensure that the probe cable exits straight out the back of the fixture. Connect the probe to the eddy current instrument front panel receptacle. NOTE: Connect the eddy current probe to the front panel receptacle of the NDT-19 utilizing an 8-pin Burndy to 3-pin Cannon adapter (Nortec P/N PA-8BC). Use adapter B1-N0B3H with the Elotest B1.
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Application of Teflon Tape to Probe Tip Figure 3
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-08-250-025 F. Pre-inspection Part Preparation. (1) (2) Visually inspect the bore under white light for evidence of adhering dirt, cracks, rubbing, fretting, etc. Clean the bore(s) by using the materials listed in Subtask 70-32-08-250-022, Material. Then clean the bore(s) with a cloth moistened with an approved cleaning fluid. Prior to inspection, locate the serial number on the part and mark this location on the forward side of the part. This will be the 12 oclock (start/ref) position.
(3)
SUBTASK 70-32-08-250-026 G. Equipment Calibration. NOTE: As a result of differences in notch response resulting from possible variations in the fabrication process, calibration standards may have amplitude correction factors (equivalent responses) applied to them. The Honeywell laboratory will establish these equivalent responses by comparing the responses from Honeywell master standard to the response from the subordinate standard. In cases where an equivalent response is required, this equivalent response applies to the calibration only and does not alter the amplitudes specified for indication rejection limits. (1) (2) (3) (4) Connect equipment and set initial controls per Subtask 70-32-08-250-023, Equipment Setup. Place the probe and fixture onto the calibration standard. Null the instrument. Slowly lift the fixture and probe off the standard. The spot on the CRT will move off the screen. Adjust the rotation control until the spot moves from center horizontally to the left. See Figure 4, Page 11. Adjust the filter to 5 Hz high pass. Turn on the strip chart recorder to 1 mm per second. Scan the probe across the calibration standard while indexing the fixture until the EDM notch is detected. The probe should be scanned at a speed equivalent to that used for the inspection. Both should achieve a probe speed of 1 to 1.5 inch (25 to 38 mm) per second. Translate the probe back and forth across the entire EDM notch a few thousandths of an inch (hundredths of a millimeter) at a time to determine where the maximum amplitudes are achieved on both Channel 1 and 2. Examine the recorder tracings on Channels 1 and 2. Alternately adjust the rotation and gain controls to achieve calibration amplitudes of 80 percent (800 mV) full
(5) (6) (7)
(8)
(9)
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STANDARD PRACTICES MANUAL AS907-1-1A scale in Channel 1 and 70 percent (1750 mV) full scale amplitude in Channel 2 (plus or minus 5 percent full scale). Re-null after any gain or rotation adjustment. NOTE: The NDT-19 has separate vertical and horizontal gain controls. Both gain controls must be set to the same sensitivity for a correct calibration. NOTE: For re-nulling, the coil must be well off the EDM notch and away from any edge of the standard. NOTE: For calibration standards with correction factors applied to them, calibrate the equipment to those factors, plus or minus 5 percent full scale. (10) When these amplitudes have been adjusted, translate/index the probe very slowly across the entire notch length to assure the calibration has been performed at the point of maximum response from the notch. If a greater amplitude is obtained on the strip chart Channel 1 (vertical), repeat paragraphs H. and I. (11) At the calibration position and gain, run the strip chart recorder at 5mm/sec until approximately ten indications from the notch have been obtained. (12) Record all calibration data onto the strip chart recording and onto an inspection data sheet. See Figure 5, Page 12.
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CRT Display for Initial Rotation Adjustment Figure 4
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Eddy Current Inspection Data Sheet Figure 5
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-08-250-027 H. Part Inspection. (1) (2) (3) (4) (5) (6) (7) (8) Complete pre-inspection part preparation in accordance with Subtask 70-32-08250-025, Pre-inspection Part Preparation. Calibrate all equipment in accordance with Subtask 70-32-08-250-026 Equipment Calibration. Inspect all areas per the appropriate scan plans as identified by specific Service Bulletin and Engine/Shop Manual procedures. Assure the teflon tape is still covering the coil on the end of the probe. Replace if it is worn or wrinkled and recheck calibration. Reassemble and/or adjust the probe and fixture to the configuration required to inspect the bore(s). Place the probe completely within the bore so the coil is away from any edges and re-null instrument. Turn the recorder on to the 5 mm/sec chart speed. Start scanning the bore without translation and observe the noise on Channel 1 of the recorder. If this noise exceeds 50 percent of the rejection amplitude, adjust the rotation control to minimize the noise on Channel 1. Refer to Subtask 70-32-08-250029, Inspection Requirements. NOTE: Ensure the probe/coil is traveling at a speed equivalent to the calibration speed. (a) If the rotation control is adjusted, return to the Calibration standard and repeat paragraph 7.H. of Subtask 70-32-08-250-026, Equipment Calibration. Adjust the gain only to achieve 80 percent (800 mV) on Channel 1. If the noise observed is below 50 percent of the rejection amplitude, do not adjust the rotation control.
(b) (9)
Scan the entire bore (edge-to-edge) with Channel 1 (vertical) at 20 mv/div, Channel 2 (horizontal) at 50 mv/div, and the recorder chart speed at 5 mm/sec. NOTE: Ensure adequate coverage of all inspection areas is achieved. This is accomplished by starting and stopping with at least 50 percent of the probe exposed to air.
(10) Mark the bore for evaluation and continue the inspection if you find any indications exceeding the requirements of Subtask 70-32-08-250-029, Inspection Requirements. NOTE: Check the teflon tape if a sudden noise increase is noted on the strip chart record. Replace it if worn or wrinkled and recheck calibration. (11) After all bore areas have been inspected, evaluate the indications from paragraph 8.J. per Subtask 70-32-08-250-030, Indication Evaluation.
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-08-250-028 I. Post-Inspection Check. (1) After completion of the part inspection, or after intervals not to exceed four hours, check the calibration of the system. (a) (b) If the calibration repeats within 5 percent of full scale in the vertical channel, the test was acceptable. If the amplitude of the response in the vertical channel has decreased by more than 5 percent of full scale amplitude, repeat the calibration procedure and reinspect all parts inspected since previous calibration. If the amplitude of the response in the vertical channel has increased by more than 5 percent of full scale amplitude, reinspect any parts which were previously found to be rejected per Subtask 70-32-08-250-030, Indication Evaluation.
(c)
SUBTASK 70-32-08-250-029 J. Inspection Requirements. (1) Reference the applicable Service Bulletin or applicable shop manual as specified for the inspection being performed. The inspection requirements shall be as specified in that document.
SUBTASK 70-32-08-250-030 K. Indication Evaluation. NOTE: The optimum time to perform these evaluations is either at the time the indication is found or immediately after the completion of the inspection of a specific area. (1) Examine the traces in the Channel 1 (vertical) of the strip chart for the bore. For a bore with an indication(s) meeting the requirements of paragraph 10, reclean the bore with Scotch Brite pad C10-010 and a cloth moistened with cleaning fluid and reinspect the bore. Refer to Subtask 70-32-08-250-029, Inspection Requirements. If the indication remains, it is considered repeatable and should be evaluated as stated below. If not, proceed to the next indication. For all repeatable indications, record the bore identification, amplitude of the Channel 1 (vertical) on the recorder, and the location within the bore on the appropriate inspection data sheet. See Figure 5, Page 12. Carefully examine the area under evaluation in bright white light using a glass of 5 to 10 power. Note any unusual conditions such as discoloration, scratches, score marks, sharp edges, uneven surfaces, etc. Record these conditions on the inspection summary sheet. See Figure 5, Page 12. Carefully reclean the area of the indication per Subtask 70-32-08-250-025, Preinspection Part Preparation. Ensure no protruding material exists in the area.
(2)
(3)
(4)
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STANDARD PRACTICES MANUAL AS907-1-1A (5) Reinspect the area. If the indication response amplitude remains the same after cleaning, repeat paragraph 11.D. one time. If it still has not reduced in amplitude, proceed to paragraph 11.F. If the response amplitude is reduced but still meets the requirements in paragraph 10, the bore may be recleaned and re-evaluated since the response is most likely due to surface contamination. If the indication is no longer there, if its amplitude is below the limits in paragraph 10, note that fact on the data sheet and proceed with the evaluation of the next indication. If the indication(s) remains but is part of a general background noise, note that fact in the "Comments" section of the Data Sheet. See Figure 5, Page 12 and Subtask 70-3208-250-029, Inspection Requirements. If the indication response amplitude has not reduced or will not reduce to below the limits in paragraph 10, the part shall be rejected for engineering evaluation and disposition. Refer to Subtask 70-32-08-250-029, Inspection Requirements.
(6)
SUBTASK 70-32-08-250-031 L. Records. (1) As a minimum, the following information shall be permanently written on each strip chart recording and an inspection summary sheet. Figure 5 shows a basic and recommended type of inspection summary sheet. DATA Type/Model Number Serial Number Gain level Rotation control setting Filter setting Type/Model Number Horizontal channel coarse sensitivity Vertical channel coarse sensitivity Chart speed Model number Serial number Type Part number Serial Number All evaluated indications and results Part number Part serial number Inspection area TSN - time since new CSN - cycles since new Name (2) All inspection records should be maintained with permanent records of the part.
ITEM Eddy Current Instrument
Recorder
Probe Fixture
Indications Part
Inspector
EFFECTIVITY: ALL
70-32-08
STANDARD PRACTICES MANUAL AS907-1-1A (3) Copies of strip chart recordings or rescans shall be kept with the suspect hardware if the indications exceed the criteria of Subtask 70-32-08-250-030, Indication Evaluation.
EFFECTIVITY: ALL
70-32-08
IMMERSION ULTRASONIC INSPECTION - IMMERSION ULTRASONIC INSPECTION OF ENGINE RUN HARDWARE TASK 70-32-09-270-002 1. Immersion Ultrasonic Inspection of Engine-Run Hardware SUBTASK 70-32-09-99G-002 A. General. (1) This document describes the equipment, technique, and procedure for conducting component level immersion ultrasonic inspections of engine-run titanium and nickel alloy hardware. The inspection areas and specific requirements are detailed in the appropriate scan plans, inspection plans, and scanning logs included in this document. The rejection criteria is also included. (a) Procedure A Procedure A is a complete inspection of the appropriate hardware. It is intended to be a one time inspection. (b) Procedure B Procedure B is a partial inspection of the appropriate hardware. It is intended to be performed on a repetitive basis as defined by the appropriate applicable shop manual. (2) (3) The inspection procedure utilizes 08 longitudinal sound waves, 458 and 608 circumferential shear waves, and 458 radial/axial shear waves. For specific cases where the procedure or equipment described in this document cannot be applied in their total content, specific exceptions shall be obtained in writing from Honeywell to document the deviation. The following documents shall form a part of this procedure to the extent specified herein. Unless a specific issue is specified, the latest revision shall apply. (a) (b) (c) (5) Appropriate equipment instruction manuals. National Aerospace Standard (NAS-410) (latest revision). Appropriate Service Bulletin or applicable manual procedure.
(4)
Personnel requirements (a) Personnel performing this inspection must be certified in accordance with National Aerospace Standard (NAS-410), American Society of Nondestructive Testing (ASNT-TC-1A), Air Transport Association Specification No. 105 (ATA 105), COSAC, or any equivalent certification document acknowledged by the local regulatory agencies.
EFFECTIVITY: ALL
70-32-09
IMMERSION ULTRASONIC INSPECTION OF ENGINE RUN HARDWARE Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (b) It is strongly recommended that personnel performing this inspection receive practical training in the use of this procedure and must demonstrate proficiency in the calibration and evaluation routines before accept/reject authority is delegated. Any training which may be provided by Honeywell for a technique requiring the performance of this inspection method does not imply that the personnel who receive that training have met the requirements for inspector certification in accordance with NAS-410, ASNT-TC-1A, or ATA 105.
(c)
SUBTASK 70-32-09-270-051 B. Equipment. (1) The following list does not include all of the equipment necessary to do this inspection, but does include all items for which substitution cannot be made without written approval from Honeywell. (a) Immersion inspection system 1 The immersion inspection system used shall be comprised of an immersion tank, a motor-driven rotary table, a bridge providing X and Y axis motion and a Z axis search tube providing A and B axis motion. The system shall be under computer or numeric control. Inspection systems capable of semi-automatic operation may be used for the inspection of stage 3-9 spool bores with prior agreement from Honeywell. The system shall be capable of following the contours of the part being inspected in all inspection modes. The capability of the system to follow the contour of the part shall be demonstrated to Honeywell before approval to use this procedure is given. The system shall be checked annually to determine that the accuracies described in table 1, Page 2 are being maintained. Inspection facilities should generate a quality plan which describes this process. Table 1. Inspection System Accuracies X Axis Straightness/Parallelism to turntable Straightness perpendicular to turntable Positioning accuracy Positioning backlash Y Axis Straightness/Parallelism to turntable Straightness perpendicular to turntable Positioning accuracy Within 0.006 inches per foot (0.50 mm/m) Within 0.006 inches per foot (0.50 mm/m) Within 0.009 inches per foot (0.75 mm/m)
2 3
Within 0.006 inches per foot (0.50 mm/m) Within 0.006 inches per foot (0.50 mm/m) Within 0.009 inches per foot (0.75 mm/m) Within 0.010 inches (0.25 mm)
EFFECTIVITY: ALL
70-32-09
Table 1. Inspection System Accuracies (Cont) X Axis Positioning backlash Z Axis Straightness/Perpendicularity to turntable in both X and Y planes Positioning accuracy Positioning backlash Manipulator A Axis positioning accuracy A Axis positioning backlash A Axis parallelism to Y Axis B Axis positioning accuracy B Axis positioning backlash B Axis parallelism to Y Axis Turntable Surface runout Runout part centering Speed accuracy (b) Ultrasonic instrument 1 Krautkramer Branson USIP20 ultrasonic instrument with DAC, Krautkramer Branson KB6000 with microdac, or similar instrument approved by Honeywell for this inspection. The instrument shall be checked on an annual basis using ASTM E127 area amplitude blocks to prove that the instrument can maintain linearity as described in table 2. Within 0.015 inches (0.38 mm) total indicator runout at 45 inches (1143 mm) diameter Within 0.010 inches (0.25 mm) Within 3 percent of indicated speed Within 0.5 degrees Within 0.2 degrees Within 0.010 inches (0.25 mm) Within 0.5 degrees Within 0.2 degrees Within 0.010 inches (0.25 mm) Within 0.020 inches per foot (1.67 mm/m) Within 0.010 inches per foot (0.83 mm/m) Within 0.010 inches (0.25 mm) Within 0.010 inches (0.25 mm)
Table 2. Ultrasonic Instrument Linearity Parameters Area Amplitude Checks FBH # 5 4 3 2 1 Expected amplitude percent Full Screen Height (FSH) 95 61 2 34 2 15 2 42
EFFECTIVITY: ALL
70-32-09
Table 2. Ultrasonic Instrument Linearity Parameters (Cont) Area Amplitude Checks FBH # Expected amplitude percent Full Screen Height (FSH)
NOTE: The area amplitude blocks may have correction factors. The amplitude of each response should be corrected accordingly. Attenuator Tracking dB Change 0 -2 -4 -6 -8 -10 -12 -14 -16 -18 -20 -22 -24 (c) Ultrasonic transducers 1 2 3 A Harisonic I70512T transducer or equivalent transducer approved by Honeywell shall be used for this inspection. A Harisonic I2G0512T transducer with a 1.25 inch (31.8 mm) water path may be used if part geometry prohibits the use of an I7 transducer. The transducer(s) shall be checked on an annual basis using a block containing a #2 flat bottomed hole (FBH) 0.125 inch (3.18 mm) deep and a ball bearing 0.125 inch (3.18 mm) diameter to prove that the transducer can maintain the requirements as described in table 3. Expected amplitude percent Full Screen Height (FSH) 95 75 2 60 2 48 2 38 2 30 2 24 2 19 2 15 2 12 2 92 82 62
(d)
Calibration block 1 SGP044 calibration block or equivalent calibration block approved by Honeywell shall be used for this inspection.
EFFECTIVITY: ALL
70-32-09
Table 3. Transducer Parameters I70512T 6 dB beam Dia at Nominal wp. Resolution Signal-to-Noise ratio 0.100 0.010 in. (2.54 0.25 mm) IG20512T 0.060 0.010 in. (1.52 0.25 mm)
Full base line recovery when signal from #2 flat-bottomed hole (FBH) 0.125 in. (3.18 mm) deep is 80 percent FSH. Noise at 0.125 to 0.200 in. (3.18 to 5.08 mm) deep no greater than 13 percent at gain level used to set #2 FBH 0.125 in. (3.18 mm) deep to 80 percent FSH. Data recording instruments/systems 1 2 An electronic data recording system or equivalent approved by Honeywell shall be used for this inspection. The ability of the recorder to record a response from a 0.125 inch (3.18 mm) deep #2 flat-bottomed hole at the designated inspection speeds shall be demonstrated to Honeywell. The response shall be set to 30 percent FSH when peaked statically in the longitudinal mode and shall not be recorded at less than 25 percent FSH. The ability of the recorder to record a response at the designated inspection speeds shall be checked on an annual basis.
(e)
3 (2)
A complete ultrasonic inspection tooling kit can be obtained by contacting the following: Honeywell. Refer to the List of Suppliers in Step D of Subtask 70-80-00-800-003.
SUBTASK 70-32-09-270-052 C. Procedure. (1) Set up and calibrate as follows: (a) The initial instrument settings are shown in table 4, Page 5 (for USIP 20) and table 5, Page 6 (for KB6000): Table 4. Initial Instruments Settings for USIP 20 ASCAN1 Delay Display Start RECEIVER 5.898 Video Init Pulse Range Gate Trace Dac Dis 2.500 Step Single Off
EFFECTIVITY: ALL
70-32-09
Table 4. Initial Instruments Settings for USIP 20 (Cont) ASCAN1 Freq Rectifier DAC Aux Gain PULSER Voltage HI Damping Energy Probe VELOCITY Delay Coupling Wave IF GATE Delay IF Thresh DAC DAC Function MAC Vel Offset Off Off 0.24000 0.0 dB 5.838 T50 Width Sync Input 2.000 Int Echo VID 5.898 Imm Long Range Vel Dvel 2.500 0.24000 0.05850 500 Ohms Hi Single 0.5 - 25 MHz Pos Off Off Filter Gain Off 67.0
Table 5. Initial Instruments Settings for KB6000 Control Frequency Vid Proc Reject Filters Delay/Delay Mod. TCG Delay TWS Coarse Delay Fine Delay Setting BB HWN OFF OFF INT OFF 60 LO 9.50 Control Range TWS Coarse Range Fine Range Range Switch Receiver Delay BE ATT Rep Rate Coarse Fine 5 Full CCW Setting 25 LO 1.80 Long 5801 OFF
EFFECTIVITY: ALL
70-32-09
STANDARD PRACTICES MANUAL AS907-1-1A (b) (c) Record the transducer and calibration block serial numbers. Align the calibration block parallel to either the X or Y axis. Level the calibration block at a sufficient depth to ensure a 6.0 inch (152 mm) water path can be obtained. The block should be shimmed as required so the change in water path during calibration does not exceed 0.010 inch (0.25 mm) total runout. Normalize the beam to the calibration block in the A and B axes. Calibrate the longitudinal mode as follows: 1 2 3 4 Adjust the instrument per paragraph C.(1)(a). With the beam normal to the calibration block, set the water path to 6.0 inches (152 mm). Set the peak of the front surface response to the first major division (1.0) on the CRT baseline. Position the transducer over the 2.0 inch (51 mm) deep side-drilled hole (SDH) and maximize the response using linear axes only, without changing the water path. Using the range control and delay control calibrate the sweep range to 0.250 inch (6.35 mm) per major division on the CRT baseline such that the peak of the front surface response is at the first major division on the CRT and the peak of the response from the 2.0 inch (51 mm) deep SDH is at the ninth major division on the CRT. Record all instrument settings. For the KB6000 instrument, set the fine gain to full clockwise. The instrument gain shall be calibrated for the 0.250 inch (6.35 mm) SDH through the 2.0 inch (51 mm) deep SDH. Maximize the response from each hole using linear translation without changing the water path and adjust the gain to set the amplitude of the response from each hole to a minimum of 80 percent of FSH. Record the gain and amplitude for each hole. NOTE: The amplitude of the response should be set as close as possible to 80 percent but shall not exceed 90 percent. 10 Adjust the gain recorded for the 0.250 inch (6.35 mm) deep SDH by the appropriate correction factor table 6. Record the final gain and amplitude. Adjust the gain recorded for the 2.0 inch (51 mm) deep SDH by the appropriate correction factor and record the final gain and amplitude. These gains recorded shall be the calibration gains used to set the inspection levels.
(d) (e)
6 7 8 9
EFFECTIVITY: ALL
70-32-09
Table 6. Correction Factors for Calibration Block Titanium 6-4 0.250 IN. (6.35 MM) LONGITUDINAL 458 SHEAR 608 SHEAR -4 DB -2 DB -7 DB 11 2.000 IN. (50.80 MM) -4 DB +1 DB NA Inconel 718 0.250 IN. (6.35 MM) -2 DB 0 DB -6 DB 2.000 IN. (50.80 MM) -2 DB +6 DB NA
Plot the final gain for the two holes on a chart of gain versus depth. Join the two points with a straight line. For evaluation purposes, the gain required to evaluate an indication at a particular depth shall be taken from this chart. Calibrate the DAC of the instrument for longitudinal mode from 0.250 inch (6.35 mm) through 2.0 inch (51 mm).
12 (f)
Calibrate in the 45 degree Shear Mode as follows: 1 2 Adjust rectification to Full Wave. Adjust interface synchronization to Artificial. Angle the transducer to create a 45 degree refracted shear wave such that the sound is being directed from the shallow hole to the deep hole. Set the water path to 6.0 inches (152 mm). Set the peak of the front surface response to the first major division (1.0) on the CRT baseline. NOTE: If a sufficient front surface response cannot be obtained, the edge of the block may be used. 4 Position the transducer over the 2.000 inch (50.80 mm) deep SDH and maximize the response using linear axes only, without changing the water path. Using the range control and the delay control, calibrate the sweep range to 0.250 inch (6.35 mm) per major division on the CRT baseline such that the peak of the front surface response is at the first major division on the CRT and the peak of the response from the 2.000 inch (50.80 mm) deep SDH is at the ninth major division on the CRT. Record all instrument settings. For the KB6000 instrument, set the fine gain to full clockwise. The instrument gain shall be calibrated for the 0.250 inch (6.35 mm) SDH and the 2.000 inch (50.80 mm) deep SDH.
6 7 8
EFFECTIVITY: ALL
70-32-09
STANDARD PRACTICES MANUAL AS907-1-1A 9 Maximize the response from each hole using linear translation without changing the water path and adjust the gain to set the amplitude of the response from each hole to a minimum of 80 percent of FSH. Record the gain and amplitude for each hole. NOTE: The amplitude of the response should be set as close as possible to 80 percent but shall not exceed 90 percent. 10 Adjust the gain recorded for the 0.250 inch (6.35 mm) deep SDH by the appropriate correction factor for the specific material to be inspected ( Table 6, Page 8) and record the final gain and amplitude. Adjust the gain recorded for the 2.000 inch (50.80 mm) deep SDH by the appropriate correction factor and record the final gain and amplitude. These gains recorded shall be the calibration gain used to set the inspection levels. Plot the final gain for the two holes on a chart of gain versus depth. Join the two points with a straight line. For evaluation purposes, the gain required to evaluate an indication at a particular depth shall be taken from this chart. Calibrate the DAC of the instrument for 45 degree shear mode from 0.250 inch (6.35 mm) through 2.000 inches (50.80 mm).
11
12 (g)
Calibrate in the 60 degree Shear Mode as follows: 1 2 Adjust rectification to Full Wave. Adjust interface synchronization to Artificial. Angle the transducer to create a 60 degree refracted shear wave such that the sound is being directed from the shallow hole to the deep hole. Set the water path to 6.0 inches (152 mm). Set the peak of the front surface response to the first major division (1.0) on the CRT baseline. NOTE: If a sufficient front surface response cannot be obtained, the edge of the block may be used. 4 Position the transducer over the 0.250 inch (6.35 mm) SDH hole and maximize the response using linear axes only, without changing the water path. Using the fine range control and the fine delay control, calibrate the sweep range to 0.050 inch (1.27 mm) per major division on the CRT baseline such that the peak of the front surface response is at the first major division on the CRT and the peak of the response from the 0.250 inch (6.35 mm) deep SDH is at the sixth major division on the CRT. Record all instrument settings. For the KB6000 instrument, set the fine gain to full clockwise.
6 7
EFFECTIVITY: ALL
70-32-09
STANDARD PRACTICES MANUAL AS907-1-1A 8 9 The instrument gain shall be calibrated for the 0.250 inch (6.35 mm) deep SDH. Maximize the response from the 0.250 inch (6.35 mm) deep hole using linear translation without changing the water path and adjust the gain to set the amplitude of the response from the hole to a minimum of 80 percent of FSH. Record the gain and amplitude of the response. NOTE: The amplitude of the response should be set as close as possible to 80 percent but shall not exceed 90 percent. 10 Adjust the gain recorded for the 0.250 inch (6.35 mm) deep SDH by the appropriate correction factor for the specific material to be inspected ( Table 4, Page 5) and record the final gain and amplitude. This gain recorded shall be the calibration gain used to set the inspection levels.
(h)
Calibrate the electronic data acquisition as follows: 1 2 The acquisition system shall be calibrated at least once per month. Calibrate the system in 10 percent steps beginning with an 80 percent FSH signal on the CRT. Calibrate by scanning over the calibration block using a 0.010 inch (0.25 mm) index rate. The final step shall be a minimum of 20 percent FSH signal. The recorded amplitude shall be within 2 percent of the amplitude on the CRT. A hard copy of the system response for the 80 percent signal and the 20 percent FSH signal shall be saved for reference and retained with the system certification records.
(i)
If a strip chart recorder is used, calibrate as follows: 1 2 The strip chart recorder shall be calibrated at least once per part. Calibrate the recorder in 10 percent steps beginning at 80 percent of FSH on the CRT. The final step shall be a minimum of 20 percent. The recorder amplitude shall be within 2 percent of the amplitude on the CRT. A copy of the recorder response shall be saved for reference and at the completion of the inspection, attached to the inspection records.
3 (j)
Check the instrument linearity as follows: 1 2 3 Calibrate for the longitudinal mode including the DAC calibration. Disengage the DAC. Using the calibration gain for the 0.250 inch (6.35 mm) deep SDH, maximize the response for the 0.250 inch (6.35 mm) deep hole using linear axes only, without changing the water path.
EFFECTIVITY: ALL
70-32-09
STANDARD PRACTICES MANUAL AS907-1-1A 4 Move off the hole in the direction parallel to the block so that the amplitude of the response from the SDH falls to 40 percent 2 percent of FSH. Add 6 dB of gain. The response shall now be 80 percent 4 percent of FSH. Remove 6 dB of gain. The response shall be 40 percent 2 percent of FSH. Remove a further 6 dB of gain the response from the SDH shall drop to 20 percent 4 percent of FSH. If the requirements of paragraphs C.(1)(j) 5 through C.(1)(j) 7 cannot be met, the instrument is considered unacceptable for use and should be forwarded to an authorized repair facility. Repeat paragraphs C.(1)(j) 4 through C.(1)(j) 8 for the 2.000 inch (50.80 mm) deep SDH. Repeat paragraphs C.(1)(j) 3 through C.(1)(j) 9 using the DAC and DAC gain.
5 6 7 8
9 10 (k)
Use the following guidelines to determine calibration frequency: NOTE: After sufficient calibrations have been performed and data has been gathered over a sufficient period of time, the calibration frequency may be extended with the prior approval of Honeywell. 1 Calibration should be performed at the beginning of each part, the calibration should be checked at the end of each part or whenever a change in equipment (including cables) is made, whenever a power outage occurs or whenever the operator suspects a problem. If the amplitude of the responses from each of the holes has decreased by more than 10 percent then the system must be recalibrated and the inspection repeated for the modes in which the post calibration showed a decrease in amplitude. If the amplitude of the responses from each of the holes has increased by more than 10 percent then the system must be recalibrated and all rejectable indications must be re-evaluated.
(l)
Calibrate for inspections to a depth of 3.000 inches (76.20 mm) in the longitudinal and shear mode as follows: 1 2 Use this calibration only when inspections are required for depths greater than 2.000 inches (50.80 mm) and up to 3.000 inches (76.20 mm). Calibrate following the procedures detailed in paragraphs C.(1)(e) and C.(1)(f) for the longitudinal mode and paragraph C.(1)(g) for 45 degree shear mode with the following exceptions:
EFFECTIVITY: ALL
70-32-09
STANDARD PRACTICES MANUAL AS907-1-1A a Use the range control and delay controls to calibrate the sweep range to 0.500 inch (12.70 mm) per major division on the CRT baseline. NOTE: The peak of the front surface response must be at the first major division on the CRT and the peak of the response from the 2.000 inch (50.80 mm) deep SDH must be at the fifth major division on the CRT. b Plot the final gain for the two holes on a chart of gain versus depth. NOTE: The depth range on the chart axis must be at least 3.000 inches (76.20 mm). c d Join the two points with a straight line. Extend the straight line to a depth of 3.000 inches (76.20 mm). NOTE: For evaluation purposes, the gain required to evaluate an indication at a particular depth shall be taken from this chart. e f g h Plot the chart for both modes of inspection. Determine the gain for both modes of inspection from the charts for a depth of 3.000 inches (76.20 mm). Use this gain to construct a DAC from 0.0 to 3.000 inches (76.20 mm). Calibrate the DAC of the instrument for each mode from 0.250 inch (6.35 mm) through 2.000 inches (50.80 mm) and 2.000 inches (50.80 mm) through 3.000 inches (76.20 mm) in two successive parts.
(2)
Prepare the part as follows: NOTE: The part to be inspected shall be clean and free of any foreign material or marking which will interfere with the sonic beam penetration and reflection or will obscure significant indications. (a) Remove paint as follows: 1 2 Note the content and location of any markings to be removed. Soak the painted area with acetone C04-003 or MEK C04-001 for 1 hour to soften the paint. It is recommended that a cloth should be placed over the painted area and solvent applied every 10-15 minutes. Scrub with Scotch Brite pad C10-010 or a stiff bristle brush to remove the paint.
EFFECTIVITY: ALL
70-32-09
STANDARD PRACTICES MANUAL AS907-1-1A 4 (b) It is not necessary to remove every trace of paint, but all paint with any thickness must be reduced to a minimum.
Prior to inspection, mask the aluminum rub coat to prevent electrolysis as follows: 1 Wrap Scotch vinyl electrical tape C10-180 tightly around rub coat areas, ensuring complete coverage.
(c)
Prior to inspection, locate the serial number. Mark on the forward and aft flanges the bolt holes which most closely line up with the / in S/N. This will be the 12 oclock position. Record the part number and serial number. Center the part in the tank so that the water path variation is 0.010 inch (0.25 mm) or less for a complete revolution of the part.
(d) (e) (3)
Inspect as follows: NOTE: Surface speed for all modes of inspection shall be 6.0 inches (152 mm) per second. Deviations must be approved by Honeywell. (a) See the appropriate scan plans, inspection plans, and evaluation amplitudes of the particular hardware being inspected. The nominal index rate is 0.040 inch (1.02 mm) for each revolution. Refer to table 7, Page 13 for alternative index rates and evaluation amplitudes that may be used as appropriate. If the index rate is other than 0.040 inch (1.02 mm), the index rate shall be documented. NOTE: If an I2 transducer is to be used, the nominal index rate shall be 0.020 inch (0.51 mm) and no variation in index rate or evaluation limit is allowed. Table 7. Index Rate Verses Evaluation Limits
EVALUATION AMPLITUDES % FSH 6 INCHES (152.4 MM) PER SECOND Reject % FSH 30 40 50 30 40 50 0.010 IDX 29 38 48 28 37 46 0.020 IDX 28 37 46 28 37 46 0.040 IDX 27 36 45 26 34 43 0.060 IDX 24 32 40 23 30 38
12 INCHES (304.8 MM) PER SECOND
18 INCHES (457.2 MM) PER SECOND
EFFECTIVITY: ALL
70-32-09
Table 7. Index Rate Verses Evaluation Limits (Cont) EVALUATION AMPLITUDES % FSH 30 40 50 (b) 27 36 45 27 35 45 25 30 40 20 25 33
Inspect in longitudinal mode as follows: 1 2 3 4 5 Calibrate per paragraph C.(1) as required. Use the appropriate scan plans and inspection plans to inspect. Set scanning gain for all longitudinal scans to calibration (AC) gain (including the appropriate correction factors) plus 6 dB. Gate from 0.150 inch (3.81 mm) and include the maximum part thickness being inspected. As each scan is completed, check the appropriate box on the operators scanning log.
(c)
Inspect in the 45 degree shear mode as follows: 1 2 3 Calibrate per paragraph C.(1) as required. Use the appropriate scan plans and inspection plans to inspect. Set scanning gain for all 45 degree shear mode inspections to calibration (AC) gain (including the appropriate correction factors) plus 6 dB. Gate from 0.100 inch (2.54 mm) and include the maximum part thickness being inspected. Record the gate depth settings on the scan recordings. As each scan is completed, check the appropriate box on the operators scanning log.
5 (d)
Inspect in the 60 degree shear mode as follows: 1 2 3 Calibrate per paragraph C.(1) as required. Use the appropriate scan plans and inspection plans to inspect. Set the scanning gain for all 60 degree shear mode scans to calibration gain (including the appropriate correction factors) plus 6 dB.
EFFECTIVITY: ALL
70-32-09
STANDARD PRACTICES MANUAL AS907-1-1A 4 5 (4) Gate from 0.020 inch (0.51 mm) to 0.450 inch (11.43 mm). As each scan is completed, check the appropriate box on the operators scanning log.
Evaluate using the following Criteria: NOTE: Noise level for signal-to-noise ratio determinations is the average noise throughout the particular scan being performed. (a) Evaluate signals detected in the longitudinal mode as follows: 1 Evaluate all repeatable responses which are equal to or exceed the following criteria: a b 2 3 All repeatable responses which are equal to or exceed the evaluation criteria at scanning gains. All repeatable responses which are equal to or exceed a 3:1 signal-to-noise ratio at scanning gains.
Evaluate all indications with DAC off. All indications shall be evaluated at calibration gain + 6 dB. The calibration gain is obtained from the chart of gain versus depth by reading the gain at the appropriate depth. The calibration gain for indications at 0.250 inch (6.35 mm) deep or less shall be the 0.250 inch (6.35 mm) gain. Peak the response by translation and rotation only. Reject all hardware for indications which are repeatable, and are equal to or exceed either of the following criteria: a b All responses which are equal to or exceed the reject limits at evaluation gains. All responses which are equal to or exceed a 3:1 signal to noise ratio at evaluation gains.
4 5
Reject all fan disks P/N 1703M77 for indications which are repeatable, and are equal to or exceed the following criteria: a Indications detected in a minimum of both longitudinal mode and 45 degree circumferential shear mode either clockwise or counterclockwise. The indications shall be above the longitudinal reject level contained in the appropriate figure and have an amplitude of at least 10 percent above the average background noise on the CRT in the gated zone in the 45 degree shear mode. In addition the indication depth should be the same for both longitudinal and 45 degree shear mode within 0.050 inch (1.27 mm) and the calculated indication position should have the same circumferential location 0.100 inch (2.54 mm) within the part.
EFFECTIVITY: ALL
70-32-09
STANDARD PRACTICES MANUAL AS907-1-1A (b) Evaluate signals detected in the 45 degree shear mode as follows: 1 2 3 Evaluate all repeatable responses which are equal to or exceed the evaluation criteria at scanning gains. Evaluate all indications with DAC off. All indications shall be evaluated at calibration gain + 6 dB. The calibration gain is obtained from the chart of gain versus depth by reading the gain at the appropriate depth. The calibration gain for indications at 0.250 inch (6.35 mm) deep or less shall be the 0.250 inch (6.35 mm) gain. All indications shall be evaluated as follows: a b For circumferential shear modes, indications shall be evaluated in both directions (clockwise and counterclockwise). For radial/axial shear modes, indications shall be evaluated from the same side where the geometry allows. If geometry does not allow evaluation in both directions from the same side, then the indication shall be evaluated in other directions or modes (such as circumferential shear, longitudinal and scans from opposite or adjacent faces).
5 6 7
Peak the response by translation and rotation only. Reject all hardware for indications which are repeatable, and are equal to or exceed the reject limits at evaluation gains. Indications have two sets of reject criteria: a b Single indications seen in one mode and direction. Indications detected in a minimum of two directions or modes. The indications shall be above the multiple direction/mode reject level contained in the appropriate figure and have an amplitude of at least 10 percent above the average background noise on the CRT in the gated zone in the other direction/mode. In addition the indication depth should be the same in both direction/modes within 0.050 inch (1.27 mm) and the calculated indication position should have the same circumferential location 0.100 inch (2.54 mm) within the part.
(c)
Evaluate indication detected in the 60 degree shear mode as follows: 1 2 3 Evaluate all repeatable responses which are equal to or exceed the evaluation criteria at scanning gains. All indications shall be evaluated at calibration gain + 6 dB. All indications shall be evaluated both directions (clockwise and counterclockwise).
EFFECTIVITY: ALL
70-32-09
STANDARD PRACTICES MANUAL AS907-1-1A 4 5 6 Peak the response by translation and rotation only. Reject all hardware for indications which are repeatable, and are equal to or exceed the reject limits at evaluation gains. Indications have two sets of reject criteria: a b Single indications seen in one mode and direction. Indications detected in a minimum of two directions or modes. The indications shall be above the multiple direction reject level contained in the appropriate figure and have an amplitude of at least 10 percent above the average background noise on the CRT in the gated zone in the other direction. In addition, the indication depth should be the same in both directions/modes within 0.050 inch (1.27 mm) and the calculated indication position should have the same circumferential location 0.100 inch (2.54 mm) within the part. 7 If the indication is determined visually to be surface related, rework the area as shown in the appropriate applicable shop manual and reinspect using the original inspection direction. Reject all hardware for indications which are greater than 10 percent FSH above the average background noise in the reworked area.
(d) (5)
Record the indication number, depth, mode, direction, amplitude, gain level, and location.
Post-inspection. (a) After inspection, remove Scotch vinyl electrical tape used to mask the part in paragraph C.(2)(b). 1 (b) Remove residual tape adhesive with acetone C04-003.
After inspection, apply paint removed in C.(2)(a) as follows: 1 2 Clean the web area with an acetone C04-003 soaked cloth. Using the approved epoxy primer C03-005, re-mark the disk with the characters and in the location as noted in C.(2)(a) 1. The characters are to be between 0.5 and 1.0 inch (13 and 25 mm) in height.
(6)
Document inspection as follows: (a) (b) (c) Ensure that the calibration worksheet and calibration chart are complete. Ensure that the operators log sheets for the part being inspected are complete. Record the following with each scan file or strip chart recording. 1 Part number
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STANDARD PRACTICES MANUAL AS907-1-1A 2 3 4 (d) Part serial number Date Operator
Record the following data for each scan: 1 2 3 4 Scan area number Mode/Direction Date Operator
(e)
Document indications as follows: 1 2 3 If an indication is found, carefully mark the beam entry point for the indication on the part. Record the scan area where the indication is located. Record the circumferential position as referenced from the / of serial number and recorded clockwise looking aft. Record the radial position as referenced from the ID bore surface to the nearest 0.100 inch (2.54 mm).
(f)
It is the inspection facilitys responsibility to maintain all inspection records. The records should be maintained with the permanent record of the part and shall be maintained for the life of the part.
EFFECTIVITY: ALL
70-32-09
EDDY CURRENT INSPECTION - 2 MHZ EDDY CURRENT INSPECTION OF BORES IN ROTATING ENGINE HARDWARE USING SYSTEMS UNDER COMPUTER, NUMERIC, OR ROBOTIC CONTROL TASK 70-32-10-250-003 1. 2 MHz Eddy Current Inspection of Bores in Rotating Engine Hardware Using Systems Under Computer, Numeric, or Robotic Control SUBTASK 70-32-10-99G-003 A. General. (1) This document describes the equipment, techniques, and procedures for conducting component level, 2 MHz eddy current inspections of bores in engine run rotating hardware manufactured from titanium, Inconel and Rene alloys. The inspection areas and specific requirements are detailed in the appropriate inspection scan plans and operators scanning logs included in this document or in applicable Service Bulletins and applicable manual. This inspection procedure utilizes a 2 MHz eddy current technique to inspect various part surface features (i.e., bore inside diameter, bore faces, bore corners, webs, etc.). Inspection systems under computer, numeric, or robotic control shall be used for this inspection, which may be accomplished in air or water. For specific cases where the procedure or equipment described in this document cannot be applied in their total content, specific exceptions shall be obtained in writing from the Honeywell to document the deviation. The following documents shall form a part of this procedure to the extent specified herein. Unless a specific issue is specified, the latest revision shall apply. (a) (b) (c) (6) Appropriate equipment instruction manuals. National Aerospace Standard (NAS-410) (latest revision). Appropriate Service Bulletin or applicable manual procedure.
(2)
(3) (4)
(5)
The following requirements shall be met by inspection personnel: (a) Personnel performing this inspection must be certified in accordance with National Aerospace Standard (NAS-410), American Society of Nondestructive Testing (ASNT-TC-1A), Air Transport Association Specification No. 105 (ATA 105), COSAC, or any equivalent certification document acknowledged by the local regulatory agencies. It is strongly recommended that personnel performing this inspection receive practical training in the use of this procedure and must demonstrate proficiency in the calibration, inspection and evaluation routines before accept/reject authority is delegated.
2 MHz EDDY CURRENT INSPECTION OF BORES IN ROTATING ENGINE HARDWARE USING SYSTEMS UNDER COMPUTER, NUMERIC, OR ROBOTIC CONTROL Page 1 Dec 01/03
(b)
STANDARD PRACTICES MANUAL AS907-1-1A (c) Any training which may be provided regarding the performance of this inspection does not imply that the personnel who receive that training have met the requirements for inspector certification in accordance with the appropriate certification document.
SUBTASK 70-32-10-250-031 B. Equipment. (1) The instrumentation/tooling listed in this section does not include all of the equipment necessary to perform this inspection, but does include all items for which substitution cannot be made without written approval from Honeywell. System and Instrumentation: NOTE: Items in paragraphs B.(1) and B.(2). are to be supplied by the inspection site. The eddy current inspection system may be obtained from an approved vendor or may be manufactured or obtained by the inspection site provided that approval of the system is obtained from Honeywell. (a) Eddy Current Inspection System 1 The inspection system used shall be comprised of at least 3 motor driven axes, one providing movement in a rotary direction (C axis), one providing movement in a direction parallel to the rotary axis (X axis) and one providing movement in a direction perpendicular to the rotary axis (Z axis). The inspection system used shall be capable of accurately indexing the eddy current probe in the axial/radial direction across the test surface during the inspection. The inspection system shall be under computer or numeric control. The capability of this system must be demonstrated to Honeywell prior to approval for this inspection procedure. The system mechanical accuracies for the appropriate axes shall meet the requirements described in table 1, Page 2 and shall be checked annually. Table 1. Inspection System Accuracies X axis Parallelism to C axis Positioning accuracy Positioning backlash Z axis Perpendicularity to C axis Positioning accuracy Positioning backlash Within 0.020 inches per foot (1.67 mm/m) Within 0.010 inches per foot (0.83 mm/m) Within 0.010 inches (0.25 mm)
(2)
3 4 5
Within 0.010 inches per foot (0.83 mm/m) Within 0.010 inches per foot (0.83 mm/m) Within 0.010 inches (0.25 mm)
Table 1. Inspection System Accuracies (Cont) X axis C axis Surface runout Runout part centering Speed accuracy 6 Within 0.020 inches (0.51 mm) total indicator runout at 39 inches (991 mm) diameter Within 0.010 inches (0.25 mm) Within 3 percent of indicated speed A list of approved systems and manufacturers for this equipment is available from: Honeywell Refer to the List of Suppliers in Step D. of Subtask 70-80-00800-003. (b) Eddy Current Instruments 1 2 (c) Nortec Model NDT-19, -19e, -19eII, -24 or 3000 Eddyscope. Rohmann Elotest B1 SDM Eddy Current Instrument.
Data Recording Instruments/Systems 1 2 3 4 Gould 3200, TA240, Windograf Strip Chart Recorders. Data/Video Integrators, SCR-16/STD. AIMS Data Acquisition system. Equivalent data recording system approved by Honeywell.
(3)
Tooling: (a) (b) Eddy current calibration standard P/N MOD-030 Titanium or equivalent approved by Honeywell. Eddy current probe manufactured by Xactex P/N PPE-1041, PPE-1049, PPE1065, PPE-1070, PPE-1078, and eddy current probe manufactured by ANAFAB P/N ANA-2MRDF-01 and ANA-2MRDF-02 or equivalent approved by Honeywell. NOTE: PPE-1041 was designed to help reduce tape wear. If high noise levels are experienced which are attributed to rough surfaces, the PPE-1049 should be used. NOTE: Use PPE-1065 for the inspection of the 3-9 spool slot bottoms only (Areas 3S, 4S, and 5S). NOTE: Use PPE-1070 for the inspection of bore internal diameters of 5 inches (127 mm) or less.
STANDARD PRACTICES MANUAL AS907-1-1A (c) (4) Eddy Current Probe holder fixture manufactured by Xactex P/N PAC 5015 or equivalent approved by Honeywell.
A complete eddy current inspection kit can be obtained by contacting the following: Honeywell. Refer to the List of Suppliers in Step D of Subtask 70-80-00-800-003.
(5)
Materials: No. C10-040 C04-035 C04-003 C10-010 C05-003
Consumable Product Teflon Tape Solvent - Isopropyl alcohol (halogen free) Solvent - Acetone (halogen free) Scotch Brite Action Marker SUBTASK 70-32-10-250-032 C. Pre-inspection Part Preparation. (1) (2) (3)
Visually inspect the features to be scanned under white light for evidence of adhering dirt, cracks, rubbing, fretting, etc. Clean the features by using the applicable process in the applicable manual. Prior to inspection, locate the serial number on the part. Mark this location on the forward side of the part using an approved marker (see TASK 70-16-02-350-017, Temporary Marking). This will be the 12:00 oclock (start/ref) position. Center the part on the turntable within 0.005 inch (0.13 mm) or less.
(4)
SUBTASK 70-32-10-250-033 D. Equipment Set-Up. (1) Connect the equipment and allow it to warm up in accordance with the manufacturers specifications. NOTE: It is important that the cables from the eddy current instrument to the recording instrument be connected correctly. Ensure the vertical analog output channel from the eddy current instrument is connected to Channel 1 on the recording instrument (left channel on strip chart recorders). The horizontal channel should then be connected to Channel 2 on the recording instrument (right channel on strip chart recorders). (2) Prepare Teflon tape C10-040 for probe wear face as follows: (a) Lay a strip of Teflon tape C10-040 approximately 1.0 inch (25 mm) long on a firm, smooth, clean surface. With a razor blade, cut the Teflon tape to a length that will sufficiently cover the probe face.
STANDARD PRACTICES MANUAL AS907-1-1A (b) (c) Apply the tape tightly across the coil face and around each side. Smooth all edges back from the coil. Draw the probe back and forth across some fabric with the coil face in contact with the fabric. Heat from the resulting friction will soften the tape adhesive to provide a tight fit. Ensure unwrinkled edges adhere to the probe tip. NOTE: It may also be desirable to cover the cam wheels/shoe of the probe with tape to reduce wear and friction. (3) (4) (5) (6) (7) Insert the eddy current probe into the probe holder. Connect the fixture to the manipulator and align the fixture parallel to the indexing direction. Connect the probe to the eddy current instrument front panel receptacle. Adjust the instrument control settings as shown in table 2. Adjust the standard so the eddy current probe will travel transverse/perpendicular to the length of the EDM notch. Table 2. Initial Instrument Control Settings Parameter Nortec Series Eddyscope: Frequency Vertical Gain Horizontal Gain Phase Vertical Position Horizontal Position Low Pass Filter High Pass Filter Special Function 2 - Probe Drive Rohmann Elotest B1 Eddy Current Instrument: Frequency Y Axis Gain X Axis Gain Preamplifier Gain Bandwidth Gain Phase Filter 2.0 MHz 0 dB 0 dB 12 dB High Frequency 50 dB 0 100 Hz lowpass
Setting 2000 KHz (2 MHz) 60 dB 60 dB 0 128 128 100 Hz 0 Hz 1.0 (medium) or 2.0 2.0 (high)
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-10-250-034 E. Equipment Calibration. (1) (2) (3) Connect the equipment and set initial settings per Subtask 70-32-10-250-033, Equipment Setup. Position the probe on the calibration standard. Apply approximately 0.100 inch (2.54 mm) of spring compression on the probe fixture. Null the eddy current instrument with the probe on the calibration standard surface away from the electro-discharge machined (EDM) notch and engraving. NOTE: This procedure uses a single material calibration standard. In order to inspect different materials, calibration correction factors are assigned. The factors apply to calibration only and not to the evaluation criteria. NOTE: The calibration speed and instrument filters are dependent upon the recording instrument to be used and the desired inspection speed. NOTE: Surface inspection speeds greater than 5.0 inches (127 mm) per second must be approved by Honeywell. Surface inspection speeds greater than 5.0 inches (127 mm) per second must be accomplished with an approved recording instrument. (4) Adjust the angle on the eddyscope so lift-off is vertical. This is accomplished by manually lifting the probe off the standard surface and observing the deflection on the CRT. After setting the lift-off, adjust the filters to the correct settings for the desired inspection speed. Turn on the data recording instrument. Perform a scan of the EDM notch at the correct scan speed at a maximum index increment of 0.005 inch (0.13 mm) to determine the peak response from the EDM notch. NOTE: The peak notch response occurs when the response in Channel 1 (vertical) on the data recording instrument is at the maximum amplitudes. (7) Reposition the probe to the point where the peak notch response was received and perform a continuous scan at this point at the correct scan speed. While scanning, adjust the gain and angle controls on the eddyscope to achieve the correct calibration amplitude for the material to be inspected ( 100 mV) in Channel 1 (vertical deflection) of the recording instrument with the signal on the CRT in the vertical position. The amplitude in Channel 2 (horizontal deflection) should be at its minimum when the signal on the CRT is at the correct vertical position. Re-null the instrument after any changes in gain or angle. NOTE: The NDT-19 has separate vertical and horizontal gain controls. Both gain controls must be set to the same sensitivity for a correct calibration. NOTE: For re-nulling, the coil must be well off the EDM notch and away from any edge of the standard.
(5) (6)
STANDARD PRACTICES MANUAL AS907-1-1A (8) After completion of the above routine, perform another scan of the EDM notch at a 0.005 inch (0.13 mm) index rate to ensure the calibration is correct. Record this scan on the data recording instrument. Record all calibration data onto the appropriate calibration log contained in the scan logs.
(9)
(10) Use the following guidelines to determine calibration frequency: (a) Calibrate before and after inspecting a part, whenever an equipment change is made, whenever a power outage occurs, or whenever the operator suspects a problem. Recalibrate if the amplitude of the response from the EDM notch has decreased by more than 200 mV and reinspect all parts inspected since the previous calibration. Recalibrate if the amplitude of the response from the EDM notch has increased by more than 200 mV and reinspect any parts which were previously found to be rejected since the previous calibration.
(b)
(c)
SUBTASK 70-32-10-250-035 F. Part Inspection. (1) (2) (3) Complete pre-inspection part preparation per Subtask 70-32-10-250-032, Preinspection Part Preparation. Calibrate per Subtask 70-32-10-250-034, Equipment Calibration. Refer to the appropriate Service Bulletin, applicable manual, or the following figures for the appropriate inspection scan plan and inspect all areas of the hardware. Inspect at a surface scanning speed for all areas of inspection. Index at an increment of 0.025 inch (0.64 mm) per revolution for all areas of inspection. Ensure adequate coverage is provided on all areas by using the cam action of the eddy current probe to completely scan the corner and edge features. Renulling is required for each inspection area. Record all scans on the data recording instrument. Evaluate all repeatable indications with amplitudes greater than or equal to the limit specified in the appropriate Service Bulletin, applicable manual, or inspection scan plan. See Subtask 70-32-10-250-036, Indication Evaluation.
(4) (5) (6) (7) (8) (9)
(10) Record all inspection results on the appropriate Operators scanning log and the Certificate of Conformance.
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-10-250-036 G. Indication Evaluation. (1) Initially, all indications with amplitudes greater than or equal to the limit specified in the appropriate Service Bulletin, applicable manual, or inspection scan plan are considered rejectable. NOTE: The best time to evaluate indications is either at the time the indication is found or immediately following the completion of the specific inspection area. (2) Clean the area of indication with Scotch Brite C10-010 and approved solvents and reinspect the area. If the indication is reduced to below the reject level, it shall be considered acceptable and noted. If not, continue to evaluate the indication as detailed below. Carefully examine the area of the indication under bright white light using a 5x/10x glass. Note any unusual conditions such as discoloration, handling damage, uneven surfaces, or raised metal, and record these conditions. Reclean and reinspect the area. The following shall apply: (a) (b) If the indication amplitude falls below the reject level, the area shall be considered acceptable and noted. If the indication amplitude is reduced but still greater than the reject level, reclean and reevaluate the area since the indication is most likely due to surface contamination. If the indication amplitude does not fall below reject level, reject the part and identify it for further engineering evaluation and disposition. Record the indication number, area, amplitude, background noise, location, and comments (visual findings) on the Certificate of Conformance. NOTE: Refer to applicable manual section for disposition and rework of surface damage. Rework is only allowed on areas with visual surface damage. (d) If the indication was attributed to visual surface damage and the area was reworked, the reject level is either of the following: 1 The indication has an amplitude greater than or equal to the limit specified in the appropriate Service Bulletin, applicable manual, or inspection scan plan. The indication exceeds a 3:1 peak amplitude to average background noise.
(3)
(4)
(c)
SUBTASK 70-32-10-250-037 H. Records. (1) As a minimum, document and maintain the calibration logs and operator scan logs with the inspection data package.
STANDARD PRACTICES MANUAL AS907-1-1A (2) Record the following for each scan within the scan file. (a) (b) (c) (3) Area Date Start/Stop Location and Feature
Document all inspection results. Copies of strip chart recordings of rescans of all indications exceeding the allowable criteria shall be kept with the suspect hardware. The allowable criteria is specified in Subtask 70-32-10-250-036, Indication Evaluation. It is the Inspection Facilitys responsibility to maintain all inspection records. The inspection records shall be kept with the permanent record of the part and shall be maintained for the life of the part.
(4)
WHITE LIGHT INSPECTION - WHITE LIGHT INSPECTION TASK 70-32-11-220-011 1. White Light Inspection SUBTASK 70-32-11-99G-011 A. General. (1) This method of inspection is to be used on parts that have many sheared openings, such as a combustion liner, because it is difficult to tell the difference between shear marks and cracks under fluorescent penetrant-inspection; also use on parts that will retain fluorescent-penetrant oil after cleaning. Operational cracking of parts having sheared openings is caused by thermal fatigue. This type of crack is easily seen using white light inspection method. The white light inspection is also used to inspect parts for defects that are visible to the naked eye or with 5X to 10X magnification.
(2)
SUBTASK 70-32-11-220-111 B. Equipment. (1) The following equipment is required and may be obtained as shown: (a) (b) A 150-watt standard spotlight or 40-watt high intensity spotlight (Commercial). Magnification equipment 5X to 10X (Commercial).
SUBTASK 70-32-11-220-112 C. Materials. No. See TASK 70-16-02-350-017, Temporary Marking
Consumable Product Marker
SUBTASK 70-32-11-220-113 D. Procedure. CAUTION: TITANIUM PARTS MUST BE CLEANED PER TASK 70-21-03-160-001, CLEANING METHOD NO. 3 - STEAM CLEANING, OR TASK 70-21-09-110-007, CLEANING METHOD NO. 9 - LIGHT-DUTY ALKALINE CLEANING OF TITANIUM ALLOYS. (1) Clean parts per TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, or TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning.
EFFECTIVITY: ALL
70-32-11
WHITE LIGHT INSPECTION Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (2) (3) Inspect the part for cracks under a bright white light (150-watt standard spotlight or equivalent). Hold light within 4 feet (1.2 meters) of the surface being inspected. Examine each area where cracks are suspected (using 5- to 10-power magnification) to verify that there is a defect and to determine its course and length. Mark each unacceptable defect along its entire length (in the crack), using an acceptable marker. Circle each defect using a marker as specified in Subtask 7032-11-220-112, Materials.
(4)
EFFECTIVITY: ALL
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WHITE LIGHT INSPECTION Page 2 Dec 01/03
EDDY CURRENT INSPECTION - EDDY CURRENT INSPECTION OF BORES IN INCONEL ROTATING ENGINE HARDWARE TASK 70-32-12-250-005 1. Eddy Current Inspection of Bores in Inconel Rotating Engine Hardware SUBTASK 70-32-12-99G-005 A. General. (1) This practice describes the equipment and processes used for the application of eddy current inspection techniques to the bores of rotating engine parts. Both semi-automated and manual inspection techniques will be described. These techniques are used to detect flaws or discontinuities at the surface or near the surface of metallic parts which may be detrimental to the part life or limit its intended use. A service bulletin or applicable manual procedure shall provide the details for specific hardware inspection. This procedure describes how to accomplish bore inspections utilizing a specialized 2 MHz eddy current probe, dedicated tooling, specific eddy current equipment, and the Gould strip chart recorder. For specific cases where the procedure or equipment described in this procedure cannot be applied in their total content, specific exceptions shall be obtained in writing from Honeywell to document the deviation. The following procedures shall form a part of this procedure to the extent specified herein. Unless a specific issue is specified, the latest revision shall apply. (a) (b) Appropriate equipment instruction manuals. These industry standards or their equivalent locally approved alternatives. 1 2 3 (c) (5) National Aerospace Standard 410 (NAS 410) which replaces MIL-STD 410. American Society of Non-Destructive Testing specification ASNT-TC-1A (ASNT-TC-1A). Air Transportation Association of America specification 105 (ATA 105).
(2)
(3)
(4)
Appropriate service bulletin or applicable manual procedure for the specified part.
The following requirements shall be met by inspection personnel: (a) Only qualified personnel specifically designated, trained, and approved to perform a specified inspection shall perform that test. Operators must be capable of performing equipment calibrations, doing the intended inspection, and must be capable of acceptable interpretation of output test data before
EDDY CURRENT INSPECTION OF BORES IN INCONEL ROTATING ENGINE HARDWARE Page 1 Dec 01/03
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A approval is given for the acceptance or rejection of hardware in accordance with inspection procedure. (b) (c) (6) Personnel performing this inspection shall be certified in accordance with NAS-410, ASNT-TC-1A, ATA 105, or locally approved certification program. Training per this procedure does not imply personnel certification per National Aerospace Standard (NAS-410), ASNT-TC-1A, or ATA 105.
Procedure Locator: Method A is the semi-automatic procedure. Refer to Subtask 70-32-12-250-051, Method A. Method B is the manual procedure. Refer to Subtask 70-32-12-250-052, Method B.
SUBTASK 70-32-12-250-051 B. Method A - Semi-automated Eddy Current Inspection Method. (1) Equipment. The instrumentation/tooling listed in this section does not include all of the equipment necessary to perform this inspection, but does include all items for which substitution cannot be made without prior written approval from Honeywell. (a) One of the following eddy current instruments are required. Nortec Model NDT 19 Series Eddyscope. Nortec Model NDT 16 Eddyscope. Nortec Model NDT 25L Eddyscope. Rohmann Elotest B1 SDM Eddyscope with probe socket B1-N0B3H or B1AN02. Gould 220 strip chart recorder or approved equivalent recording system. (b) (c) (d) (e) (f) (g) (h) (i) Appropriate cables and connectors. Required equipment, tooling, and accessories. Oakley Die and Mold eddy current probe holders P/Ns 4425-1A and 4425-2A. Reference Figure 2, Page 13. Staveley SGE-591 eddy current probe or equivalent. Reference Figure 3, Page 14. Spacer for SGE-591 eddy current probe. Reference Figure 3, Page 14. Oakley Die and Mold eddy current calibration standard fixture P/N 4412-1A. Reference Figure 5, Page 16. Eddy current calibration standard P/N 4013316-178. Reference Figure 5, Page 16. Kapton or Teflon tape - maximum thickness.0035 inch (.089mm) X.25 inch (6.35mm).
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (j) (k) (l) (m) (n) (o) (p) (q) Scotch Brite pads, #7447 or equivalent. Action Marker, Q404 or equivalent. Custom Tool shaft support stand P/N CT-9890. Reference Figure 6, Page 17. Razor Blades, single edge or equivalent. Scanner (only one required) Nortec model PS-2M scanner with model PS-2 speed control. Nortec model PS-3R scanner and PS-3T translator with respective controllers. A rigid fixture for holding the Nortec scanners. The fixture must have provisions for positioning the scanner over the bores securely and 5 degree adjustment so that the fixture body axis can be set parallel to the axis of the bore. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003.
(r) (2)
Pre-inspection Part Preparation. (a) Position the part with the aft end facing up. For parts with forward shafts, place the part into the shaft support stand (P/N CT-9890). Refer to Figure 6, Page 17. Ensure that the part is level and stable. Take care not to damage the part when positioning. Clean the inspection area(s) with Scotch Brite and approved solvents. Refer to Figure 1, Page 12. Visually examine the inspection area under bright white light. The area shall be clean and free of any foreign material or marking which would interfere with the eddy current inspection process. NOTE: Any surface irregularities (i.e., nicks, scratches) that will obviously cause eddy current signals should be blended or polished in accordance with the appropriate procedures prior to inspection. (d) (e) Locate the serial number on the part and mark this location on the aft side of the part. This will be the 12 oclock position. Mark the inspection zones on the part as indicated below. 1 Aft bore face (ZONES 1A and 1B). a b Measure the width of the aft bore face and divide this value by 2. Measuring from the outer edge of the bore face, mark the dimension from the previous step. This will identify inspection ZONES 1A and 1B. Refer to Figure 1, Page 12.
(b) (c)
Bore ID (ZONES 2A, 2B, and 2C).

EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A a Measure the axial length of the bore. Depending upon the scanner to be used, divide this number by 2 or 3. Mark the bore ID accordingly. Refer to Figure 1, Page 12.
Forward bore face (ZONES 3A and 3B). a b Measure the width of the forward bore face and divide this value by 2. Measuring from the outer edge of the bore face, mark the dimension from the previous step. This will identify inspection ZONES 3A and 3B. Refer to Figure 1, Page 12.
(3)
Calibration (a) Connect the equipment and allow it to warm up in accordance with the manufacturers specifications or 10 minutes. NOTE: It is important that the cables from the eddy current instrument be connected to the strip chart recorder correctly. Ensure that the vertical output channel from the instrument is connected to channel 1 (the left channel) on the chart recorder. The horizontal output channel from the instrument shall be connected to channel 2 (the right channel) on the chart recorder. (b) Apply Kapton or Teflon tape to completely cover the coil face and sides. Apply the tape tightly and smoothly so that there are no wrinkles and the tape edges adhere to the probe tip. Tape may also be applied to the wheels of the eddy current probe to help increase the life of the probe. Insert eddy current probe holder (P/N 4425-2) into the scanner and tighten the collar. Position the lower half of the probe holder into position No. 2. Refer to Figure 2, Page 13.
(c) (d)
CAUTION: DO NOT OVER TIGHTEN THE SET SCREW ON THE PROBE HOLDER AS THIS COULD RESULT IN DAMAGE TO THE PROBE OR PROBE HOLDER. (e) (f) (g) Insert the eddy current probe into the probe holder and connect the electrical cable into the side of the fixture. Set the initial equipment control settings as indicated in table 1, Page 5. Set up the Elotest B1 as follows: 1 Determine the maximum possible preamplifier gain by increasing the preamplifier gain until the "PREAMP OVERLOAD" indication appears. NOTE: To minimize instrument produced noise, the preamplifier gain should be increased to the maximum possible value without producing a preamplifier overload condition.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A 2 Reduce the preamplifier gain just enough to eliminate the overload indication.
CAUTION: DO NOT PRESS THE COMPENSATION BUTTON AFTER SWITCHING BACK TO THE LOW-PASS FILTER. 3 To operate at higher amplifier gain levels, tune the impedance bridge circuitry. Set the filter to 100 Hz high-pass and press the compensation (null) button (with the probe in air). Change the filter back to 100 Hz lowpass. Table 1. Initial Instrument Control Settings PARAMETER NORTEC NDT-19 EDDYSCOPE: POWER LOCK TAPE IN DISPLAY SWEEP MEMORY 2 PROGRAM ALARM LATCH FREQUENCY (KZ) ANGLE FILTER - LOW PASS (HZ) FILTER - HIGH PASS (HZ) ERASE GAIN - VERTICAL GAIN - HORIZONTAL POSITION - VERTICAL POSITION - HORIZONTAL SPECIAL FUNCTION - 2 PROBE DRIVE SPECIAL FUNCTION - 6 BACKLIGHT SPECIAL FUNCTION - 7 ERASE SPECIAL FUNCTIONS 1, 3, 4 & 5 CONTINUOUS NULL NULL C/F (COARSE/FINE) F1/F2 (FREQUENCY) NORTEC NDT-16:
EFFECTIVITY: ALL
SETTING ON OFF OFF FREQUENCY 1 OFF OFF OFF OFF OFF 2000 (2MHz) 0 100 0 AS NEEDED 50 (SEE NOTE) 50 (SEE NOTE) 128 128 HIGH OPTIONAL OPTIONAL NOT USED OFF AS REQUIRED AS REQUIRED FREQUENCY 1
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Table 1. Initial Instrument Control Settings (Cont) PARAMETER Frequency Gain Vertical Display Sensitivity Horizontal Display Sensitivity Rotation Filter Filter Module (Internal Switch) NORTEC NDT-25L Frequency Gain Angle Filter Vertical Sensitivity Horizontal Sensitivity Position Special Function 5 (SP-5) ROHMANN ELOTEST B1 Frequency Y Axis Gain X Axis Gain Preamplifier Gain Bandwidth Gain Phase Filter GOULD 220 RECORDER Vertical fine sensitivity Horizontal fine sensitivity Vertical coarse sensitivity Horizontal coarse sensitivity MM/SEC NORTEC PS-2 OR PS-3 SCANNER Rotation Translation 9 RPM (PS-2 & PS-3) 0.09 in/min (PS-3 only) Full CW Full CW 20 mv/div 50 mv/div IN 2.0 MHz 0 dB (SEE NOTE) 0 dB (SEE NOTE) 12 dB High Frequency (HF) 50 dB 0 100 Hz LOW PASS 2000 KHz (2 MHz) 40 0 0-HIGH PASS FILTER 1 1 As needed to center dot 100 Hz-LOW PASS FILTER SETTING 2MHz 2.00 1 volt / division 1 volt / division 0.00 FILTER OUT - depressed X1
EFFECTIVITY: ALL
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Table 1. Initial Instrument Control Settings (Cont) PARAMETER SETTING
NOTE: The vertical and horizontal gains must, at all times, be set to the same value for a correct calibration and inspection.
4 5
Place the probe on a test piece or calibration standard. Adjust the two small potentiometers on the adapter to move the dot as close as possible to the null point on the display. NOTE: If the dot position function is set to 0/0 then the null point will be at the center of the display.
If necessary, reduce the gain to bring the dot on screen so that this adjustment may be made. NOTE: With proper bridge adjustment it is possible to operate at high preamplifier gain settings. This adjustment may be different for each probe. After completing this adjustment, the compensation button can be used as needed to null the instrument.
(h)
Position the inspection tooling so it is centered within the bore. Centering can be verified with the use of dial indicator. NOTE: Centering the scanner to the bore is extremely important. Once positioned, take care not to change the position.
(i)
If a dial indicator is not available, centering can be verified by monitoring the eddy current signal response after performing the following steps. 1 2 3 4 5 Select an unfiltered display for the eddyscope. Assemble the eddy current probe spacer onto the probe as shown in Figure 3, Page 14. Index the probe so the coil is positioned on the outer radial edge of the bore face. Null the instrument. Rotate the scanner and observe the dot on the CRT screen. Adjust the position of the scanner to minimize the dot movement while the probe continues to scan the outer edge of the bore face. Lock in place. Remove the eddy current probe spacer and set the equipment to the initial settings.
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STANDARD PRACTICES MANUAL AS907-1-1A (j) Raise the scanner and place the calibration standard holder into the bore. NOTE: Verify that the top surface of the calibration standard is flush with the holder. If required readjust the spring loaded set screw so the transition between the standard and the holder is level and will not cause damage to the eddy current probe. (k) (l) (m) (n) (o) Manipulate the scanner so the eddy current probe is seated flush on the calibration standard away from the EDM notch. Null the instrument for 5 to 10 seconds or until the spot stabilizes near the center of the screen. Slowly lift the probe off the standard. Adjust the rotation control until the liftoff signal moves from the center horizontally to the left. Adjust the high bypass filter to 20 Hz and null the eddyscope. Turn on the strip chart recorder to 5 mm per second.
CAUTION: ENSURE THAT THE SCANNER IS SET FOR THE ROTATION MODE ONLY. DAMAGE TO THE PROBE AND PROBE HOLDER WILL OCCUR IF TRANSLATION IS USED AT THIS POINT. (p) (q) With the scanner in the rotate mode only, slowly increase the rotation speed until a scan speed of 9 RPM is obtained. Once each revolution, index the probe (1/4 turn of the indexing knob) across the EDM notch to determine where the maximum amplitudes are achieved on both Channel No. 1 and No. 2. Refer to Figure 7, Page 18. To accomplish final probe positioning, index the probe across the EDM notch again while alternately watching Channel No. 1 and No. 2 on the recorder. The point where Channel No. 1 is maximum and Channel No. 2 is maximum is the point at which the instrumentation is to be adjusted for calibration. Examine the recorder tracings on Channels No. 1 and No. 2. Alternately adjust the rotation and gain controls to achieve calibration amplitudes of 40 percent (400 mV) full scale in Channel No. 1 and 35 percent (875 mV) full scale amplitude in Channel No. 2 (plus or minus 1 percent full scale). Renulling is required after any adjustment. Assure that the EDM notch response remains in the upper left quadrant of the Eddyscope CRT. NOTE: For renulling, it is required that the coil be well off the EDM notch and away from any edge of the standard. (s) Perform a scan of the entire EDM notch at an index rate of 1/4 revolution of the indexing knob to ensure the calibration is correct. Record this scan on the strip chart recorder at a speed of 5 mm/sec. Record the calibration information onto the strip chart recording and onto an inspection data sheet (Reference Form 724-1, ( Figure 4, Page 15)). Remove the calibration standard holder from the bore.
(r)
(t) (u)
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STANDARD PRACTICES MANUAL AS907-1-1A (4) Inspection. (a) (b) (c) (d) (e) (f) (5) Complete the pre-inspection part preparation per paragraph B.(2). Calibrate in accordance with paragraph B.(3). Inspect all areas per the appropriate scan plans as identified by the specific service bulletin or applicable manual procedure for the part being inspected. Evaluate all indications exceeding the criteria stated in paragraph B.(5). Complete a post calibration per paragraph B.(6) of this procedure. Record all inspection results on Form 724-1, Figure 4, Page 15 of this procedure.
Evaluation. (a) All indications exceeding the criteria specified in the appropriate service bulletin or applicable manual shall be considered suspect. These indications shall be subjected to evaluation as detailed below. NOTE: The optimum time to perform these evaluations is either at the time the indication is found or immediately after the completion of the specific inspection area. (b) Clean the area of the indication with Scotch Brite or approved solvents and reinspect this area. If the indication is reduced to below the criteria specified in the appropriate service bulletin or applicable manual, it shall be considered acceptable and noted on the strip chart recording. If not, continue to evaluate the indication as detailed below. Carefully examine the area of the indication under bright white light using a 5x or 10x glass. Note any unusual conditions such as discoloration, handling damage, uneven surfaces, raised metal, etc. and record these conditions on the strip chart recording. Reclean and reinspect the area. The following shall apply. 1 If the indication amplitude falls below the criteria specified in the appropriate service bulletin or applicable manual, the area shall be considered acceptable and this shall be noted on the strip chart recording. If the indication amplitude is reduced, but is still greater than the criteria specified in the appropriate service bulletin or applicable manual, the area may be recleaned and re-evaluated since the indication is most likely due to surface contamination. If the indication amplitude has not reduced below the criteria specified in the appropriate service bulletin or applicable manual, the part shall be rejected and identified for further engineering evaluation and disposition. The indication number, area, amplitude, background noise,
(c)
(d)
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STANDARD PRACTICES MANUAL AS907-1-1A location, and comments (visual findings) shall be recorded on Form 724-1, Figure 4, Page 15 of this procedure. (6) Post Calibration. (a) (b) Prior to post calibration, inspect the tape on the eddy current probe for excessive wear or other damage. Replace if necessary. After completion of the part inspection, or after intervals not to exceed four hours, a post calibration shall be completed. Assure that the post calibration scan is performed in the same rotation and index direction as the original calibration. The post calibration shall be accomplished by performing the steps identified in paragraph B.(3)(s) of this procedure. The post calibration amplitude must be 40 percent, 5 percent (350-450 mV) full scale on channel No. 1. 1 2 If the post calibration amplitude meets the above criteria, the testing process was acceptable. If the post calibration amplitude is less than the above criteria, repeat the calibration and reinspect all parts inspected since the previous acceptable calibration. If the post calibration amplitude is greater than the above criteria, only reinspect parts previously found to be rejected since the last acceptable calibration.
(c) (d)
(7)
Documentation. (a) As a minimum, the following information shall be recorded at the start of each strip chart: Detail - model number - serial number - gain settings - phase angle - filters
Item o Date o Eddyscope
o Recorder o Probe o Standard
- model number - serial number - part number/manufacturer - serial number - part number - serial number
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Item o Part
Detail - part name - part number - serial number - inspection area
o Inspector (b) o Area o Date (c)
- name & number The following shall be recorded for each scan: o Inspector o Start/stop locations Record all inspection results on Form 724-1, Figure 4, Page 15 of this procedure.
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Inspection Areas Figure 1
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Eddy Current Probe Holders Figure 2
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Eddy Current Probe and Spacer Figure 3
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Form 724-1 Inspection Data Sheet Figure 4
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Calibration Standard and Fixture Assembly Figure 5
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Shaft Support Stand Figure 6
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Example of a Strip Chart Recording Figure 7
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-12-250-052 C. Method B - Manual Eddy Current Inspection Method. (1) Equipment. The instrumentation/tooling listed in this section does not include all of the equipment necessary to perform this inspection, but does include all items for which substitution cannot be made without prior written approval from Honeywell. (a) One of the following eddy current instruments are required. Nortec Model NDT 19 Series Eddyscope. Nortec Model NDT 16 Eddyscope. Nortec Model NDT 25L Eddyscope. Rohmann Elotest B1 SDM Eddyscope with probe socket B1-N0B3H or B1AN02. (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) (o) (p) Gould 220 strip chart recorder or approved equivalent recording system. Appropriate cables and connectors. Required equipment, tooling, and accessories. Oakley Die and Mold hand held scanning fixtures. Use P/N 4459-1 for bore ID and 4459-2 for the bore face. Refer to Figure 10, Page 29. Stavely eddy current probe P/N SGE-603, or equivalent. Spacer for P/N SGE-603 eddy current probe. Refer to Figure 11, Page 30. Parkway Products eddy current calibration standard holder P/N GE055-0011. Refer to Figure 11, Page 30. Eddy current calibration standard P/N 4013316-178. Refer to Figure 5, Page 16. Kapton or Teflon tape - maximum thickness 0.0035 inch (0.089mm) X 0.25 inch (6.35mm). Allen Wrench Set 6 inch scale Scotch Brite pads, No. 7447 or equivalent. Action Marker, Q404 or equivalent. Razor Blades, single edge or equivalent. Custom Tool turntable with variable speed motor P/N CT-9891, or equivalent. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. (2) Pre-inspection Part Preparation.
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STANDARD PRACTICES MANUAL AS907-1-1A (a) (b) Clean the inspection area with Scotch Brite and approved solvents. Refer to Figure 9, Page 28. Visually examine the inspection area under bright white light. The area shall be clean and free of any foreign material or marking which would interfere with the eddy current inspection process. NOTE: Any surface irregularities (i.e., nicks, scratches) that will obviously cause eddy current signals should be blended or polished in accordance with the appropriate procedures prior to inspection. (c) Prior to the inspection, locate the serial number on the part and mark this location on the aft side of the part with the marker. This will be the 12:00 oclock position, aft looking forward.
(3)
Calibration. (a) Connect the equipment and allow it to warm up in accordance with the manufacturers specifications or for a minimum of 10 minutes. NOTE: It is important that the cables from the eddy current instrument be connected to the strip chart recorder correctly. Ensure that the vertical output channel from the instrument is connected to channel 1 (the left channel) on the chart recorder. The horizontal output channel from the instrument shall be connected to channel 2 (the right channel) on the chart recorder. (b) Eddy Current probe wear face: 1 Apply Kapton or Teflon tape to completely cover the coil face and sides. Apply the tape tightly and smoothly so that there are no wrinkles and the tape edges adhere to the probe tip.
(c) (d) (e)
Insert the eddy current probe/holder assembly into the bore ID inspection fixture. Refer to Figure 10, Page 29. Refer to table 2, Page 21 for the initial instrument control settings. For inspections to be conducted using an Elotest B1, set up the Elotest B1 as follows: 1 Determine the maximum possible preamplifier gain by increasing the preamplifier gain until the "PREAMP OVERLOAD" indication appears. NOTE: To minimize instrument produced noise, the preamplifier gain should be increased to the maximum possible value without producing a preamplifier overload condition. 2 Reduce the preamplifier gain just enough to eliminate the overload indication.
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STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: DO NOT PRESS THE COMPENSATION BUTTON AFTER SWITCHING BACK TO THE LOW-PASS FILTER. 3 To operate at higher preamplifier gain levels, tune the impedance bridge circuitry. Set the filter to 100 Hz high-pass and press the compensation (null) button (with the probe in air). Change the filter back to 100 Hz low-pass. Place the probe on a test piece or calibration standard. Adjust the two small potentiometers on the adapter to move the dot as close as possible to the null point on the display. NOTE: If the dot position function is set to 0/0 then the null point will be at the center of the display. 6 If necessary, reduce the gain to bring the dot on screen so that this adjustment may be made. NOTE: With proper bridge adjustment it is possible to operate at high preamplifier gain settings. This adjustment may be different for each probe. After completing this adjustment, the compensation button can be used as needed to null the instrument. (f) Place the calibration standard into the holder. Place the calibration standard holder onto the turntable. NOTE: Verify that the top surface of the calibration standard is flush with the holder. Ensure that the transition between the standard and the holder is level and will not cause damage to the eddy current probe. Table 2. Initial Instrument Control Settings PARAMETER NORTEC NDT-19 EDDYSCOPE: POWER LOCK TAPE IN DISPLAY SWEEP MEMORY 2 PROGRAM ALARM LATCH FREQUENCY (KZ) ANGLE FILTER - LOW PASS (HZ) ON OFF OFF FREQUENCY 1 OFF OFF OFF OFF OFF 2000 (2 MHz) 0 100
4 5
SETTING
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Table 2. Initial Instrument Control Settings (Cont) PARAMETER FILTER - HIGH PASS (HZ) ERASE GAIN - VERTICAL GAIN - HORIZONTAL POSITION - VERTICAL POSITION - HORIZONTAL SPECIAL FUNCTION - 2 PROBE DRIVE SPECIAL FUNCTION - 6 BACKLIGHT SPECIAL FUNCTION - 7 ERASE SPECIAL FUNCTIONS 1, 3, 4 & 5 CONTINUOUS NULL NULL C/F (COARSE/FINE) F1/F2 (FREQUENCY) NORTEC NDT-16: Frequency Gain Vertical Display Sensitivity Horizontal Display Sensitivity Rotation Filter Filter Module (Internal Switch) NORTEC NDT-25L: Frequency Gain Angle Filter Vertical Sensitivity Horizontal Sensitivity Position Special Function 5 (SP-5) ROHMANN ELOTEST B1 Frequency Y Axis Gain X Axis Gain
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SETTING 0 AS NEEDED 50 (SEE NOTE) 50 (SEE NOTE) 128 128 HIGH OPTIONAL OPTIONAL NOT USED OFF AS REQUIRED AS REQUIRED FREQUENCY 1 2 MHz 2.00 1 volt / division 1 volt / division 0.00 FILTER OUT - depressed X1 2000 KHz (2 MHz) 40 0 0-HIGH PASS FILTER 1 1 As needed to center dot 100 Hz-LOW PASS FILTER 2.0 MHz 0 dB (SEE NOTE) 0 dB (SEE NOTE)
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Table 2. Initial Instrument Control Settings (Cont) PARAMETER Preamplifier Gain Bandwidth Gain Phase Filter GOULD 220 RECORDER: Vertical fine sensitivity Horizontal fine sensitivity Vertical coarse sensitivity Horizontal coarse sensitivity MM/SEC Full CW Full CW 20 mv/div 50 mv/div IN SETTING 12 dB High Frequency (HF) 50 dB 0 100 Hz LOW PASS
NOTE: The vertical and horizontal gains must, at all times, be set to the same value for a correct calibration and inspection.
(g) (h) (i) (j) (k) (l) (m)
Position the hand held fixture so that the eddy current probe is seated flush on the calibration standard away from the EDM notch. Null the instrument for 5 to 10 seconds or until the spot stabilizes near the center of the screen. Slowly lift the probe off of the standard. Adjust the rotation control until the spot moves from center horizontally to the left. Adjust the high pass filter to 20 Hz and null the eddyscope. Turn on the strip chart recorder to 5mm per second. Turn on the turntable and start rotating at approximately 9 RPM. Rotating the knob, index the probe across the EDM notch, shown in Figure 12, Page 31, to determine where the maximum amplitudes are achieved on both Channel 1 and 2. To accomplish final probe positioning, very slowly start to move across the EDM notch again while alternately watching Channel 1 and 2 on the recorder. The point where Channel 1 is maximum and Channel 2 is maximum is the point at which the instrumentation is to be adjusted for calibration. Examine the recorder tracings on Channels 1 and 2. Alternately adjust the rotation and gain controls to achieve calibration amplitudes of 40 percent (400 mv) full scale in Channel 1 and 35 percent (875 mv) full scale amplitude in Channel 2 (plus or minus 1 percent full scale). Refer to Figure 12, Page 31.
(n)
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STANDARD PRACTICES MANUAL AS907-1-1A Renulling is required after any gain adjustment. Assure that the EDM notch response remains in the upper left quadrant of the Eddyscope CRT. NOTE: For renulling, it is required that the coil be well off the EDM notch and away from any edge of the standard. (o) Perform a scan of the entire EDM notch at 9 RPM and an index rate of 1/4 revolution of the indexing knob to assure the calibration is correct. Record this scan on the strip chart recorder at a speed of 5 mm/sec. Record the calibration information onto the strip chart recording and onto an inspection data sheet. Reference Form 726-1 Figure 8, Page 27.
(p) (4)
Inspection. (a) (b) (c) (d) (e) Complete the pre-inspection part preparation per paragraph C.(2). Calibrate per paragraph C.(3). Inspect all areas per the appropriate scan plans as identified by the specific service bulletin or shop manual procedure for the part being inspected. Evaluate all indications exceeding the criteria stated in paragraph C.(5). Complete a post calibration per paragraph C.(6).
(5)
Evaluation. (a) All indications exceeding the criteria specified in the appropriate service bulletin or applicable manual shall be considered suspect. These indications shall be subjected to evaluation as detailed below. NOTE: The optimum time to perform these evaluations is either at the time the indication is found or immediately after the completion of the specific inspection area. (b) Clean the area of the indication with Scotch Brite or approved solvents and reinspect this area. If the indication is reduced to below the criteria specified in the appropriate service bulletin or applicable manual, it shall be considered acceptable and noted on the strip chart recording. If not, continue to evaluate the indication as detailed below. Carefully examine the area of the indication under bright white light using a 5x or 10x glass. Note any unusual conditions such as discoloration, handling damage, uneven surfaces, raised metal, etc. and record these conditions on the strip chart recording. Reclean and reinspect the area. The following shall apply. 1 If the indication amplitude falls below the criteria specified in the appropriate service bulletin or applicable manual, the area shall be considered acceptable and this shall be noted on the strip chart recording.
(c)
(d)
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STANDARD PRACTICES MANUAL AS907-1-1A 2 If the indication amplitude is reduced, but is still greater than the criteria specified in the appropriate service bulletin or applicable manual, the area may be recleaned and re-evaluated since the indication is most likely due to surface contamination. If the indication amplitude has not reduced below the criteria specified in the appropriate service bulletin or applicable manual, the part shall be rejected and identified for further engineering evaluation and disposition. The indication number, area, amplitude, background noise, location, and comments (visual findings) shall be recorded on Form 726-1, Figure 8, Page 27 of this procedure.
(6)
Post Calibration. (a) (b) (c) (d) Prior to post calibration, inspect the tape on the eddy current probe for excessive wear or other damage. Replace if necessary. After completion of the part inspection, or after intervals not to exceed four hours, a post calibration shall be completed. The post calibration shall be accomplished by performing the steps identified in paragraph C.(3)(0). The post calibration amplitude must be 40 percent, 5 percent (350-450 mV) full scale on Channel No. 1. 1 2 If the post calibration amplitude meets the above criteria, the testing process was acceptable. If the post calibration amplitude is less than the above criteria, repeat the calibration and reinspect all parts inspected since the previous acceptable calibration. If the post calibration amplitude is greater than the above criteria, only reinspect parts previously found to be rejected since the last acceptable calibration.
(7)
Documentation. (a) As a minimum, the following information shall be recorded at the start of each strip chart: Detail model number serial number gain settings phase angle filters
Item o Date o Eddyscope
o Recorder
- model number - serial number

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Item o Probe o Standard o Part
Detail - part umber/manufacturer - serial number - part number - serial number part name part number serial number inspection area
o Inspector (b) o Area o Date (c)
- name & number The following shall be recorded for each scan: o Inspector o Start/stop locations Record all inspection results on Form 726-1, Figure 8, Page 27 of this procedure.
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Form 726-1 Inspection Data Sheet Figure 8
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Bore Inspection Areas Figure 9
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Hand-Held Bore Inspection Fixtures Figure 10
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Eddy Current Probe with Spacer Figure 11
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Scanning of the EDM Notch Figure 12
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ENHANCED VISUAL INSPECTION - ENHANCED VISUAL INSPECTION TASK 70-32-19-220-001 1. Enhanced Visual Inspection SUBTASK 70-32-19-99G-001 A. General. (1) The enhanced visual inspection process is intended for in-process weld inspections. It is a localized process using fluorescent penetrant inspection materials and techniques, limited to small specific areas for inspection. It is not intended as a substitute for final acceptance inspection. It is convenient to use as an in-process inspection during welding. The process may be performed by certified welders with the additional inspection training described below. If visible color dye penetrant has been used on parts which are to be subsequently inspected with fluorescent penetrants, the contamination by the dye may prevent reliable fluorescent penetrant inspection. Any color dye indications evident by white light visual inspection shall be considered valid indications even if not detectable by ultraviolet light. Titanium alloy parts are subject to stress corrosion cracking when residues of halogen containing compounds remain on a part that is subsequently subjected to elevated temperatures typical of welding, heat-treating, or engine operation. These parts must be thoroughly cleaned with nonhalogen compounds after exposure to any halogen containing compound to prevent the cracking and possible failure of parts. Personnel Requirements. (a) (b) Personnel performing this inspection must be certified in accordance with MIL-STD-1595, or locally approved welder certification program. As part of, or in addition to, the above certification process; personnel performing this inspection shall receive classroom instruction on the fluorescent penetrant process to include basic theory, application techniques, and necessary quality control procedures. Additional training shall include proper etching technique and safety procedures. The training shall include practical training in the use of this procedure and personnel must demonstrate proficiency in use and control of inspection equipment, inspection of in-process welds, and evaluation of indications before approval is granted. The classroom and practical training in etching and enhanced visual inspection shall be approved by a Level III inspector certified in fluorescent penetrant inspection in accordance with National Aerospace Standard (NAS 410), American Society of Non Destructive Testing (ASNT-TC-1A), Air Transportation Association (ATA-105) or other locally approved certification programs.
(2)
(3)
(4)
(c)
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ENHANCED VISUAL INSPECTION Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-19-220-001 B. Equipment. (1) Inspection booth, darkroom, or black cloth hood (for remote locations) to prevent excessive admission of white light. NOTE: Excessive white light may interfere with detection of a rejectable size indication. A test part having a known defect can be used to evaluate effectiveness of white light shielding. (2) Ultraviolet lamp to detect fluorescent indications. The ultraviolet (black) light source used for the detection of fluorescent indications shall have an intensity no less than 1000 microwatts per sq. centimeter when measured at 15 in. (381 mm). The black light should be checked on a weekly basis or before use, whichever is less frequent. White light lamp for visual inspection of parts. Time piece for timing operations. Tools for inspection personnel. (a) (b) Three-power and 10-power magnifying lenses. Cotton swabs or small fine hair art brush to apply solvents for evaluating questionable indications.
(3) (4) (5)
SUBTASK 70-32-19-220-002 C. Materials. (1) Penetrant inspection systems. NOTE: Qualified Products listed in QPL-AMS-2644-1 (Qualified Products List) as Level 3, Method D, are considered acceptable alternates to the products listed. Penetrant Inspection System Ardrox Britemor Dubl-Chek Fluro-Chek Met-L-Chek Magnaflux Eishen
Penetrant 985P13 or P7F3 600 or 667 RC65 P41H FP95A ZL27A F6A/1
Dry Powder 9D4A PD3 D99A or D90G DD2A or DD2B D72A or D76B ZP4B or ZP14A F-5D/1
NAWD NQ-1 or 9D1B LD-3 D100 or D104 or D106 NAD or NAD-5B D-70 ZP-9F or SKD-S2 F-4S-(NT)/1 or R1S(NT)/1
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STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: ONLY NON-HALOGENATED SOLVENTS MAY BE USED ON TITANIUM HARDWARE. (2) Solvents Isopropyl alcohol (halogen-free) MEK (halogen-free) Acetone (halogen-free) SUBTASK 70-32-19-220-003 D. Procedure. (1) Parts must be cleaned of all traces of oil, grease, carbon, rust scale prior to penetrant application. Use one of the approved solvents to pre-clean the surface. Allow time for solvent to evaporate. Apply penetrant oil with soft-bristle brush, cotton swab or spray application. Allow a minimum of 15 minutes for penetration. Solvents Consumable Code C04-035 C04-001 C04-003
(2)
CAUTION: INDICATIONS OF DEFECTS CAN BE LOST BY USE OF EXCESSIVE SOLVENT. (3) (4) Wipe off excess penetrant with a clean cloth using a solvent. Apply either dry powder or NAWD as a fine thin coating at ambient temperature to a dry surface. Allow a minimum of 10 minutes for developer to absorb penetrant before inspecting part. Evaluate any indication to the required in-process weld inspection standards.
(5)
CAUTION: TITANIUM ALLOY PARTS ARE SUBJECT TO STRESS CORROSION CRACKING WHEN RESIDUES OF HALOGEN-CONTAINING COMPOUNDS REMAIN ON A PART THAT IS SUBSEQUENTLY SUBJECTED TO ELEVATED TEMPERATURES TYPICAL OF WELDING, HEAT-TREATING, OR ENGINE OPERATION. THESE PARTS MAY BE THOROUGHLY CLEANED WITH NONHALOGEN COMPOUNDS AFTER EXPOSURE TO ANY HALOGENCONTAINING COMPOUND TO PREVENT THE CRACKING AND POSSIBLE FAILURE OF PARTS. (6) Remove all residues by spraying, wiping, or soaking with approved solvents.
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THERMOGRAPHIC INSPECTION - THERMOGRAPHIC INSPECTION PROCEDURE TASK 70-32-20-220-001 1. Thermographic Inspection Procedure SUBTASK 70-32-20-99G-001 A. General. (1) The thermographic inspection process is a non-destructive method of detecting delaminations in composite structures and disbonds in composite, bonded metal, or hybrid parts. The thermographic process uses the fact that all objects emit infrared radiation in proportion to their surface temperature. Thermography is the technique of measuring the emitted radiation and displaying the information as a visual image. To detect a delamination or disbond the part surface is heated. The reduced thermal conductivity in the defect area makes the part stay hotter in the defect area. This difference in temperature is detected with an infra-red camera which provides a fast, non-contact method of viewing the different amounts of thermal radiation in the form of images which show the hot and cold areas in different colors or shades of gray. The images can be analyzed to determine the defect area. Personnel Requirements. (a) Personnel performing this inspection must be certified in accordance with NAS 410, American Society of Non Destructive Testing (ASNT-TC-1A), Air Transport Association Specification No. 105 (ATA 105), or locally approved certification program. Personnel performing this inspection should receive practical training in the use of this procedure and must demonstrate proficiency in the use and control of inspection equipment, inspection of hardware, and evaluation of indications before the authority to accept and reject hardware is delegated. Any training which may be provided by Honeywell for a technique requiring the performance of this inspection method does not imply that the personnel who receive that training have met the requirements for inspector certification in accordance with NAS 410, ASNT-TC-1A or ATA 105.
(2)
(3)
(4)
(b)
(c)
(5)
The materials referenced in this procedure may be used anytime an inspection per TASK 70-32-20-220-001, Thermographic Inspection Procedure, is specified in a process document. Surfaces to be inspected shall be clean, dry, and free of oil, grease, soils, and loose paint flakes, which may cause variations in the thermal pattern when the part is heated.
(6)
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STANDARD PRACTICES MANUAL AS907-1-1A (7) The area where the inspection is to be performed shall be designed to minimize external sources of heat, for example: (a) (b) (c) Direct sunlight. Heat producing light sources such as lamps with incandescent bulbs. Air currents, for example from heating or ventilation ducts, that could cause local temperature changes to the part.
SUBTASK 70-32-20-220-001 B. Equipment. (1) (2) (3) (4) (5) (6) Infrared scanner, Inframetrics Company Model 600, 740, or 760 to provide digitized thermal images for viewing and recording. Image recording device (VCR or equivalent) and video tape to record the thermographic images from the scanner. Television monitor to view the images stored with the VCR. Computer image processor (optional). Test Identification Board to identify the test to the camera before recording the scan. Heat gun 7508F or 10008F - 1500 watt (3998C or 5388C - 1500 watt), or equivalent heat source, with a heat diffuser nozzle or equivalent that will provide uniform heat to the part. Erasable silver pencil C05-003 or equivalent. A part of similar construction with known defects is required as a calibration standard. The defect sizes should range from smaller to larger than the allowable defect size for each defect type in each of the areas where inspection is required by the process document.
(7) (8)
SUBTASK 70-32-20-220-002 C. Procedure. (1) Set up the part. (a) Put the parts to be thermographically inspected in an inspection area as described in Step A.(1)(g).
CAUTION: USE CARE WHEN HANDLING PARTS DURING PREPARATION FOR THE INSPECTION. THIS IS TO PREVENT DAMAGE TO THE PART. (b) Prior to testing, look at the surface to be inspected for any debris or contamination. If contamination is found, clean the part. Refer to Composite Cleaning Method 3 (Hot or Cold Water Hand Wash Cleaning) in TASK 70-4601-350-030, Masking and Cleaning of Epoxy and Polyester Matrix Thermosetting Composite Materials.
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STANDARD PRACTICES MANUAL AS907-1-1A (c) Look at the illustrations of the part in the referencing process document and in the inspection section of the applicable manual. Make note of variations in skin thickness, core density, and the presence of metal or composite parts. Put the part to be inspected such that the surface to be inspected is approximately at right angles to the line of site of the camera, if an angled view is necessary. If necessary, use the calibration standard to make sure the technique is effective at the angle that is required.
(d)
(2)
Set-up the thermographic equipment. (a) Adjust the distance between the part being tested and the IR scanner. The required resolution and field of view will determine the distance. The maximum distance used for inspection shall be no greater than the maximum distance at which the calibration standard is shown to be effectively tested. Make sure the video tape is ready for recording. Write the part information and tape location (VCR counter information) on the inspection form. Refer to Figure 1, Page 6.
(b)
(3)
Inspect the part. (a) Write the date, specimen location, part number, serial number, and operator name on the inspection form, refer to Figure 1, Page 6, and verbally on the video tape (when applicable). Put the calibration standard at the distance and orientation for the required test configuration. NOTE: When multiple parts are to be tested, the calibration standard set-up procedures can be performed at the beginning of the inspection and before every ninth part. (c) Set the IR scanner temperature span to 188F (108C). Set color to black and white. Do a preliminary focus on the calibration standard and make sure that the camera is correctly positioned for the field of view required. Focus the infrared scanner on the calibration standard. Start to record the thermal images of the calibration standard. Apply uniform heat to the calibration standard. 1 Hold the heat gun with the diffuser approximately 2 inches (50 mm) from the calibration standard and move it horizontally with a constant sweeping motion. Move the heat gun at a constant speed. Do not change direction or stop the heat gun within the field of view. Keep the distance between the heat gun and surface as constant as possible. Follow the contour of the part.
(b)
(d) (e) (f)
2 3
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A 4 Make sure that the part temperature does not exceed 1108F (438C). Avoid making hot or cold spots which may be misinterpreted as subsurface defects.
(g)
When the section of the part has been completely heated, remove the heat source and adjust the temperature span and center temperature scanner controls to obtain an interpretable picture on the monitor. Once an accurate, legible picture has been obtained, save the image to VCR tape. Compare the size and type of defects detectable with the known defects on the calibration standard. Make adjustments until all the required defect sizes can be found. Mark the position of the part. Remove the calibration standard and put the part to be inspected in the marked position. Point the infrared scanner toward the area of the part to be inspected. Start to record the thermal images of the part. Apply uniform heat to the part. 1 Hold the heat gun with the diffuser approximately 2 inches (50 mm) from the standard and move it horizontally with a constant sweeping motion. Move the heat gun at a constant speed. Do not change directions or stop the heat gun within the field of view. Keep the distance between the heat gun and surface as constant as possible. Follow the contour of the part. Make sure that the part temperature does not exceed 1108F (438C). Avoid making hot or cold spots which may be misinterpreted as subsurface defects. Where possible, heat the required section to be inspected and include an extra 4-6 inch (100-150 mm) past the required section.
(h) (i)
(j) (k) (l) (m) (n)
2 3 4
5 (o) (p)
Once an accurate, legible picture has been obtained, save the image to VCR tape. Mark any defects. 1 2 Use the erasable silver pencil C05-003 to outline any indications of defects noted in the thermographic image. Use the monitor to assist in properly identifying and marking the indications of the defect. A defect will be an area that is visually lighter
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A or darker than surrounding areas (which should be generally homogeneous) as seen on the monitor. NOTE: Make sure that the defect is not surface debris, an emittance variation, a reflection, or an acceptable variation in the structure of the part, such as core splice, repair, or inserts of other materials. (q) (r) If defects are found, repeat Steps C.(3)(l) through (p) after the surface has cooled until the defect area has been fully defined. When the first section has been completed, move the infrared scanner to the next section. Repeat Steps C.(3)(l) through (p) overlapping the heated area approximately 2-3 inches (50-75 mm) over the previous section until the part inspection requirements have been completed.
(4)
Document the defects. (a) Document the size and location of all defects detected using the inspection form. Refer to Figure 1, Page 6.
EFFECTIVITY: ALL
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Thermographic Inspection Video Tape Log Figure 1
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-20-220-003 D. Acceptance Criteria. (1) The defects shall be compared to the acceptance criteria defined in the process document.
EFFECTIVITY: ALL
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EFFECTIVITY: ALL
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ULTRASONIC THICKNESS INSPECTION - ULTRASONIC THICKNESS INSPECTION OF ENGINE HARDWARE FOR THIN WALL MATERIAL TASK 70-32-21-270-001 1. Ultrasonic Thickness Inspection of Engine Hardware for Thin Wall Material SUBTASK 70-32-21-99G-001 A. General. (1) This document describes the equipment, technique, and procedure used for conducting an ultrasonic thickness inspection of engine hardware for thin wall material. An Addendum to this procedure or applicable manaul is required for detailed information specific to hardware being inspected. This document describes the general procedure and equipment approved for the performance of this inspection. Specific cases where the procedure/equipment described herein cannot be applied in their total content, specific exceptions shall be obtained in writing from Honeywell.
(2)
SUBTASK 70-32-21-270-001 B. Applicable Documents. (1) (2) Appropriate equipment instruction manuals provided by the manufacturer. Appropriate Addendum or applicable manual for the hardware being inspected.
SUBTASK 70-32-21-270-002 C. Personnel Requirements. (1) Personnel performing this inspection shall be certified in accordance with one of the following: (a) (b) (c) (d) (e) (2) National Aerospace Standard 410 (NAS 410), which replaces MIL-STD 410. American Society of Non-Destructive Testing Specification (SNT-TC-1A). Air Transport Association Specification 105 (ATA-105). Comite Sectoriel Aeronautique Cofrend (COSAC). A locally approved certification program.
Personnel performing this inspection shall receive practical training and demonstrate proficiency in calibration, inspection, and evaluation routines before accept/reject authority is delegated.
ULTRASONIC THICKNESS INSPECTION OF ENGINE HARDWARE FOR THIN WALL MATERIAL Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (3) Any training which may be provided regarding the performance of this inspection does not imply that personnel who receive that training have met the requirements of inspector certification in accordance with Steps 3.A and 3.B.
SUBTASK 70-32-21-270-003 D. Equipment Requirements. (1) Ultrasonic Instrument - An ultrasonic instrument shall be provided by the inspection site. Ultrasonic instruments listed in Step F. of this document are approved for use with this procedure. NOTE: The following items shall be specified in the appropriate Addendum, Service Bulletin, or applicable manual. (2) (3) (4) (5) Inspection transducer. Ultrasonic thickness standard. Inspection location template (if required). Coaxial cable, couplant, and couplant dispensing bottle.
SUBTASK 70-32-21-270-004 E. Pre-inspection Part Preparation. (1) (2) The inspection surface shall be clean and free of all foreign materials to assure accurate measurement of wall thickness. Remove any foreign material with approved solvent and wiping cloth.
SUBTASK 70-32-21-270-005 F. Initial Equipment Setup. Table 1. Initial Equipment setup for the Novascope 2000 CONTROL DESCRIPTION FRONT PANEL: Sweep Range Gate Selector Gate Block Gate Guard Alarms Cal Damp Zero Gain (AGC) 0.1 Microseconds 1 inch Block Full Counter Clockwise Full Counter Clockwise Off Mid-Range Full Counter Clockwise Mid-Range Full Counter Clockwise
SETTING
Table 1. Initial Equipment setup for the Novascope 2000 (Cont) CONTROL DESCRIPTION Reject DPM Immersion - Contact/Delay BACK PANEL: Xmtr Pwr RF Sync T-Gate Rep Rate Metal/Plastic DC Bias Low Neg IF (up) First 5000 Metal N/A SETTING Mid-Range Full Clockwise Immersion
NOTE: The transducer used for this inspection shall always be operated with a pulser setting of Mid or Low. Pulser voltage greater than 250 v can affect transducer performance or cause damage to the crystal.
Table 2. Initial Equipment Setup for the Novascope 3000 CONTROL DESCRIPTION FRONT PANEL: Sweep Speed Coarse Fine Readout Range Cal Thickness/Velocity Gate Display IP Control T Control IF Control TAC Control Amplitude Control Sync T-Gate Sweep First IP
SETTING
2 Microseconds Full Clockwise to Cal Position 1 inch Mid-Range Thickness Full Counter Clockwise 9:00 (Nine OClock) Full Counter Clockwise Full Counter Clockwise (Off)
Table 2. Initial Equipment Setup for the Novascope 3000 (Cont) CONTROL DESCRIPTION Delay Adjust Receiver Gain Reject Video dB Atten Damp SIDE PANEL: Pulser T - Gate Start T - Gate Stop Analog Output Offset Contact or Delay/Immersion Alarms Pulse Rate Zero Matl Med. Neg. Neg. N/A Delay/Immersion Off (Full Counter Clockwise) 5000 Mid-Range (5 turns from hard stop) Metal 12:00 (Twelve OClock) 9:00 (Nine OClock) RF 0 Full Counter Clockwise SETTING Full Clockwise
NOTE: The transducer used for this inspection shall always be operated with a pulser setting of Mid or Low. Pulser voltage greater than 250v can affect transducer performance or cause damage to the crystal.
Table 3. Initial Equipment Setup for the Novascope 4000/4500 CONTROL DESCRIPTION FRONT PANEL: Sweep Speed Coarse Fine Position Readout Range Cal Zero Thickness/Velocity Gate Display 1 inch Mid-Range Mid-Range Thickness 2 Microseconds Full Clockwise to Cal Position As Required to Center Trace SETTING
Table 3. Initial Equipment Setup for the Novascope 4000/4500 (Cont) CONTROL DESCRIPTION IP Control IF Control Selector TAC Control Amplitude Control Sync T-Gate Sweep Delay Adjust Receiver Gain Reject Video dB Atten Damp RIGHT SIDE PANEL: Pulser T - Gate Start T - Gate Stop Analog Output Offset Contact or Delay/Immersion Alarms Pulse Rate Matl LEFT SIDE PANEL: Hi Res/Normal Normal NOTE: The transducer used for this inspection shall always be operated with a pulser setting of Mid or Low. Pulser voltage greater than 250 v can affect transducer performance or cause damage to the crystal. Med. Neg. Neg. N/A Delay/Immersion Off (Full Counter Clockwise) 5000 Metal 12:00 (Twelve OClock) 9:00 (Nine OClock) RF 0 Full Counter Clockwise First IP Full Clockwise Full Counter Clockwise (Off) SETTING Full Counter Clockwise Full Counter Clockwise IP
Table 4. Initial Equipment Setup for the Sonic 137 with R04A Firmware or Higher, Gate 02 or 11 CONTROL DESCRIPTION PULSER: Pulse Damping Mode Rep Rate Pulser Max Rep RANGE: Range Delay Vel Sync * Vert Position Units IF Level 0.250 in 1.00 in 0.250 in/microsecond IP 0.0 In. 80% 33 ns 50 Pulse Echo 4000 Hz 150 v 4000 Hz GATE: Gate 1 Horn Gate 2 Level Posn Width Horn Off Off + or 40% 1.00 0.200 Off SETTING CONTROL DESCRIPTION GAIN/RECEIVER: Gain Display Freq. Reject 56 dB Half + 15 MHz Off SETTING
* Due to software variations between instruments, if the initial pulse (IP) does not work, use the interface (IF). Alm Dwell Alm Filter BEA Sync 2 Gate I - Level Holdoff THICK N/A N/A 0.0 dB (off) Interface 40% 1.6 NOTE: In the Thickness menus, Vel and Offset will automatically adjust during calibration. On 1 or Auto High Off (CCW) N/A N/A Off N/A N/A
T-Gauge T-Range Calmode Blocking Gate Vel Offset Alarm Mode High Tol Lo Tol
Table 4. Initial Equipment Setup for the Sonic 137 with R04A Firmware or Higher, Gate 02 or 11 (Cont) CONTROL DESCRIPTION Lo Res ANGLE BEAM Angle Beam Angle Show Thick On N/A Sound N/A SETTING Off DAC Dac Off CONTROL DESCRIPTION SETTING
NOTE: To check the firmware and gate installed, hold the setup key while turning on the instrument and the information will be displayed. NOTE: With the instrument turned off, press and hold in the RANGE key while turning the instrument on. This resets the instrument to the factory default settings and prevents hidden functions within the menus from interfering with the setup. NOTE: Resetting the instrument will not change data, instrument settings, or programs stored in the instrument memory.
Table 5. Initial Equipment Setup for the Sonic 137 and 138 with R03A Firmware or Lower, Gate 00 CONTROL DESCRIPTION PULSER: Pulse Damping Mode Rep Rate Pulser Max Rep RANGE: Range Delay Vel Sync Vert Position Units IF Level 0.250 1.00 0.250 in/microsecond IP 0.0 In. 80%
SETTING 33 ns 50 Pulse Echo 4000 Hz 150 v 4000 Hz
CONTROL DESCRIPTION GAIN/RECEIVER: Gain Display Freq. Reject
SETTING 56 dB Half + 15 MHz Off
GATE: Gate 1 Horn Gate 2 Off Off Off
Table 5. Initial Equipment Setup for the Sonic 137 and 138 with R03A Firmware or Lower, Gate 00 (Cont) CONTROL DESCRIPTION THICK: SETTING CONTROL DESCRIPTION SETTING
NOTE: Note: In the Thickness menus, Vel and Offset will automatically adjust during calibration. 40% 1.00 0.200 1 Off 1.000 0.500 Off DAC: Off Dac Off
Level Posn Width T-Range Alarm Mode High Tol Lo Tol Lo Res ANGLE BEAM: Angle Beam
NOTE: With the instrument turned off, press and hold in the RANGE key while turning the instrument on. This resets the instrument to factory default settings and prevents hidden functions within the menus from interfering with the setup. NOTE: Resetting the instrument will not change data, instrument settings, or programs stored in the instrument memory. NOTE: Pulser voltage greater than 250 v can affect transducer performance or cause damage to the crystal.
Table 6. Initial Setup for the Sonic 138 with RO4A Firmware or Higher, Gate 00 or 13 CONTROL DESCRIPTION PULSER: Pulse Damping Mode Rep Rate Pulser Max Rep RANGE: 33 nanoseconds 50 Pulse Echo 4000 Hz 150 v 4000 Hz GATE:
SETTING
CONTROL DESCRIPTION GAIN/RECEIVER: Gain Display Freq. Reject
SETTING 56 dB Half + 15 MHz Off
Table 6. Initial Setup for the Sonic 138 with RO4A Firmware or Higher, Gate 00 or 13 (Cont) CONTROL DESCRIPTION Range Delay Vel Sync * Vert Position Units IF Level SETTING 0.250 in 1.00 in 0.250 in/microsecond IP 0.0 In. 80% CONTROL DESCRIPTION Gate 1 Horn Gate 2 Level Posn Width Horn SETTING Off Off + or 40% 0.00 0.200 Off
* Due to software variations between instruments, if the initial pulse (IP) does not work, use the interface (IF). Alm Dwell Alm Filter BEA Sync 2 Gate I - Level Holdoff THICK N/A N/A 0.0 dB (off) Interface 40% 1.6 NOTE: In the Thickness menus, Vel and Offset will automatically adjust during calibration. On 1 or Auto High Off (CCW) N/A N/A Off N/A N/A Off DAC On N/A Sound N/A Dac Off
T-Gauge T-Range Calmode Blocking Gate Vel Offset Alarm Mode High Tol Lo Tol Lo Res ANGLE BEAM Angle Beam Angle Show Thick
Table 6. Initial Setup for the Sonic 138 with RO4A Firmware or Higher, Gate 00 or 13 (Cont) CONTROL DESCRIPTION SETTING CONTROL DESCRIPTION SETTING
NOTE: To check the firmware and gate installed, hold the setup key while turning on the instrument and the information will be displayed. NOTE: With the instrument turned off, press and hold in the RANGE key while turning the instrument on. This resets the instrument to the factory default settings and prevents hidden functions within the menus from interfering with the setup. NOTE: Resetting the instrument will not change data, instrument settings, or programs stored in the instrument memory.
Table 7. Initial Setup for the SONIC 1000HR CONTROL DESCRIPTION PULSER: Gain Pulse Damping Mode Voltage RANGE: Range Delay Vel Max Rep SPECIAL: Knob Res. Grat 4 digits 10 x 10 0.250 in 1.20 in 0.2500 in/microsecond 3450 Hz GATE 1: Gate 1 Posn Width Level + 1.250 0.100 40% 50 dB 35 nanoseconds 50 Single 150 v RECEIVER: dB Diff Display Freq. Reject THICK: T-Gauge Trigger T-Vel A IP-1 Edge N/A N/A Half + 15 MHz 0% SETTING CONTROL DESCRIPTION SETTING
NOTE: Pulser voltage greater than 250 v can affect transducer performance or cause damage to the crystal. NOTE: The pulse setting, in the pulser menu, changes to default settings every time the frequency setting is changed. 33 ns is the default setting for 15MHz.
Table 8. Initial Setup for the Krautkramer-Branson USD 15S and USD 15S/AF CONTROL DESCRIPTION BASIC: Gain Range MTL Vel D-Delay P-Delay PULSER: Damping Ascan Power PRF-Mod PRF-Val RECEIV:. Frequ Reject Rectif Dual AMPLITUDE: Fine dB Lo-Noise Pul-Amp Pul-Wid GATES: Gate-Sel A-Start A-Width A-Ampli DIALOG: English UNIT: Inch A-NOISE: Off Gate-A 0.050 0.100 40% GATE-SEL: Gate-A A-OUT: Amplit A-LOGIC: Pos
SETTING 53 dB 0.250 in 200 in/ms 0.000 in 0.00 microseconds
CONTROL DESCRIPTION MEAS: A-TOF A-AMP MEAS-VA
SETTING Peak % S-A
KEYS: 50 ohms (33 ohms 15S) Normal (15S/AF only) 220 pF (15S only) Auto Off 4000 Hz 15 MHz 0% Pos H-W Off (USD 15S/AF only) 0.00 dB Off 150 30 ns Magnify Trigger Copy Freeze Gate-A Init pul N/A N/A
Table 8. Initial Setup for the Krautkramer-Branson USD 15S and USD 15S/AF (Cont) CONTROL DESCRIPTION A-O-AMP: 0.0 v A-O-TOF: 0.0 v SETTING CONTROL DESCRIPTION A-HORN: Off A-ALARM: Off SETTING
Table 9. Initial Setup for the Krautkramer-Branson USN60 CONTROL DESCRIPTION GAIN: Basic RANGE: Range Probe Delay Velocity Display Delay CONFIG: Material Display Start Ascan Ascan Enhance PLSRCVR: PULSER: Energy Damping PRF Mode PRF Value RECEIVER: Frequency Rectify Dual Reject GAIN: 10 MHz Pos Halfwave Off 0% Low 50 OHM Auto High (Adjusts automatically) Custom IP Hollow Optional GATES: POSITION: Gate Select Gate Start Gate Width Gate Threshold GATE MODE: Gate Select Detection Start Mode Magnify Gate ALARMS:
SETTING 75.0 dB
CONTROL DESCRIPTION
SETTING
DISPLAY: 0.140 in 0.000 in/microsecond 0.2320 in/microsecond 0.000 in RESULTS: Reading 1 Reading 2 Reading 3 Reading 4 REGIONAL: OPTIONS:
Optional Optional Optional
Off Off Off Off
Gate A 0.020 in 0.140 in 40%
Gate A Peak IP Gate A
Table 9. Initial Setup for the Krautkramer-Branson USN60 (Cont) CONTROL DESCRIPTION User Gain dB Ref Amplitude dB Step SETTING 10.0 dB (Default) Off % Screen HT 0.01 dB CONTROL DESCRIPTION Gate Select Logic SETTING Gate A Positive
SUBTASK 70-32-21-270-006 G. Equipment Calibration. (1) (2) (3) (4) Turn on the instrument and allow it to warm up according to the manufacturers recommendation. Remove the transducer delay line, apply a drop of mineral oil to the crystal, and replace the delay line. Connect the BNC cable to both the transducer and the instrument. Wipe the delay line tip so that it is free of couplant. Place a drop of couplant on each step of the thickness calibration standard. NOTE: The initial settings for the instruments listed in Subtask 70-32-21-270-005, Initial Equipment Set Up are to be used as a general guideline for materials in the 0.020 inch to 0.100 inch range of thickness. When inspecting materials of greater wall thickness, adjustments to the instrument Range and Gates will be necessary. (5) For the NOVASCOPE 2000 set the instrument controls according to Table 1, Page 2 in Subtask 70-32-21-270-005, Initial Equipment Setup. (a) Adjust the FOCUS and INTENSITY as required. NOTE: During setup, calibration, and inspection, the transducer position must at all times remain normal to the surface being measured. (b) Seat the transducer on the thickest step of the calibration standard (refer to Figure 1, Page 25).
CAUTION: THIS IS A CRITICAL STEP. IT IS IMPORTANT TO MAXIMIZE THE DISTANCE BETWEEN THE LAST CYCLE OF THE FIRST INTERFACE ECHO AND THE FIRST BACK SURFACE ECHO, WHILE KEEPING THE FIRST INTERFACE SIGNAL UNDISTORTED. THE PROPER TRANSDUCER DAMP CONTROL SETTING USUALLY OCCURS WITHIN THE FIRST 25 DEGREES FROM THE FULL CCW POSITION. (c) Rotate the DAMP control to maximize the distance between the first interface and the back wall reflection (refer to Figure 2, Page 26).
STANDARD PRACTICES MANUAL AS907-1-1A (d) Seat the transducer on the thinnest step of the calibration block. Rotate the BLOCK control clockwise to position the training edge of the gate 2 minor divisions to the left of the last half cycle of the first interface signal (refer to Figure 3, Page 27). Set the GATE SELECTOR control to the T (thickness). Seat the transducer on the thickest step of the calibration standard. Adjust the RECEIVER REJECT CONTROL to minimize unwanted baseline signals between the first interface echo and the first back wall echo. Adjust the REJECT so the gate is not signaling on the baseline noise. NOTE: Observe the first interface and the first back wall signals. These signals must be repeated to ensure that the probe is perpendicular to the surface of the thickness step. (h) Seat the transducer in the center of the thinnest step of the calibration standard. Adjust the ZERO control so that the LED readout displays the corresponding thickness. NOTE: It may be necessary to adjust the range potentiometer on the bottom of the Novascope 2000 if the reading on the thinnest step cannot be obtained. Contact the vendor if this adjustment is necessary. (i) (j) Seat the transducer in the center of the thickest step and adjust the CAL controls so that the LED readout displays the corresponding thickness. Repeat Steps G.(5)(h) and G.(5)(i) until the thickness readings on the LED readout are within 0.001 inches of the indicated thicknesses for the thinnest and the thickest steps.
(e) (f) (g)
(6)
For the NOVASCOPE 3000, 4000 and 4500, set the instrument control settings according to Table 2, Page 3 or Table 3, Page 4 (depending on the instrument being used) in Subtask 70-32-21-270-005Initial Equipment Setup. (a) (b) (c) Adjust the FOCUS and INTENSITY as required. Adjust the GAIN so that the largest signal is almost saturated. Displayed on the top trace of the CRT will be several signals. The signal to the left is the initial pulse signal. The remaining signal(s) are the first, second, etc. interface signals (refer to Figure 4, Page 28). NOTE: To verify which signal is the first interface or tip signal, touch the transducer delay tip with your finger and observe which signals are dampened. The first signal dampened is the first interface signal. (d) Using the gate display IP control, adjust the trailing edge of the gate to the left edge of the first interface reflection of the delay line tip first interface reflection of the delay line tip (refer to Figure 5, Page 29). Because the gate signal is used only as a visual reference in this step, placement of the gate signal is not critical.
STANDARD PRACTICES MANUAL AS907-1-1A (e) (f) Adjust the coarse sweep speed to 0.01 microseconds. Set the sync sweep control to delay, and using the Delay Adj. Control, position the leading edge of the first interface reflection to the third major screen division on the CRT. When the first interface signal is displayed on the top trace of the CRT, it will be accompanied by the gate signal on the lower trace of the CRT display (refer to Figure 6, Page 30). Place the receiver video switch to the negative (center) position. Using the gate display IP control, Position the gate at the second major screen division (refer to Figure 7, Page 31). Seat the transducer on the thickest step of the calibration standard in the center, perpendicular to the surface. The transducer is perpendicular to the surface when the back wall reflection is maximized. NOTE: During setup, calibration, and inspection, the transducer position must at all times remain normal to the surface being measured. (j) Adjust the receiver gain control to the AGC position. NOTE: THIS IS A CRITICAL STEP. IT IS IMPORTANT TO MAXIMIZE THE DISTANCE BETWEEN THE LAST CYCLE OF THE FIRST INTERFACE ECHO AND THE FIRST BACK SURFACE ECHO. THE PROPER TRANSDUCER DAMP CONTROL SETTING USUALLY OCCURS WITHIN THE FIRST 25 DEGREES OF THE TRANSDUCER DAMP CONTROL FROM THE FULL CCW POSITION. (k) Carefully adjust the transducer damp control to maximize and flatten out the signal between the end of the first interface reflection and the first back surface echo (refer to Figure 8, Page 32) if the first damping has been used. Adjust the gate display selector to the IF position. Seat the transducer on the thinnest step of the calibration standard. Rotate the IF control CCW and position the gate one minor screen division to the left of the leading edge of the first back wall reflection (refer to Figure 9, Page 33). NOTE: If the gate is set too close to the first interface signal, it will lead to false signals. If the gate is set too far from the first interface signal, the Novascope will not be able to resolve thin walled sections. (n) (o) Set the gate display selector to the T (thickness) position. With the transducer in the center of the thickest step on the calibration standard, adjust the receiver reject control to minimize unwanted baseline signals between the first interface echo and the first back wall echo. Adjust
(g) (h) (i)
(l) (m)
STANDARD PRACTICES MANUAL AS907-1-1A the reject for the proper display. Check the display while on the thinnest step of the standard and repeat this step if necessary. NOTE: Observe the first interface signal. This signal must be repeated to ensure that the probe is perpendicular to the surface of the thickness step. (p) Seat the transducer in the center of the thinnest step of the calibration standard. Adjust the Zero Control so that the LED readout displays the corresponding thickness. Seat the transducer in the center of the thickest step and adjust the CAL Control so that the LED readout displays the corresponding thickness. Repeat Steps G.(6)(p) and G.(6)(q) until the thickness readings on the LED readout are within 0.001 inches of the indicated thicknesses for the thinnest and the thickest steps of the calibration standard.
(q) (r)
(7)
For the SONIC 137 (RO3A FIRMWARE AND HIGHER, GATE 02 OR 11), set the instrument controls according to Table 4, Page 5 in Subtask 70-32-21-270-005, Initial Equipment Setup. (a) After resetting the instrument, set the controls according to Table 4 in Subtask 70-32-21-270-005, Initial Equipment Setup. NOTE: The pulse setting, in the pulser menu, changes to default settings every time the frequency setting is changed. 33 nanoseconds is the default setting for 15 Mhz. (b) (c) Press the view key to display the initial pulse and entire screen range. Displayed on the CRT will be several signals (refer to Figure 10, Page 34). The first signal from the left is the initial pulse (IP), the second signal is the first interface (IF), and the third signal is the second interface. NOTE: The IF signal can be verified by touching the transducer tip and observing that the IF signal is damped. In order to maintain maximum signal strength, it is important that all measurements be made with the first set of multiples, which will immediately follow the first IF. (d) (e) (f) (g) Press the RANGE key, select DELAY, and adjust so that the first IF is centered in the intensified area of the CRT (refer to Figure 10, Page 34). Press the VIEW key to expand the intensified area of the horizontal baseline. The first IF will be displayed. Select DELAY and adjust it so that the leading edge of the IF is at 2.0 on the horizontal baseline. Make note of the delay setting. Press the GATE key, select POSN, and adjust to the same setting as in Step G.(7)(f).
STANDARD PRACTICES MANUAL AS907-1-1A (h) Place couplant on the thickest step of the calibration standard, and position the transducer in the center of the step. NOTE: During setup, calibration, and inspection, the transducer position must at all times remain normal to the surface of the area being measured. (i) If necessary, adjust the gain (gain receiver key) so that the first multiple is at approximately 100%. Also, if necessary, up to 30% Reject (gain/receiver key) can be used to minimize unwanted signals. Re-select the thickness calibration functions by pressing the THICK key. Seat the transducer on the thinnest step of the calibration standard, select BLOCKING GATE from the THICK menu, and adjust it so that the trailing edge of the blank space is past the ringing of the IF, and just before the signal from the thinnest step (refer to Figure 11, Page 35). Remove the transducer from the calibration standard. Select CAL MODE HIGH, and press the ENTER key. Adjust the smart knob so that the reading on the LCD display corresponds to actual thickness of the thickest step of the calibration standard. Seat the transducer in the center of the thickest step, and when the signals are stabilized, press the ENTER key. Remove the transducer from the calibration standard. CAL MODE LOW will have automatically been selected on the menu. Press the enter key and adjust the smart knob so that the reading on the LCD display corresponds to the actual thickness of the thinnest step of the calibration standard. Seat the transducer in the center of the thinnest step and when the signals are stabilized, press the ENTER key. Check the calibration and repeat this process until both thickness readings are within 0.001 inches of the desired reading. For a more accurate calibration, or if the readings do not repeat to within 0.001 inches, do the following: 1 2 3 (8) Select OFFSET and seat the transducer in the center of the thinnest step. Adjust the smart knob to produce the desired reading. Repeat as required to achieve 0.001 inch repeatability.
(j) (k)
(l) (m) (n) (o) (p) (q)
(r) (s) (t)
For the SONIC 137 and 138 (RO3A FIRMWARE OR LOWER, GATE 00), set the instrument controls according to Table 5, Page 7 in Subtask 70-32-21-270-005, Initial Equipment Setup.
STANDARD PRACTICES MANUAL AS907-1-1A (a) After resetting the instrument, set the controls according to Table 5, Page 7 in Subtask 70-32-21-270-005, Initial Equipment Setup. NOTE: The pulse setting, in the pulser menu, changes to default settings every time the frequency setting is changed. 33 nanoseconds is the default setting for 15 Mhz. (b) (c) Press the view key to display the initial pulse and entire screen range. Displayed on the CRT will be several signals (refer to Figure 10, Page 34). The first signal from the left is the initial pulse (IP), the second signal is the first interface (IF), and the third signal is the second interface. NOTE: The IF signal can be verified by touching the transducer tip and observing that the IF signal is damped. In order to maintain maximum signal strength, it is important that all measurements be made with the first set of multiples, which will immediately follow the first IF. (d) (e) (f) (g) (h) Press the RANGE key, select DELAY, and adjust so that the first IF is centered in the intensified area of the CRT (refer to Figure 10, Page 34). Press the VIEW key to expand the intensified area of the horizontal baseline. The first IF will be displayed. Select DELAY and adjust it so that the leading edge of the IF is at 2.0 on the horizontal baseline. Make note of the delay setting. Press the THICK key, select POSN, and adjust to the same setting as in Step G.(8)(f). Place couplant on the thickest step of the calibration standard, and position the transducer in the center of the step. NOTE: During setup, calibration, and inspection, the transducer position must at all times remain normal to the surface of the area being measured. (i) If necessary, adjust the gain (gain receiver key) so that the first multiple is at approximately 100%. Also, if necessary, up to 30% Reject (gain/receiver key) can be used to minimize unwanted signals. Re-select the thickness calibration functions by pressing the THICK key. Seat the transducer on the thinnest step of the calibration standard, select BLOCKING GATE from the THICK menu, and adjust it so that the trailing edge of the blank space is past the ringing of the IF, and just before the signal from the thinnest step (refer to Figure 11, Page 35). Remove the transducer from the calibration standard. Select CAL MODE HIGH, and press the ENTER key.
(j) (k)
(l) (m)
STANDARD PRACTICES MANUAL AS907-1-1A (n) (o) (p) (q) Adjust the smart knob so that the reading on the LCD display corresponds to actual thickness of the thickest step of the calibration standard. Seat the transducer in the center of the thickest step, and when the signals are stabilized, press the ENTER key. Remove the transducer from the calibration standard. CAL MODE LOW will have automatically been selected on the menu. Press the enter key and adjust the smart knob so that the reading on the LCD display corresponds to the actual thickness of the thinnest step of the calibration standard. Seat the transducer in the center of the thinnest step and when the signals are stabilized, press the ENTER key. Check the calibration and repeat this process until both thickness readings are within 0.001 inches of the desired reading. For a more accurate calibration, or if the readings do not repeat to within 0.001 inches, do the following: 1 2 3 (9) Select OFFSET and seat the transducer in the center of the thinnest step. Adjust the smart knob to produce the desired reading. Repeat as required to achieve 0.001 inch repeatability.
(r) (s) (t)
For the SONIC 138 (RO4A FIRMWARE OR HIGHER, GATE 00 OR 13), set the instrument controls according to Table 6, Page 8 in Subtask 70-32-21-270-005, Initial Equipment Setup. NOTE: To check the firmware and gate installed, hold the setup key while turning on the instrument and the information will be displayed. NOTE: With the instrument turned off, press and hold in the Range key while turning the instrument on. This resets the instrument to factory default settings and prevents hidden functions within the menus from interfering with the setup. Resetting the instrument will not change data, instrument settings, or programs stored in the instrument memory. (a) (b) After resetting the instrument, set the controls according to Table 6, Page 8 in Subtask 70-32-21-270-005, Initial Equipment Setup. Press the view key to display the initial pulse and entire screen range.
STANDARD PRACTICES MANUAL AS907-1-1A (c) Displayed on the CRT will be several signals (refer to Figure 10, Page 34). The first signal from the left is the initial pulse (IP), the second signal is the first interface (IF), and the third signal is the second interface. NOTE: The IF signal can be verified by touching the transducer tip and observing that the IF signal id dampened. In order to maintain maximum signal strength, it is important that all measurements be made with the first set of multiples, which will immediately follow the first. (d) (e) (f) (g) Press the RANGE key, select DELAY, and adjust so that the first IF is centered in the intensified area of the CRT (refer to Figure 10, Page 34). Press the VIEW key to expand the intensified area of the horizontal baseline. The first IF will be displayed. Select DELAY and adjust it so that the leading edge of the IF is at 2.0 on the horizontal baseline. Place couplant on the thickest step of the calibration standard and position the transducer in the center of the step. NOTE: During setup, calibration, and inspection, the transducer position must at all times remain normal to the surface of the area being measured. (h) If necessary, adjust the gain (gain receiver key) so that the first multiple is at approximately 100%. Also, if necessary, up to 30% Reject (gain/receiver key) can be used to minimize unwanted signals. Seat the transducer on the thinnest calibrations step. Press the GATE key, select POSN, and adjust the blocking gate to cross over the first multiple (refer to Figure 11, Page 35). Remove the transducer from the calibration standard. Re-select the thickness calibration function by pressing the THICK key. Assure that the CAL MODE is set on High and press the ENTER key. Adjust the smart knob so that the reading on the LCD display corresponds to the actual thickness of the thickest step of the calibration standard. Re-seat the transducer in the center of the thickest step. Assure the first multiple is crossed from the blocking gate and the signals are maximized. Press the ENTER key. Seat the transducer on the thinnest step of the calibration standard, select BLOCKING GATE from the THICK menu, and adjust it so that the trailing edge of the blank space is past the ringing of the IF, and just before the signal from the thinnest step (refer to Figure 11, Page 35). Remove the transducer from the calibration standard.
(i) (j) (k) (l) (m) (n) (o)
(p)
(q)
STANDARD PRACTICES MANUAL AS907-1-1A (r) CAL MODE LOW will have automatically been selected on the menu. Press the enter key and adjust the smart knob so that the reading in the LCD display corresponds to the actual thickness of the thinnest step of the calibration standard. Seat the transducer in the center of the thinnest step and when the signals are stabilized, press the ENTER key. Check the calibration and repeat this process until both thickness readings are within 0.001 inches of the desired reading. For a more accurate calibration, or if the readings do not repeat to within 0.001 inch, do the following: 1 2 3 Select OFFSET and seat the transducer in the center of the thinnest step. Adjust the smart knob to produce the desired reading. Repeat as required to achieve 0.001 inch repeatability.
(s) (t) (u)
(10) For the SONIC 1000 HR, set the instrument control settings according to Table 7, Page 10 in Subtask 70-32-21-270-005,Initial Equipment Setup. (a) Displayed on the CRT will be one signal from the first interface (refer to Figure 12, Page 36). NOTE: The IF signal can be verified by touching the transducer tip and observing that the IF signal is dampened. In order to maintain maximum signal strength, it is important that all measurements be made with the first set of multiples, which will immediately follow the first IF. (b) Select signal delay by pressing the RANGE MENU and selecting DELAY. Adjust the value until the leading edge of the first interface signal is at 0.0 on the horizontal baseline. Press the RANGE key and adjust the instrument range to 0.100 inches. The signal should remain on the screen. If the signal has moved off screen, adjust the DELAY until it is centered on the CRT. Adjust the DELAY until the leading edge of the first interface signal is at 1.0 on the horizontal baseline (refer to Figure 13, Page 37). Select GATE 1 and set Gate 1 to +. Assure the gate WIDTH is set to 0.100 inch and the gate LEVEL is set at 40%. Adjust the gate POSN until the start position of the gate is one-half division to the RIGHT of the first interface signal. Seat the transducer in the center of the thinnest step of the calibration standard. The first signal to the right of the interface signal is the first back wall echo. Manipulate the transducer until the peak is at its maximum (refer to Figure 13, Page 37).
(c)
(d) (e) (f) (g)
STANDARD PRACTICES MANUAL AS907-1-1A (h) Adjust the instrument GAIN to achieve an 80% signal from the first back wall. NOTE: When you setup, calibrate, and inspect, the transducer position must remain normal to the surface being measured. (i) (j) Press the THICK key. Select THK CAL and press the ENTER key. The upper right display box should read CAL PT 1. Select the MAIN key. With the first back wall echo maximized, press the FREEZE selection button and rotate the knob so the FREEZE selection indicates ON. With the signal frozen on the instrument display, assure that the gate is positioned so that the first back wall echo is completely in the gate. Adjust the gate start position if necessary. Press the THICK key and select THK CAL. Adjust it until the reading on the display corresponds to the actual thickness of the thinnest step of the calibration standard. Press the ENTER key. The upper right display box will read CAL PT 2. Press the MAIN key, select FREEZE, and turn the knob until the FREEZE selection indicates OFF. Seat the transducer in the center of the thickest step. The first signal to the right of the interface signal is the first back wall echo. Manipulate the transducer until the peak is at its maximum (refer to Figure 14, Page 38). Press the FREEZE selection button or rotate the knob so the FREEZE selection indicates ON. Press the THICK key and select THK CAL. Adjust it until the reading on the display corresponds to the actual thickness of the thickest step of the calibration standard. Press the ENTER key and CAL DONE should be displayed in the upper dialogue box. Press the MAIN key, select FREEZE, and turn the knob until the FREEZE selection indicates OFF. Seat the transducer in the center of the thinnest step. Manipulate the transducer until the largest peak after the interface signals is at a maximum. If the upper right display box DOES NOT indicate the desired measurement, repeat from Step G.(10)(i). Seat the transducer in the center of the thickest step. Manipulate the transducer until the largest peak after the interface signals is at a maximum. If the upper right display box DOES NOT indicate the desired measurement, repeat from Step G.(10)(i).
(k)
(l)
(m) (n)
(o) (p)
(q) (r)
(s)
(11) For the USD 15S and USD 15S/AF, set the instrument control settings according to Table 8, Page 11 in Subtask 70-32-21-270-005, Initial Equipment Setup. (a) Only the initial pulse and "Gate A" will be displayed on the instrument display (refer to Figure ).
STANDARD PRACTICES MANUAL AS907-1-1A (b) Using the P-Delay only, move the initial pulse off screen to the left until the first interface signal moves on screen and place its leading edge at 2.0 on the horizontal baseline (refer to Figure 15, Page 39). NOTE: The IF signal can be verified by touching the transducer tip and observing that the IF signal is dampened. In order to maintain maximum signal strength, it is important that all measurements be made with the first set of multiples, which will immediately follow the first IF. (c) (d) Seat the transducer on the thinnest step of the calibration standard. To the right of the first interface will be the first back wall echo and a series of multiples from the back wall. Adjust the instrument gain to achieve an 80% FSH response from the first back wall echo (refer to Figure 16, Page 40). NOTE: If the first back wall echo exceeds 100% FSH, the thickness readings will not be accurate because the machine cannot determine the peak of the signal. Also, increasing or decreasing the gain to measure signals from different thickness will not affect the calibration as long as the peak of the signal is on screen. (e) (f) Adjust the gate start position so that the first back wall echo is in the gate (refer to Figure 16, Page 40). Seat the transducer on the thickest step of the calibration standard. The first back wall echo must also be within the gate. If not, increase the width of the gate to capture the signal. Using the arrow keys on the left side of the horizontal baseline, highlight "Sa" on the measurement line. The measurement will appear as large characters on the upper right corner of the A-Scan display. With the transducer on the thickest step of the calibration standard, adjust the MTL VEL in the basic function menu until the correct thickness is displayed. NOTE: Adjustment of the instrument Range may be required to allow the MTL VEL to be adjusted properly. (i) Move the transducer to the thinnest step of the calibration standard. Adjust the instrument P-Delay in the basic function menu until the correct thickness reading is displayed. NOTE: If either of the signals move out of the gate during the velocity or PDelay adjustment, reposition the gate as needed. (j) Repeat G.(11)(g) and G.(11)(h) until the thinnest and thickest readings are displayed on the instrument readout.
(g)
(h)
(12) For the USN 60, set the instrument control settings according to Table 9, Page 12 in Subtask 70-32-21-270-005Initial Equipment Setup. (a) Only the initial pulse and Gate A will be displayed on the instrument display.
STANDARD PRACTICES MANUAL AS907-1-1A (b) (c) Seat the transducer on the thinnest step of the calibration standard. Using the Probe Delay only, move the initial pulse off screen to the left until the first interface signal moves on the screen and place its leading edge at 0.0 on the horizontal baseline (refer to Figure 17, Page 41). NOTE: The signal from the first interface signal must be positioned to the left of Gate A so the trailing edge does not enter the gate. This may require that the leading edge of the interface signal be positioned off screen. (d) To the right of the first interface signal will be the first back wall echo and a series of multiples from the back wall. Adjust the gain to achieve an 80% FSH response from the first back wall signal. Select "Autocal" from the Home menu. The Gate A start function should be set to correspond to at least the thinnest step of the calibration standard. Select S-REF1 and adjust the setting to correspond to the thickness of the thinnest step of the calibration standard. Select S-REF2 and adjust the setting to correspond to the thickness of the thickest step of the calibration method. With the transducer seated on the thinnest step of the calibration standard, assure that the first back wall signal is within the gate. If not, adjust the Gate A start. Select the Record function. The value should change from "OFF" to "SREF1?". With the probe seated on the thinnest step of the calibration standard and the first back wall properly displayed, press the "Record" function again. The value in the function box should now read "S-REF2?". Seat the transducer on the thickest part of the calibrations standard. Assure that the first back wall signal is within Gate A and select the "Record" function and the value should change from "S-REF2?" to "OFF" (refer to Figure 18, Page 42). The system should be calibrated properly to perform the necessary wall thickness inspection. Verify that the system is properly calibrated by checking the readings displayed from the thinnest and thickest steps of the calibration standard are within 0.001 inch. If not, repeat Steps G.(12)(h) through G.(12)(j).
(e) (f) (g) (h)
(i)
(j)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-21-270-007 H. Hardware Inspection. (1) Perform a system calibration according to Subtask 70-32-21-270-006, Equipment Calibration and record the required information on the appropriate inspection data sheet. If the inspection being performed requires the use of an inspection template, place the inspection template in the correct location. Apply couplant to the inspection surface at the location where the thickness reading is to be taken. Seat the transducer at the appropriate location and seat or manipulate the transducer to obtain peak signals. Repeat this technique until a stable repeatable signal is obtained within a tolerance of 0.001 inch. Repeat Steps H.(4) and H.(5) for each area to be inspected. Document all required thickness readings on the appropriate inspection data sheet. Refer to the appropriate Addendum, Service Bulletin, or applicable manual for specific minimum thickness requirements.
(2) (3) (4) (5) (6) (7) (8)
SUBTASK 70-32-21-270-008 I. Calibration Check. (1) A calibration check shall be performed upon the completion of each inspection performed, whenever any system component or operator is changed or any time the operator suspects a change may have occurred in the system. Using the calibration standard, measure the thinnest and thickest steps of the calibration standard. If the displayed thickness is within 0.001 inch of engraved or known thickness of the calibration standard, the inspection is acceptable. Record the post calibration values on the appropriate inspection data sheet. If the displayed thickness is NOT within 0.001 inch of the engraved or known thickness of the calibration standard; the system must be re-calibrated and all hardware inspected since the initial or last valid calibration check shall be reinspected.
(2)
(3)
SUBTASK 70-32-21-270-009 J. Indication Evaluation. (1) Evaluate any area that produces a thickness reading below the minimum requirements as outlined in the appropriate Addendum, Service Bulletin, or applicable manual for the hardware being inspected.
STANDARD PRACTICES MANUAL AS907-1-1A (2) (3) (4) (5) Perform a calibration check as described in Subtask 70-32-21-270-006, Equipment Calibration. Visually observe the inspection surface for any foreign material and clean the suspect area with approved cleaning material. Repeat the inspection of the suspect area and confirm the reading previously observed. If the reading is confirmed to be below an acceptable level, refer to Subtask 70-3221-270-010, Disposition Documentation and Records.
SUBTASK 70-32-21-270-010 K. Disposition Documentation and Records. (1) Any thickness readings below the minimum requirements as outlined in the appropriated Addendum, Service Bulletin, or applicable manual shall be evaluated as described in Subtask 70-32-21-270-009, Indication Evaluation. For thickness readings below the minimum requirements, after evaluation, the hardware shall be considered reject and unserviceable. For thickness readings above the minimum requirements, the hardware shall be considered serviceable. As a minimum, record the requested information on the inspection data sheet in the appropriate Addendum, Service Bulletin, or applicable manual.
(2) (3) (4)
TEST OF MAGNETIC-PARTICLE - TEST OF MAGNETIC-PARTICLE INSPECTION PROCESS TASK 70-32-80-700-010 1. Test of Magnetic-Particle Inspection Process SUBTASK 70-32-80-99G-010 A. General. (1) (2) To ensure that the inspection process is capable of detecting defects in parts, it is necessary to process test parts having known defects. Process control tests are recommended whenever a new suspension solution is prepared and prior to processing parts. Recommendations for the frequency of the various control test is summarized in Subtask 70-32-80-700-103, Frequency of Process Checks.
SUBTASK 70-32-80-700-101 B. Test Equipment. (1) Test Ring. Make a test ring from tool steel with a Rockwell B hardness between 90 and 95 with the dimensions and subsurface discontinuities shown in Figure 1, Page 2. (2) Test Part. Obtain a test part that is similar in shape, size, material, and hardness of the parts to be inspected. The test part shall have known defects similar to those for which the inspection is being made. Test parts shall be adequately identified. (3) Light Meter capable of measuring both white and ultraviolet light.
EFFECTIVITY: ALL
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TEST OF MAGNETIC-PARTICLE INSPECTION PROCESS Page 1 Dec 01/03
Test Ring with Artificial Discontinuities Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-80-700-102 C. Method of Test. (1) Circular Magnetization Check of Test Ring. (a) Evaluate the process by magnetizing the test ring using a one inch (25.4 mm) diameter central conductor. The amperage to be used and the number of holes to be visible on the outer edge of the ring are as follows: Minimum Number of Holes Indicated 3 5 6
D.C. Ampere 1400 2500 3400
NOTE: If the process does not disclose the number of required indications on the test ring, the process shall be considered out-of-control and no parts shall be processed until the process is brought into control. (b) Perform tests of materials or equipment, as required, to locate cause of outof-control condition. Correct process deficiencies, as necessary, to bring it into control.
(2)
Ultraviolet Black Light Intensity. The ultraviolet black light intensity should be a minimum of 1000 microwatts per sq. centimeter when measured at 15 in. (381 mm).
(3)
Ambient White Light. Because of the potential reduction in inspection sensitivity when excess white light is present in the inspection booth, ambient white light should not exceed 2 footcandles when measured at the inspection surface.
(4)
Known Defect Test Part Check (KDTP). (a) Process the known defect test part using the same method and amperage as used for the parts to be inspected. NOTE: If the process does not disclose the number of required indications on the test part, the process shall be considered out-of-control and no parts shall be processed until the process is brought into control. (b) Perform tests of materials or equipment, as required, to locate cause of outof-control condition. Correct process deficiencies, as necessary, to bring it into control.
(5)
Demagnetize the test samples and clean them thoroughly with solvent. Check to ensure complete removal of all magnetic particles.
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STANDARD PRACTICES MANUAL AS907-1-1A (6) Coat the test ring, and test parts with corrosion protective oil.
SUBTASK 70-32-80-700-103 D. Check Test Ring KDTP Check Black Light Check Frequency of Process Checks. Frequency Daily, during process operation Daily, during process operation Weekly, or when the bulb and or filter are changed Requirement Ref. C.(1) Ref. C.(4) 1000 microwatts cm2 when measured at 15 in. (381 mm) Ambient white light in inspection Booth Weekly Maximum 2 foot-candles at the inspection surface
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TEST OF FLUORESCENT-PENETRANT - TEST OF FLUORESCENT-PENETRANT TASK 70-32-81-700-011 1. Test of Fluorescent-Penetrant SUBTASK 70-32-81-99G-001 A. General. (1) Every time a new container of penetrant is opened for use, a master sample shall be taken from the new container and kept at the work station for periodic comparison tests with the penetrant working bath. A penetrant control test is recommended at periodic intervals and whenever the process is thought to be out-of-control.
(2)
SUBTASK 70-32-81-700-111 B. Test Equipment. (1) Test Part. (a) Test panels. 1 Test panels of cracked chrome plate obtained from: Scientific Control Laboratories, Inc. 3136 S. Kolin Avenue Chicago, Illinois 60623 2 3 4 Type Panel Coarse Medium Scientific Control Laboratories, Inc. 3136 S. Kolin Avenue Chicago, Illinois 60623 Typical Crack Width 0.0003-0.0005 in. (0.008-0.013 mm) 0.00009-0.00013 in. (0.00230.0033 mm) Typical Crack Depth 0.00012-0.0014 in. (0.0030-0.035 mm) 0.00015-0.0010 in. (0.0038-0.025 mm)
NOTE: Test panel size is 3.75 x 2.5 x 0.020 inch (95 x 63 x 0.5 mm).
Test panels equivalent to those specified above may be used after validation tests have been made.
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70-32-81
TEST OF FLUORESCENT-PENETRANT Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (b) Preparation of test panels. 1 2 3 (2) Separate test panels into 2 areas by permanently etching a line approximately 0.25 inch (6.5 mm) wide across the center of panel. Permanently etch the letter A in one area and the letter B in the other area. Store the panels in a sealed container of solvent.
Photograph of test parts taken under ultraviolet light after processing the test part by a known acceptable process.
SUBTASK 70-32-81-700-112 C. Method of Test. (1) Select the proper test panel for the standard practice sensitivity level. Test Panel Coarse Medium
Fluorescent-Penetrant Standard Practice Water-washable penetrants Post-emulsifiable penetrants (2)
Process surface A of test part using the penetrant from the master sample and process surface B using the penetrant from the working bath. Time between application of penetrant to surfaces A and B should be kept as short as possible. Drain the part in a position that will not mix the penetrants. Remove excess penetrant from the test part using master samples of emulsifier/ remover per the fluorescent-penetrant process in use except for the following: (a) (b) For post-emulsification penetrant process, use 15 second emulsifier/remover contact time. For water-washable penetrant process, use 5 second water contact time.
(3)
(4) (5)
Apply fresh master sample developer to both areas of test part. Remove excess developer. Inspect the test part under ultraviolet light and compare it with photographs. (a) (b) If control area A and test area B exhibit approximately the same indications as the photographs, the penetrant is considered satisfactory (in-control). If there is a significant difference between control area A and test area B, relative to the photograph, the penetrant is unsatisfactory (out-of-control).
(6)
Thoroughly clean the test part by vapor degreasing, soaking in solvent, and scrubbing with brush and water. Store test part in a sealed container of solvent.
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-32-81-700-113 D. Corrective Action. (1) Discard out-of-control penetrant and refill the tank with new penetrant.
EFFECTIVITY: ALL
70-32-81
EFFECTIVITY: ALL
70-32-81
TEST OF EMULSIFIER OR REMOVER - TEST OF EMULSIFIER OR REMOVER TASK 70-32-82-700-012 1. Test of Emulsifier or Remover SUBTASK 70-32-82-99G-012 A. General. (1) This test applies to both lipophilic emulsifier and hydrophilic remover working baths. The emulsifier is used as received; the remover is diluted with water to a specific concentration when put into the working tank. The emulsifier and remover are gradually contaminated with penetrant during use. Therefore, they must periodically be compared to a retained standard sample. Every time a new container of emulsifier is opened for use, or a new mixture of remover is prepared, a master sample shall be obtained and kept as a standard sample for comparison test purposes. The emulsifier or remover comparison test is recommended at periodic intervals and whenever the process is thought to be out-of-control (not detecting defects).
(2)
(3)
SUBTASK 70-32-82-700-121 B. Test Equipment. (1) Test Part. (a) (b) (c) (d) (e) Prepare 2 test parts of aluminum alloy, about 3 x 6 inch (75 x 150 mm) area. Blast the parts with aluminum oxide grit (120 or 220-mesh). Degrease them with 1-1-1 trichloroethane, and blot dry with filter paper. Permanently mark the letter X on one part and the letter Y on the other part. Store the parts in a sealed container of solvent.
SUBTASK 70-32-82-700-122 C. Method of Test. (1) (2) Apply fresh master sample penetrant to each part by brushing or dipping. Suspend parts vertically for 10 minutes to drain. Immerse one part in working bath of emulsifier/remover under test and the other part in emulsifier/remover from master sample. Contact time for each shall be 60 seconds. Rinse both parts with water immediately, making sure that each part is identically rinsed.
(3)
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TEST OF EMULSIFIER OR REMOVER Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (4) (5) Dry both parts with clean dry air. Inspect the parts, side-by-side, under ultraviolet light. If there is no significant difference in background fluorescence between parts, the emulsifier/remover working bath is acceptable (in-control). If a significant difference in background fluorescence is noted, the working bath may be contaminated by penetrant. When a significant difference exists, thoroughly clean the test parts and repeat the test, reversing the inspection materials on the test parts. NOTE: When testing hydrophilic remover, the contaminating penetrant may be skimmed off the top of the working tank and the remover retested as above. (7) (8) If both tests indicate the working bath has significantly more background fluorescence than the master sample, the working bath is contaminated. Clean parts thoroughly after use by vapor degreasing, soaking in solvent, and scrubbing with brush and water. Store parts in a closed container of clean solvent.
(6)
SUBTASK 70-32-82-700-123 D. Corrective Action. (1) Discard contaminated emulsifier/remover and refill the tank with new materials.
EFFECTIVITY: ALL
70-32-82
TEST OF EMULSIFIER OR REMOVER Page 2 Dec 01/03
SPECIAL INSPECTIONS - SPECIAL INSPECTION PROCEDURES TASK 70-33-00-999-001 1. Special Inspection Procedures SUBTASK 70-33-00-99G-001 A. General. (1) The special inspection procedures described in this section are of a general nature, and are not intended to take the place of specific applicable manual instructions. When the applicable manuals contain specific directions that differ from those in this publication, the information in the applicable manuals shall be followed. It is presumed that personnel using these inspection procedures are familiar with the terms used, and that they are trained and qualified in the techniques of aircraft parts inspection.
EFFECTIVITY: ALL
70-33-00
SPECIAL INSPECTION PROCEDURES Page 1 Dec 01/03
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SPECIAL INSPECTION PROCEDURES Page 2 Dec 01/03
ANTIFRICTION BEARINGS - ANTIFRICTION BEARING INSPECTION TASK 70-33-01-220-004 1. Antifriction Bearing Inspection SUBTASK 70-33-01-99G-004 A. General. (1) Personnel working with antifriction bearings should be thoroughly experienced and familiar with the special requirements of handling them, as described in TASK 70-14-00-620-003, Handling of Bearings, and of proper cleaning methods ( TASK 7022-01-110-013, Special Cleaning Procedure No. 1 - Cleaning of Bearings). The terminology used in this section is in agreement with that of the Antifriction Bearing Manufacturers Association (AFBMA). The term "functional surface" refers to the entire outer surface of the rolling elements, and the surfaces on the raceways that contact the rolling elements. The corner radius of a roller is a non-functional surface. All other surfaces of the bearing are non-functional surfaces.
(2)
SUBTASK 70-33-01-220-041 B. Types of Inspection. (1) The proper inspection of bearings to determine serviceability requires several different types of checks; visual, touch or "feel", dimensional and hardness. Dimensional and hardness checks, being performed with instruments, do not require interpretation; the other types of checks are conclusive only to the extent that the inspectors experience is a reliable guide. The procedures that follow describe indications to be found in bearings undergoing inspection, and include possible causes of damage.
SUBTASK 70-33-01-220-042 C. Procedure. (1) (2) Inspect bearings in accordance with the following instructions: Visual Inspection. Visually inspect each bearing and its parts for the defects listed below. Visual inspection should be accomplished without the aid of magnification. For interpretation of type of condition only, a glass of 10X magnification may be used. (3) Standard scribers used to evaluate surface discontinuities may be fabricated locally, using AISI-01 or AISI-W1 Grade 4, steel. Tolerance of the polished nose radii should be 0.001 inch (0.03 mm) and scribers should have a Rockwell-C hardness of 55-60. A surface-finish scriber kit especially designed for bearing inspection can be procured from the following:
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70-33-01
ANTIFRICTION BEARING INSPECTION Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A RAE Bearing Service or Carbide Probes, Inc. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. (4) When inspecting bearing surfaces, any defect that cannot be felt with a scriber of designated nose radius is acceptable. No pressure should be exerted on the scriber when checking for defects; the fingers should be used only to guide the scriber. Defects that can be felt on the scriber should be checked for size to the limits stated under the specific defect, using a pocket-sized optical comparator such as the Arco 10-x deLux (F.E. Kiener Co., 1431 Atlantic Boulevard, Los Angeles, California, 90022) or equivalent. Terms and definitions of defects not described in this section can be found in TASK 70-30-00-200-001, Inspection Methods. (a) Discolored (blue or burned bearings). Refer to Heat Discoloration [paragraph C.(1)(h)]. (b) Brinelling (True). 1 Appearance. Shallow impressions of balls or rollers on race-ways, accompanied by a slight flattening of the balls or rollers, usually at 2 diametrically opposite places on each ball or roller. 2 Probable cause. Overloading or shock-loading a bearing, usually while stationary, to the degree that rollers, balls, and raceways are permanently deformed by each other. True brinelling often occurs while transporting an assembled engine in a dolly with flat wheels, or over bumpy surfaces, or from using hammers as removal tools. (c) Brinelling (False). 1 Appearance. Lines on the raceway at each roller position, or dots on the raceway at each ball position. Minor fretting or light traces of rust may be visible under magnification. 2 Probable cause. False brinelling occurs while the bearing is stationary, and is often a result of repeated or continuous low amplitude axial vibration. (d) Burnishing. 1 Appearance. Smooth metal surface without displacement or loss of material. Surface discoloration is sometimes present along outer edges of the burnished surface. 2 Probable cause. Light rubbing between nonfunctional surfaces, often under conditions in insufficient or marginal lubrication.
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70-33-01
STANDARD PRACTICES MANUAL AS907-1-1A (e) Corrosion or rust. 1 Appearance. Broken, pitted or discolored surface area which exhibits an orange peel appearance. Areas of corrosion or rust are large groups or relatively shallow small pits. 2 Probable cause. Exposure of bearing to corrosive atmosphere or materials, inadequate control of temperature and humidity during processing, chemical or electrolytic attack sometimes caused by faulty protection or by breakdown of lubricant. (f) Fretting corrosion. 1 Appearance. Characterized by rusty surfaces ranging from black to a fairly bright color, and from well bonded to loosely bonded (sometimes with free particles) respectively. Fretting corrosion occurs most frequently between inner race and shaft, outer race and housing, and race ends and retaining members. 2 Probable cause. Rapid oxidation of the surfaces of closely fitted parts, usually resulting from small relative movement between 2 mating surfaces, or the alternate expansion and contraction of a portion of a shaft or bearing ring relative to its mating surface. (g) Galling. 1 Appearance. Similar to fretting corrosion, but more severe. Distinguished by a significant transfer of material between mating surfaces resulting from friction-welding and subsequent tearing of metal particles. 2 Probable cause. Excessive motion between 2 poorly lubricated surfaces under heavy load. (h) Heat Discoloration. 1 Appearance. Light straw color to deep purple, sometimes iridescent, depending upon temperature. Some heat discoloration of bearings in hot sections of engine is normal. 2 Probable cause. Lubrication inadequate for proper cooling, bearing directly exposed to hot gases, or over-lubrication causing friction by reducing freedom of motion.
EFFECTIVITY: ALL
70-33-01
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: HARDNESS CHECKS MUST BE MADE ON NONFUNCTIONAL SURFACES. USE A ROCKWELL-A BRALE TO AVOID PENETRATING HARDENED SURFACES. (i) Load Path Markings. 1 Appearance. a Ball bearings: Normally, the unloaded side of the split inner race will show no load path marking. The loaded side will show a load path marking somewhat to one side, but not close to the edge of the shoulder. Oscillating load path markings on the inner race indicate cocked bearings or misaligned shafts. In outer races, the normal load path marking is slightly off center toward the applied load. Both inner and outer race load path markings should be the same distance from the shoulder around the entire bearing. b Roller bearings: The normal load path marking is uniform all around the bearing; i.e., not concentrated on one side of the path. The marking should be about the same distance from the edge of the raceway all around the bearing. 2 Probable cause. Work-hardening (increased density of crystalline structure) of the raceway caused by the continuous pressure of balls or rollers under load. (j) Nicks and Dents. 1 Appearance. Nicks are sharp, well defined incisions; dents are smooth depressions. On functional surfaces, each dent may exhibit the polished appearance of work-hardening around the edge of the depression. Ridges of displaced metal are frequently found at the edges of nicks and dents. 2 Probable cause. Improper handling, failure to keep elements separated during processing, dirt, chips or other foreign material in bearing that have been run over by balls or rollers during operation. (k) Pitting. 1 Appearance. Minute cavities having no sharp, high-stress corners. 2 Probable cause. Chemical or electrolytic attack, oxidation of bearing surfaces, mechanical action such as chipping, or removal of embedded material.
EFFECTIVITY: ALL
70-33-01
STANDARD PRACTICES MANUAL AS907-1-1A (l) Roller End-Wear. 1 Appearance. Concentric or eccentric scratches or rubs (burnishing) on the end of rollers. 2 Probable cause. Misalignment of one race with respect to the other, or imbalance of the roller element, or axial loading. (m) Scoring. 1 Appearance. Deep scrape marks or scratches, often multiple, that can exist on any surface of ball and roller bearings. 2 Probable cause. Skidding of rollers and balls in the presence of dirt or abrasive foreign particles. Nonfunctional surfaces may be scored by press-fitting bearings into housings or onto shafts containing burrs or foreign matter, or by other faulty mounting procedures. (n) Scratches and Chafes. 1 Appearance. a Scratches. Long, narrow, sharp-cornered incisions in any bearing surface. b Chafes. A parallel group of superficial scratches. 2 Probable cause. a Scratches. Movement of a sharp object across a surface under sufficient pressure to displace metal. b Chafes. Sliding or skidding in the presence of dirt or other abrasive foreign matter, or inadequate lubrication on functional surfaces. (o) Skidding. 1 Appearance. A burnished or frosted ring around raceways and sometimes on rollers or balls. Indications of electrical arc discharges may be present as dots, especially if the bearing shows residual magnetism. 2
EFFECTIVITY: ALL
Probable cause.
70-33-01
STANDARD PRACTICES MANUAL AS907-1-1A Too much or too little lubrication, lubricant too stiff to permit free turning (lubricant may be over-age or of incorrect type), or insufficient loading of bearing. (p) Spalling, Flaking or Fatigue Spots. 1 Appearance. Irregular, sharp-edged, rough-bottomed cavities in functional surfaces of bearing. 2 Probable cause. Internal binding, out-of-round housings or shafts causing ring members to assume mounting over-loads, normal metal fatigue resulting from excessive preloading or use beyond normal life of bearing. (q) Stains. 1 Appearance. Discoloration other than burning or heat discoloration and other than varnishing film. Stains are not accompanied by etching or pitting. 2 Probable cause. Deposits of penetrating dyes in the crystalline structure of the metal. (r) Varnish Film. 1 Appearance. Light brown-to-black surface discoloration on bearing surfaces. 2 Probable cause. Breakdown or carbonization of lubricant resulting from moderate-tohigh temperature operation. (s) Cage Defects - Damage and Wear. 1 Appearance. Damage and wear may be indicated on cages by one or more of the following conditions: a b c d e Broken or cracked edges. Bent or out-of-round edges. Nicks or dents in the bronze or steel on land-riding or pocket surfaces, over 0.125 inch (3.18 mm) longest dimension. Nicks or dents other than those described in fault 3, and over 0.250 inch (6.35 mm) largest dimension. Wear through silver to bronze or steel in the cage pockets, more than 0.125 inch (3.18 mm) wide.
EFFECTIVITY: ALL
70-33-01
STANDARD PRACTICES MANUAL AS907-1-1A f g 2 Wear on the land-riding surface through silver into the bronze or steel. Wear of cage pocket sufficient to let balls or rollers come out of a nonseparable cage.
Probable cause. Faults a and b are often caused by improper handling, or failure to segregate parts while cleaning. Other defects may be caused by misalignment of inner and outer races, improper lubrication or set-up lubricant.
(t)
Cage Defects - Flaking, Peeling and Blistering. 1 Appearance. Tearing away or separation of plating from the substrate metal. Plating separated but not missing is blistered; plating missing in strips is peeled; other missing patches are flaked. 2 Probable cause. Bond between substrate metal and plating is imperfect or lacking.
(5)
Dimensional Inspection. Inspect bearings dimensionally in accordance with the following instructions. (a) Bearing dimensional inspection conditions. 1 Temperature. The inspection room temperature must be controlled to be within a range of 66 to 708F (19 to 218C) with a rate of change not more than 0.58F per hour (0.38C per hour). Normalization Time. Each bearing must be allowed to equalize to the inspection room temperature for a period of 12 hours before dimensional inspection is attempted. Bearing Handling: Care should be taken when handling bearings for measurement. Body heat transferred to the bearing can significantly change the dimensions of bearing components, especially thin races or rings.
(b)
Bore and outside measurements. 1 Determine bore diameter with 2-point measuring equipment, taking 4 readings approximately 45 degrees apart. The average of the smallest and largest readings must be within the limits specified in the applicable manual. Determine OD with 2-point measuring equipment, taking 4 readings approximately 45 degrees apart. Bearing must be in horizontal position when measuring. The average of the smallest and largest readings must be within the limits specified in the applicable manual.
EFFECTIVITY: ALL
70-33-01
STANDARD PRACTICES MANUAL AS907-1-1A 3 Equipment for both bore and outside measurement shall be capable of accurate measurement to within 0.0001 inch (.0003 mm). A dial bore gage, or a bore gage using the air-gap principle, may be used for measuring the bore. A fixture employing either the dial indicator or the air-gap principle may also be used for measuring the outside diameter. NOTE: Measuring instruments shall have a maximum gage force of 4 ounces (113 grams), however, to avoid undue deflection of thin rings, gage pressures should be minimized and if significant distortion is present, a load deflection factor shall be introduced to correct the measurement to the free unloaded value. (c) Internal radial clearance. Preferred Method. Use the following procedure to check internal radial clearance. See Figure 1, Page 10. 1 Clamp inner ring to a surface plate, using a shim between the ring and the plate. Ordinary writing paper or newsprint 0.002-0.003 inch (0.050.08 mm) thick makes a satisfactory shim for small bearings; 2-3 thicknesses should be used for large bearings. Place the spindle of a sensitive dial indicator radially against the surface of the outer race at the circumferential centerline. Press the outer race in direction A ( Figure 1, Page 10) release pressure, and reapply several times while intermittently turning the outer race back and forth circumferentially a small amount to seat the rolling elements. While continuing to hold gentle pressure in direction A, move the outer race up and down several times until the dial indicator repeats its maximum reading consistently. Record the maximum indicator reading. Without rotating the outer race from its original position, press it in direction B, release pressure, and reapply several times while intermittently turning it back and forth circumferentially a small amount to reseat the rolling elements. While continuing to hold gentle pressure in direction B, move the outer race up and down several times until the dial indicator repeats its minimum reading consistently. Record the minimum indicator reading. Repeat steps 2 through 5 with the outer race turned 120 degrees from its original position with respect to the inner race, and again with the outer race turned 240 degrees from its original position. Average the 3 sets of readings; the average must be within the limits specified in the applicable manual for internal radial clearance. Alternate Method. Using a standard radial-play tester, check radial clearance at 3 points approximately 60 degrees apart. Use loading specified in the applicable manual (Table of Bearing Limits in the Inspection Section). The average of the 3 readings must be within the limits specified in the applicable manual.
EFFECTIVITY: ALL
70-33-01
STANDARD PRACTICES MANUAL AS907-1-1A (6) Supplementary Testing. The following tests may be used to supplement the inspection procedures described in this section, particularly for nonseparable bearings. (a) A bearing analyzer can be used to check bearings for defects. Use Bearing Inspection Incorporated Model BA-20-3 or equivalent. Follow the manufacturers instructions. NOTE: Bearing Inspection Inc. 10041 Shumaker Road, Sante Fe Springs, CA 90670. The following tests depend upon the experience and judgment of the inspector for their validity; hence, only thoroughly experienced personnel should perform them. In general, proceed as follows: 1 Using a new bearing as a guide, check the wear on the bearings by feeling the end-play, radial play, and rock. End-play is felt by holding the inner race in one hand, and the outer race in the other, then alternating pushing together and pulling apart along the axis of the bearing, being careful to avoid tilting either ring with respect to the other. Check radial play by applying pressure on the bore and outside surface, perpendicular to the axis of the bearing. Check each bearing at several points. Feel rock by tilting one race relative to the other. Check several directions. A slight increase in internal clearance is not cause for rejection. Make sure that the bearing is oiled, then slowly rotate the outer race while holding the inner race stationary and vertical. Check several times, with a different part of the inner race at the top each time. Any rough running bearings should be recleaned ( TASK 70-22-01-110-013, Special Cleaning Procedure No. 1 - Cleaning of Bearings), relubricated, and rechecked. If the bearing continues to run roughly, reject it.
EFFECTIVITY: ALL
70-33-01
Internal Radial Clearance Setup Figure 1
EFFECTIVITY: ALL
70-33-01
HONEYCOMB STRUCTURES - CAPILLARY INSPECTION OF OPEN FACE HONEYCOMB STRUCTURES TASK 70-33-02-220-005 1. Capillary Inspection of Open Face Honeycomb Structures SUBTASK 70-33-02-99G-005 A. General. (1) This inspection is used to check the integrity of the bond between honeycomb cells, cell walls, and the base following brazing. This examination process reveals brazing discontinuities in the honeycomb structures through visual observation for fluid entering the cells and by fluid retention. Defective cells will fill rapidly with liquid and capillary forces will retain fluid in completely bonded cells whereas defective cells will not retain fluid and will empty more rapidly. Two different test methods utilize these facts in this inspection technique. NOTE: Visual inspection systems approved by Honeywell - Repair Engineering will be considered as alternate equivalent inspection procedures for inspection of open face honeycomb structures. Equipment identified to perform such an inspection can be found in C05-113 and C05-114. SUBTASK 70-33-02-220-051 B. Equipment. (1) A tank large enough to contain the inspection fluid and allow inspection part to be immersed.
SUBTASK 70-33-02-220-052 C. Materials. No. C04-035 S1169
Consumable Product Isopropyl Alcohol Kodak Photo-Flo Solution SUBTASK 70-33-02-220-053 D. Procedure 1. (1) (2)
Ensure that part to be inspected is clean and free from all dirt, grease, and oil. Immerse the inspection part in the inspection fluid as follows: NOTE: If the parts are small and flat, they can be immersed in the inspection fluid at one time. If the parts are cylindrical, they will need to be marked into convenient sectors for proper inspection.
EFFECTIVITY: ALL
70-33-02
CAPILLARY INSPECTION OF OPEN FACE HONEYCOMB STRUCTURES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (a) (b) (3) Insert the part, cell openings upward, into the liquid at an angle in order to allow air to escape from the cells. Ensure all honeycomb cells are filled with inspection fluid before removing part from tank.
Carefully withdraw the inspection part from the inspection fluid bath being careful not to jar the part or spill fluid from the honeycomb cells. Prevent any contact with area to be inspected. Visually examine the honeycomb to find any cells that fail to hold the inspection fluid. (a) After the part has been removed from the inspection fluid, slowly rotate the part around the axes of the honeycomb surface to be inspected. Angles of rotation shall be both positive 90 degrees and negative 90 degrees around the stated axes when measured from the horizontal. NOTE: If the part has a shape difficult to inspect with one immersion, it may be necessary to process it a sector at a time. (b) Identify those cells that are partially or completely empty. NOTE: Completely empty cells indicate lack of bond between honeycomb and base. Partially empty cells, a void between cell walls.
(4)
(5) (6)
Accept or reject parts in accordance with limits specified for particular parts in the process document. Remove the solvent from the honeycomb cells by inverting the parts over the solvent container and shaking the part vigorously.
SUBTASK 70-33-02-220-055 E. Procedure 2. NOTE: Procedure 2 is not recommended for honeycomb cell sizes larger than 1/16 inch (1.6 mm) diameter. (1) (2) Ensure that part to be inspected is clean and free from all dirt, grease, and oil. Immerse the inspection part in the inspection fluid as follows: NOTE: If the parts are small and flat, they can be immersed in the inspection fluid at one time. If the parts are circular, they will need to be marked into convenient sectors for proper inspection. (a) (b) Insert the part, cell openings upward, into the liquid. For 30-60 seconds, carefully observe the rate at which the honeycomb cells fill with the inspection liquid. Defective cells will appear dark colored, while completely bonded cells will form an air bubble and prevent fluid from quickly entering the cells and appear bright as they reflect light back. For an example, see Figure 1, Page 4.
EFFECTIVITY: ALL
70-33-02
STANDARD PRACTICES MANUAL AS907-1-1A (3) Carefully withdraw the inspection part from the inspection fluid bath being careful not to jar the part or spill fluid from the honeycomb cells. Prevent any contact with area to be inspected. Visually examine the honeycomb while keeping the honeycomb in a horizontal position. Identify as defective those cells that appear dark. NOTE: The defective area may be marked while the part is still immersed to ease inspection. (5) (6) Accept or reject parts in accordance with limits specified for particular parts in the process document. Remove the solvent from the honeycomb cells by inverting the parts over the solvent container and shaking the part vigorously.
(4)
EFFECTIVITY: ALL
70-33-02
Honeycomb Acceptance/Rejection Criteria Figure 1
EFFECTIVITY: ALL
70-33-02
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-33-02-220-054 F. Quality Assurance. (1) Visually examine inspection fluid to determine if it has been contaminated with foreign material. Inspection fluid must remain clear and free of floating particles for proper inspection. Replace if contaminated or discolored.
EFFECTIVITY: ALL
70-33-02
EFFECTIVITY: ALL
70-33-02
FRETTING OR GALLING - SPECIAL INSPECTION FOR SURFACE FRETTING OR GALLING TASK 70-33-03-220-006 1. Special Inspection for Surface Fretting or Galling SUBTASK 70-33-03-99G-006 A. General. (1) The inspection of fretting or galling on surfaces requires special techniques to determine serviceability. The nature of these defects (refer to definitions in TASK 70-30-00-200-001, Inspection Methods) makes the assessment of the damage difficult. Due to this difficulty, the following method may be used, when referenced by the applicable manual for a specific part.
SUBTASK 70-33-03-220-061 B. Materials. No. C10-072
Consumable Product A. Bright Boy Stick with Holder ST-090-ALO-801H B. Bright Boy Stick with Holder ST-180-ALO-801H SUBTASK 70-33-03-220-062 C. Procedure. (1) (2) Initial Inspection.
C10-072
Visually determine the boundaries of the affected area and inspect as follows: (a) Survey the entire affected area with a 0.03 inch (0.8 mm), radius scriber. Move the scriber in a random motion. Use feel, not sight, to determine if the affected area has a change in the surface when compared to the adjacent unaffected area resulting in increased roughness. If a change cannot be felt with the scribe, the area is serviceable; if a change can be felt, see paragraph (3).
(b) (3)
Cleanup of Area. (a) Using an abrasive stick, rub the affected area briskly to remove any deposited material buildup. The abrasive stick is indicated in Subtask 70-3303-220-061, Materials.
SPECIAL INSPECTION FOR SURFACE FRETTING OR GALLING Page 1 Dec 01/03
EFFECTIVITY: ALL
70-33-03
STANDARD PRACTICES MANUAL AS907-1-1A (b) (4) Brush the area clean of any residue and see paragraph (4).
Glass Inspection. (a) Using a 3-7X glass and bright light, inspect the cleaned area for missing material. NOTE: Missing material is defined as displacement or missing surface material which results in depressions extending below original surface. (b) If missing material is not evident the part is serviceable; if missing material is evident, see paragraph (5).
(5)
Final Inspection. (a) (b) Using a 0.03 inch (0.8 mm) radius scriber, inspect the area (reference Subtask 70-33-03-220-061, Materials.). If a change cannot be felt, the part is serviceable. If a change is felt, the part is not serviceable. Refer to applicable manual for part disposition.
EFFECTIVITY: ALL
70-33-03
SPECIAL INSPECTION FOR SURFACE FRETTING OR GALLING Page 2 Dec 01/03
INSPECTION OF SPLINES - INSPECTION OF SPLINES TASK 70-33-04-220-012 1. Inspection of Splines SUBTASK 70-33-04-99G-012 A. General. (1) Use the following procedure for measuring spline wear when directed by the applicable manual.
SUBTASK 70-33-04-220-121 B. Equipment. (1) (2) Fine-bristle brush (Commercial). Spline measuring kit (Commercial).
SUBTASK 70-33-04-220-122 C. Materials. No. C04-002 C02-017 C05-001
Consumable Product A. Solvent, Stoddard (P-D-680 Type 1) B. Grease, General Purpose C. Gear Marking Compound, No. 10
EFFECTIVITY: ALL
70-33-04
INSPECTION OF SPLINES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-33-04-220-123 D. Procedure. WARNING: STODDARD SOLVENT P-D-680 IS COMBUSTIBLE - DO NOT USE NEAR OPEN FLAMES, NEAR WELDING AREAS, OR ON HOT SURFACES. PROLONGED CONTACT OF SKIN WITH LIQUID CAN CAUSE DERMATITIS. REPEATED INHALATION OF VAPOR CAN IRRITATE NOSE AND THROAT AND CAN CAUSE DIZZINESS. IF ANY LIQUID CONTACTS SKIN OR EYES, IMMEDIATELY FLUSH AFFECTED AREA THOROUGHLY WITH WATER. REMOVE SOLVENT-SATURATED CLOTHING. IF VAPORS CAUSE DIZZINESS, GO TO FRESH AIR. WHEN HANDLING LIQUID OR WHEN APPLYING IT IN AN AIR-EXHAUSTED, PARTIALLY COVERED TANK, WEAR APPROVED GLOVES AND GOGGLES. WHEN HANDLING LIQUID OR WHEN APPLYING IT AT UNEXHAUSTED, UNCOVERED TANK OR WORKBENCH, WEAR APPROVED RESPIRATOR, GLOVES AND GOGGLES.
CAUTION: IF A GEAR MARKING COMPOUND HAS BEEN USED, REMOVE ALL RED OXIDE OR OTHER GEAR MARKING COMPOUND FROM INTERNAL AND EXTERNAL SPLINES. IF IT IS NOT REMOVED, SPLINE WILL WEAR FASTER. (1) (2) Before inspecting, clean splines with a fine bristle brush and Stoddard solvent C04002. Visually inspect the spline for wear. See Figure 1, Page 4. If a step or unworn portion of the spline is noted, measure the wear by comparing the worn and unworn portions of the tooth. Use a dial indicator wherever possible. Wear limits, diameters over or under balls and sizes of balls are in the inspection tables in the applicable engine manual. NOTE: Measuring wear depth directly should be given preference over measurement over/under balls whenever possible. The use of wear depth method results in a higher acceptance rate than with the measurement over/under balls method. With the latter method, the wear depth varies and is dependent on original manufacturing tolerances. (3) When the tooth is worn uniformly across the entire surface so that there is no measurable step, and depth of wear cannot be determined, measure over or under balls as follows: NOTE: Use balls rather than pins wherever possible for measurement of wear because of the potential risk of the pins not being properly seated. Use of the incorrect balls when measuring wear will result in erroneous readings. Make positive identification of ball size. Extreme care must be exercised, particularly with internal splines, to ensure that balls are not hanging up. (a) (b) Measure spline diameter as shown in Figure 1, Page 4. Use correct size balls. Do not use pins. Hold balls in place with a light coat of grease.
EFFECTIVITY: ALL
70-33-04
STANDARD PRACTICES MANUAL AS907-1-1A (c) For internal splines, use balls with a flat. Grind the flat on the ball as shown. The flat must face the root of the spline so that the ball does not touch the root when measuring. Measure the spline diameter at three places along the length of the spline. Inspect the part containing the spline for other defects as specified in the inspection tables in the applicable engine manual. Refer to the inspection table in the applicable engine manual for limits applicable to the part being inspected.
(d) (e) (f)
EFFECTIVITY: ALL
70-33-04
Spline Wear - Inspection Figure 1
EFFECTIVITY: ALL
70-33-04
HONEYCOMB SEALS - INSPECTION OF HONEYCOMB SEALS TASK 70-33-05-220-013 1. Inspection of Honeycomb Seal Sealing Surfaces SUBTASK 70-33-05-99G-013 A. General. (1) Use this procedure to determine the acceptability of honeycomb sealing surfaces.
SUBTASK 70-33-05-220-131 B. Procedure. (1) Accept of reject sealing surfaces formed by honeycomb material in accordance with the following damage limits. NOTE: Damage is defined as crushed honeycomb cells. Damage referred to in the following criteria is not the damage caused by knife-edge seal contact (grooves) but damage caused by other factors, such as foreign object damage, mishandling, and tools. NOTE: Grooves cut into honeycomb caused by knife-edge seal contact are acceptable to any depth. NOTE: Segmented honeycomb seals are to be checked as a set. Damage limits apply to the complete circle of the seal. Segments may be replaced individually to provide an acceptable set. (a) Damage to honeycomb cells must not exceed an area of six adjacent damaged cells circumferentially by one-half of the seal width. (See Figure 1, Page 3 and Table 1, Page 2.) Partial cells at the edge of the seal are allowed. Damaged areas may not overlap and should be separated by a minimum of four complete undamaged cells. Grooves cut by knife-edge seals may be any depth; however, distance between wear grooves shall not be less than 0.065 inch (1.65 mm). (See Figure 2, Page 4.) Any separation of the braze joint visible at the seal edge between seal and backing ring is not permitted. Any honeycomb seal or seal segment damaged beyond the allowable limits can be repaired by sending the seal assembly to the following. Honeywell Distribution Center 1944 East Sky Harbor Circle Phoenix, AZ 85034-9003
(b) (c) (d)
(e) (f)
EFFECTIVITY: ALL
70-33-05
INSPECTION OF HONEYCOMB SEALS Page 1 Dec 01/03
Table 1. Honeycomb Acceptance/Rejection Criteria Seal Size (Diameter) Less than 16 inches (406 mm) Maximum Damage Area Size 1/2 seal width by six cells circumferentially OR Less than 16 inches (406 mm) 1/2 seal width by six cells circumferentially OR Less than 16 inches (406 mm) Greater than 16 inches (406 mm) Greater than 16 inches (406 mm) Greater than 16 inches (406 mm) 1/2 seal width by three cells circumferentially 1/2 seal width by six cells circumferentially OR 1/4 seal width by three cells circumferentially OR 1/2 seal width by three cells circumferentially 16 16 6 8 6 Number of Damaged Areas Allowed 3
EFFECTIVITY: ALL
70-33-05
Honeycomb Acceptance/Rejection Criteria Figure 1
EFFECTIVITY: ALL
70-33-05
Acceptable Wear Patterns of Honeycomb Material Figure 2
EFFECTIVITY: ALL
70-33-05
INSPECTION OF SPLINES - INSPECTION OF SPLINES TASK 70-33-06-220-014 1. Inspection of Splines SUBTASK 70-33-06-99G-014 A. General. (1) Use the following procedure to inspect tubes, hoses, and fittings when directed by the applicable manual.
SUBTASK 70-33-06-220-141 B. Materials and Equipment. Table 1. Materials and Equipment Description Calibrating Fluid (MIL-PRF-7024) Stoddard solvent Pinpoint Micrometers SUBTASK 70-33-06-220-142 C. Procedure. (1) Inspect tubes, hoses, and fittings per Table 2, Page 1. Table 2. INSPECTION OF TUBES, HOSES, AND FITTINGS Inspect A. Tubes for: (1) Splits and cracks. (2) Nicks, scratches, wear, and chafing. None allowed. (a) On all tubes except those carrying fuel, any amount 0.005 inch (0.13 mm) deep, without high metal. Not repairable. Same as usable limits, with high metal. Replace tube. (a) Remove high metal and blend area (in an axial direction to tube centerline) to surrounding contour, using a fine abrasive stone per 70-42-00. Replace tube. Usable Limits Max Repairable Limits Corrective Action Code No. CO5-006 S1040 E05-406
(b) Not allowed on fuel-carrying tubes.
Not repairable.
EFFECTIVITY: ALL
70-33-06
Table 2. INSPECTION OF TUBES, HOSES, AND FITTINGS (Cont) Inspect (3) Dents. Usable Limits Depth not to exceed 20% of tube diameter on a straight section, or a curved section having a radius twice the tube diameter. On a sharply bent radius, depth must not exceed 10% of the tube diameter. OD must not be less than 3/4 of the original OD. Refer to item I. Max Repairable Limits Not repairable. Corrective Action Replace tube.
(4) Flattened cross section. (5) Packing grooves for nicks and scratches. (6) Wearstrips on all tubes for wear.
Not repairable.
Replace tube.
Any amount up to 0.005 inch (0.13 mm) deep, below original surface. Any amount provided assembly can be made without the use of force. None allowed. Creased area not over 20% of tube OD on straight or curved section. None allowed. (a) Any amount, 0.005 (0.13 mm) deep, without high metal, on all tubes except those that carry fuel.
Not repairable.
Replace tube.
(7) Distortion.
Any amount.
Cold-work to fit properly without force per 70-47-05. No kinks allowed. Replace tube. Replace tube.
(8) Internal scratches. (9) Creases.
Not repairable. Not repairable.
B. Brazed ferrules for: (1) Splits or cracks. (2) Nicks, scratches, and wear. Not repairable. (a) Any amount, 0.005 inch (0.13 mm) deep, with high metal. Replace assembly. (a) If area has not been previously blended, remove high metal and blend (in an axial direction to tube centerline) to adjacent contour using a fine abrasive stone per 7042-00. (b) Replace tube.
(b) None allowed on fuel carrying tubes. C. Bolt flanges on tubes for:
(b) Not repairable.
EFFECTIVITY: ALL
70-33-06
Table 2. INSPECTION OF TUBES, HOSES, AND FITTINGS (Cont) Inspect (1) Cracks. (2) Flatness of mating surfaces. Usable Limits None allowed. Flat within 0.005 inch (0.13 mm) (hold against flat surface and try to insert a 0.005 inch (0.13 mm) shim). Not allowed. Not allowed. 50% of band removed. Band edges must be covered, and identification must be readable. Not allowed. Max Repairable Limits Not repairable. 90% of the original flange thickness to remain after rework. Corrective Action Replace tube. Rework to usable flatness by lapping, stoning, or machining where possible. Reinspect for cracks; none are allowed. Replace tube. Replace tube. Repair per 70-40-03. Repair per 70-40-03.
D. Hoses for: (1) Kinks or buckling. (2) Frayed and broken wire braid. (3) Worn clamp identification band. (4) Torn band sleeves (identification). Not repairable. Not repairable. Any amount. Any amount.
(5) Looseness (rotating) of endfittings. (6) Nicks, cuts, and gouges in silicone insulation. (7) Worn, chafed, or charred silicone insulation.
Not repairable.
Replace hose.
Any number that do not penetrate to the wire braid. Pressure test per Step (2). Any amount not deeper than 0.0625 inch (1.588 mm) below original contour. Pressure test per Step (2).
Any number if repaired area does not exceed 20 percent of total insulation. Any number it repaired area does not exceed 20 percent of total insulation.
Repair insulation per 70-40-01.
Repair insulation per 70-40-02.
E. Hex coupling nuts for: (1) Cracks. (2) Damage to corners. None allowed. Any amount, without high metal, it at least two opposite corners are not rounded, so that a wrench can be used. Any amount, without high metal. Not repairable. Same as usable limits, with high metal. Replace assembly. Blend high metal per 70-42-00.
(3) Nicks and burrs.
Any amount, with high metal.
Blend high metal using a fine abrasive stone per 70-42-00.
EFFECTIVITY: ALL
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Table 2. INSPECTION OF TUBES, HOSES, AND FITTINGS (Cont) Inspect (4) Damaged threads (nicks, dents, burrs, high metal). Usable Limits One thread, continuous or cumulative without high metal or cross threads. None allowed. Any number of circumferential defects no rougher than 63-microinches (1.6 micrometers) finish, if fitting passes pressure test. Any number superficial axial defects without high metal on aft half (nearest fitting threads) of sealing surface, if fitting passes pressure test per Step (2). Cumulative length of defects no more than one thread length, without high metal. Any number, 0.005 inch (0.13 mm) deep, without high metal. Any amount, if fitting passes pressure test per Step (2). The first thread may be missing, if fitting can be used without cross-threading, and without high metal. Max Repairable Limits Same as usable limits, with high metal. Corrective Action Remove high metal per 70-42-00.
F. Male fittings for: (1) Cracks. (2) Nicks, dents, scratches, ridges, and pits on sealing surfaces. Not repairable. Same as usable limits, with high metal. Replace assembly. Blend sealing surfaces per 70-42-00, maintaining the original contour using a fine abrasive stone. Pressure test per Step (2).
(3) Nicks, dents, and scratches, burrs on threads. (4) Nicks, dents, and scratches, burrs on remaining surfaces of fittings. (5) Shiny, burnished sealing surfaces. (6) Stripped threads.
Same as usable limits, with high metal.
Blend high metal using a die, fine file, or equivalent per 7042-00. Blend high metal to adjacent contour, using a fine abrasive stone per 70-42-00. Replace assembly.
Not repairable.
Blend high metal using a die, fine file or equivalent per 70-4200.
G. Female fittings for:
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Table 2. INSPECTION OF TUBES, HOSES, AND FITTINGS (Cont) Inspect (1) Nicks, dents, scratches, ridges, and pits on sealing surfaces. Usable Limits Any number of circumferential defects no rougher than 32-microinches (0.8 micrometers) finish, if fitting passes pressure test. Any number superficial axial defects without high metal on leading half of sealing surface, if fitting passes pressure test per Step (2). Any number, 0.010 inch (0.25 mm) deep, without high metal, if fitting passes pressure test per Step (2). Any amount if fitting passes pressure test per Step (2). The first thread may be missing, if fitting can be used without cross-threading, and without high metal. Pressure test per Step (2). Max Repairable Limits Same as usable limits, with high metal. Corrective Action Blend high metal to usable limits per 7042-00. Pressure test per Step (2).
(2) Nicks.
Any number, 0.010 inch (0.25 mm) deep, with high metal.
Blend high metal to usable limits per 7042-00. Pressure test per Step (2).
(3) Shiny sealing surfaces. (4) Stripped threads.
Not repairable.
Replace assembly.
Blend high metal using a die, fine file or equivalent per 70-4200. Replace assembly.
H. Assemblies for leaks (only when leaks are suspected). I. Packing grooves for: (1) Nicks and scratches on floor.
Not repairable.
0.003 inch (0.08 mm) deep with no sharp edges. Tubes must pass pressure test per Step (2). 0.010 inch (0.25 mm) deep with no sharp edges. Tubes must pass pressure test per Step (2).
Not repairable.
Replace part.
(2) Nicks and scratches on walls.
Not repairable.
Replace part.
(2)
If tube, hose, or fitting has been repaired or if leaks are suspected, pressure test per limits specified in the applicable manual and in the steps that follow.
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STANDARD PRACTICES MANUAL AS907-1-1A WARNING: CALIBRATING FLUID MIL-PRF-7024

*
COMBUSTIBLE - DO NOT USE NEAR OPEN FLAMES, NEAR WELDING AREAS, OR ON HOT SURFACES. PROLONGED CONTACT WITH SKIN MAY CAUSE IRRITATION. PROLONGED INHALATION OF VAPOR CAN CAUSE DIZZINESS, HEADACHE, AND INTOXICATION. IF THERE IS ANY PROLONGED CONTACT WITH SKIN, WASH AFFECTED AREA WITH SOAP AND WATER. IF LIQUID CONTACTS EYES, FLUSH EYES THOROUGHLY WITH WATER. REMOVE SOLVENT-SATURATED CLOTHING. IF VAPORS CAUSE LIGHT-HEADEDNESS, GOTO FRESH AIR. IF LIQUID IS SWALLOWED, DO NOT TRY TO VOMIT. GET MEDICAL ATTENTION. WHEN HEATED, HOT FLUID MAY CAUSE BURNS. AVOID CONTACT WITH HOT FLUID. IF SKIN CONTACTS HOT FLUID, FLUSH AFFECTED AREA WITH COLD WATER FOR 10 MINUTES. SEEK MEDICAL HELP IMMEDIATELY. WHEN HANDLING OR WHEN APPLYING LIQUID AT AN AIR-EXHAUSTED WORKBENCH, WEAR APPROVED GLOVES AND GOGGLES (OR FACE SHIELD). WHEN HANDLING OR WHEN APPLYING LIQUID AT AN UNEXHAUSTED WORKBENCH, WEAR APPROVED GLOVES, GOGGLES (OR FACE SHIELD) AND APPROVED RESPIRATOR. DISPOSE OF LIQUID-SOAKED RAGS IN APPROVED METAL CONTAINER.
(a)
Flush tube, hose, or fitting thoroughly with calibrating fluid. HIGH-PRESSURE TESTING
*
WARNING:
HIGH PRESSURES USED DURING TESTING MAY CAUSE RUPTURING OR BURSTING OF FAULTY TUBES AND HOSES. THE RESULT COULD BE SERIOUS INJURY. TO PREVENT INJURY, COVER ALL TUBES AND HOSES WITH A SUITABLE SAFETY SHIELD DURING TESTING. WHEN CAPS OR PLUGS ARE USED, BE SURE THEY ARE SECURELY INSTALLED TO PREVENT THEM FROM BEING BLOWN OUT. BE SURE THAT PRESSURES ARE BLED OFF BEFORE EXPOSING OR TOUCHING HOSES OR TUBES.
(b)
Restrict one end of tube, hose, or fitting and use calibrating fluid to build up pressure to amount specified in the applicable manual. Maintain the specified test pressure for a minimum of 2 minutes. Any leakage or a decrease in pressure is not allowed. If a tube, hose, or fitting fails the test due to high metal on a sealing surface, then blend high metal (70-42-00); otherwise, part is not repairable. Replace defective part.
(c)
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STANDARD PRACTICES MANUAL AS907-1-1A WARNING: STODDARD SOLVENT IS FLAMMABLE. TAKE PRECAUTIONS AGAINST FIRE. DO NOT USE NEAR WELDING AREAS, NEAR OPEN FLAMES OR ON HOT SURFACES. USE ONLY WITH ADEQUATE VENTILATION. AVOID PROLONGED OR REPEATED BREATHING OF VAPORS. DO NOT SMOKE WHEN USING IT. USE PROTECTIVE CREAMS. WEAR AN APRON AND WEAR GOGGLES (OR FACE SHIELD) TO PROTECT THE SKIN. STORE IN APPROVED SAFETY CONTAINERS.
(d)
Use stoddard solvent, to pressure flush tubes, hoses, or fittings in both directions. Cap all inlets immediately after flushing.
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HARDNESS MEASUREMENT - HARDNESS MEASUREMENT - GENERAL TASK 70-34-00-200-003 1. Hardness Measurement - General SUBTASK 70-34-00-99G-003 A. General. (1) (2) The hardness of a metal is the resistance which it exerts against the penetration of another harder body, or to a permanent deformation of its surface. The hardness measurement is an indentation measurement using a calibrated machine to force a penetrator into the surface of the material being measured. The dimensions of the remaining imprint provide a measurement of the hardness. Hardness measurements are often used to verify the heat treatment condition of metals or to determine if overtemperature conditions may have occurred during engine operation on parts which change in hardness and strength when exposed to excessively high temperatures.
(3)
SUBTASK 70-34-00-200-031 B. Types of Hardness Measurements. (1) Brinell Hardness Test. (a) The Brinell hardness test uses a calibrated machine to force a ball into the surface of a metal and measures the diameter of the resulting impression following removal of the load. The Brinell hardness number is the load divided by the spherical area of the imprint.
(b) (2)
Vickers Hardness Test. (a) The Vickers hardness test consists of impressing into the metal, without shock, a penetrator in the form of a right pyramid with a square base, under a given load. The penetrator has an angle of 136 degrees at the tip. For the majority of repair procedures, the application of Vickers hardness testing refers to MICROHARDNESS TESTING which is performed on a mounted metallurgical cross-section. The Vickers hardness number is the load divided by the surface area of the imprint.
(b) (3)
Rockwell Hardness Test. (a) Regular tester. The regular Rockwell hardness tester measures the depth of penetration of a penetrator (diamond cone or hardened steel ball) under fixed conditions.
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HARDNESS MEASUREMENT - GENERAL Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (b) (c) The Rockwell hardness number is related to the depth of penetration caused by two superimposed impressions. Superficial tester. The tester for making the superficial hardness test is a specialized form of the regular Rockwell hardness tester. It measures hardness by the same principle as the regular tester, but employs a smaller minor load, smaller major loads, and a more sensitive depth measuring system for use on thin strip or sheet material.
(4)
Portable Rockwell Test. (a) (b) Portable hardness testing equipment is used when the weight, shape, or condition of the part prevents measurement by other methods. The tester is attached by clamp or magnet to the surface to be measured or to an adjacent surface. The load is generally applied by means of a screw through a calibrated spring with a dial gage to measure deflection of the spring and another dial gage to indicate depth of penetration. NOTE: The portable tester is not considered to be a precise measuring device. It is used only when other testing equipment cannot be practically used.
SUBTASK 70-34-00-200-032 C. Conversion Tables. (1) There is no exact method for converting, accurately, from one hardness scale to another. Such conversion should be made only when necessary. The following tables list some approximate conversion values. (See Figure 1 (Sheet 1 of 3), Page 3 and Figure 2 (Sheet 1 of 2), Page 6.)
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Hardness Conversion for Nickel and High Nickel Alloys Figure 1 (Sheet 1 of 3)
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Hardness Conversion for Nickel and High Nickel Alloys Figure 1 (Sheet 2 of 3)
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Hardness Conversion for Nickel and High Nickel Alloys Figure 1 (Sheet 3)
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Hardness Conversion for Steel Figure 2 (Sheet 1 of 2)
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Hardness Conversion for Steel Figure 2 (Sheet 2)
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BRINELL HARDNESS TESTING - BRINELL HARDNESS TESTING TASK 70-34-01-220-007 1. Brinell Hardness Testing SUBTASK 70-34-01-99G-007 A. General. (1) The Brinell hardness test uses a calibrated machine to force a hard steel ball into the surface of the material under test and measures the diameter of the resulting impression. A ball 10 mm in diameter is normally used with loads of 3000, 1500, or 500 kilogram force (kgf). The testing conditions to be used shall be specified in the process document. The testing machine supports the test specimen and applies a predetermined load to the ball in contact with the part tested. The loading system should be operated with caution to prevent momentary overload or large acceleration. A measuring microscope is used to measure the diameter of the impression. This test is not recommended for Brinell hardness greater than 450.
(2)
(3) (4) (5) (6)
SUBTASK 70-34-01-220-071 B. Equipment. (1) (2) Brinell testing machine equipped with measuring microscope capable of measuring the diameter impression to 0.1 percent of the ball diameter. Steel indentation balls with Vickers hardness of at least HV850. (a) (b) (3) Standard 10 mm diameter. See Figure 1, Page 3 for tolerance. Nonstandard balls from 1-8 mm. See Figure 1, Page 3 for tolerances.
Standard hardness test blocks. OPERATOR SHOULD WEAR SAFETY GLASSES WHILE OPERATING TESTING EQUIPMENT.
WARNING: (4)
Calibrate the machine as follows if it is newly installed or rebuilt. (a) Establish load to be used for test from the process document.
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BRINELL HARDNESS TESTING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (b) Check load with proving ring, dead weights and proving levers, a calibration device, or other approved methods. The tolerance under load must be equal to one percent of the applied load. Apply load for 10-15 seconds and take at least 3 hardness impressions in a standard test block. Using the measuring microscope, measure diameter of each impression twice, 90 degrees apart, and calculate the mean. Calculate the average of the mean diameters: d = d1 + d2 + d3...+ dn divided by n where: d = average mean diameter of impression d1, d2, etc. = mean diameter of an impression listed in increasing order n = number of impressions taken dn = mean diameter of last impression taken (f) Calculate percent error. Error = d - dtest divided by dtest where d = average mean diameter of impression dtest = the diameter of the impression in standard hardness test block (g) (h) If error does not exceed 2 percent, machine is acceptable for routine testing. If error exceeds 2 percent, check procedure and recalibrate.
(c) (d) (e)
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Brinell Hardness Ball Tolerance Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-34-01-220-072 C. Materials. (1) None required.
SUBTASK 70-34-01-220-073 D. Procedure. (1) Establish test conditions as specified in the process document and the following: (a) (b) (c) (d) Ensure that the surface to be tested is perpendicular to the axis of indenter. Ensure that surface to be tested and contact surface on machine are clean and free from oxidation. Ensure part to be tested is rigidly supported. Unless otherwise indicated, position the part to be tested so that the distance from the center of an indentation to the edge of the specimen or to the edge of another indentation is at least 2 and one-half times the diameter of the indentation. Unless otherwise indicated, select sufficiently even, flat specimen surface to enable the dimensions of the impression to be accurately measured. If the surface is curved, the minimum radius of curvature should not be less than 25 mm for a 10 mm ball.
(e)
(2)
Apply specified load for 10-15 seconds unless otherwise stated in process document. (a) (b) Do not use the first reading after changing machine setting. Make 3 impressions. NOTE: The distance between impression centers must be 3 times the impression diameter.
(3)
Measure the diameter of each impression using a measuring microscope. Take 2 diameter measurements, 90 degrees apart, of each impression and record. Calculate the mean. Compare the calculated mean diameter of indentation to Figure 2 (Sheet 1 of 8), Page 6 to arrive at the proper Brinell hardness number. If a ball of less than 10 mm is used or a load used which varies from the 500/1500/ 3000 kilogram force (kgf) standard, the Brinell hardness number must be calculated using the formula: HB = P / [(3.1416 D/2)(D - SQRT (D2-d2))] where P = load (kgf), D = diameter of ball (mm) and d = diameter of impression (mm), SQRT = square root
(4) (5)
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STANDARD PRACTICES MANUAL AS907-1-1A (6) function. NOTE: If a ball is used in a test in which the hardness of the part being tested exceeds the limit of HV450, the ball should be measured and if the diameter change is greater than 0.005 mm, the ball and test results should be discarded. (7) Record the Brinell hardness number using the prefix HB. Example: HB158. NOTE: If load application time differs from the 10-15 second standard it must be recorded. If the ball diameter and load differ from the standard values, i.e. D = 10 mean and F = 3000 kgf, they must also be recorded. (8) Perform test on standard hardness test block of the same hardness range as part tested and compare results to ensure accuracy of readings.
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Brinell Hardness Numbers Sheet 1 Figure 2 (Sheet 1 of 8)
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Brinell Hardness Numbers Sheet 8 Figure 2 (Sheet 8)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-34-01-220-074 E. Quality Assurance. (1) None required.
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VICKERS HARDNESS TESTING - VICKERS HARDNESS TESTING TASK 70-34-02-220-008 1. Vickers Hardness Testing SUBTASK 70-34-02-99G-008 A. General. (1) The Vickers hardness test uses a calibrated machine to force a square-based pyramidal diamond indenter into the material being tested. The impression made is then measured from corner-to-corner on a diagonal, and the hardness calculated using this measurement. For the majority of repair procedures, the application of Vickers hardness testing refers to MICROHARDNESS TESTING which is performed on a mounted metallurgical cross-section. The testing machine supports the part being tested and permits the indenter and the part to be brought together smoothly as the load is applied. Test loads are applied to the part to be tested through the machine. These loads can be varied from 0.001 kilogram force (kgf) to 120 kgf. The indenter is a highly polished, square-based pyramidal diamond with face angles of 136 degrees 30 minutes. A measuring microscope used to determine the impression diagonal dimension is usually mounted on the machine.
(2) (3) (4) (5)
SUBTASK 70-34-02-220-081 B. Equipment. (1) Vickers testing machine with indenter and measuring microscope. For diagonal dimensions less than 0.2 mm, the reading accuracy must be 0.001 mm. For diagonal dimensions equal to or greater than 0.2 mm, the accuracy should be 0.5 percent. Hardness test blocks. OPERATOR SHOULD WEAR SAFETY GLASSES WHILE OPERATING TESTING EQUIPMENT.
(2)
WARNING: (3)
Calibrate the machine as follows if it is newly installed or rebuilt. (a) (b) Establish load to be used for test from the process document. Check load with dead weight and proving levers, an elastic calibrating device, or other approved method. The tolerance under load must be equal to one percent of the applied load.
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VICKERS HARDNESS TESTING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (c) (d) Apply load for 10-15 seconds and make a minimum of 5 impressions on at least 3 standard test blocks of different hardness levels. Using the measuring microscope, measure both diagonal dimensions of each impression, corner-to-corner, and calculate the mean for each test block. Record d1, d2,..., d5 (the means of each pair of diagonals) arranged in increasing order for each test block. Calculate repeatability for each test block. Repeatability = d5-d1. Compare calculated repeatability to Figure 1, Page 3 to ensure machine is properly calibrated.
(e) (f) (g)
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Repeatability of Machines Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-34-02-220-082 C. Procedure. (1) Establish test conditions as specified in the applicable manual and the following: (a) (b) (c) (d) Ensure that the surface to be tested is perpendicular to the axis of indenter. Ensure that surface to be tested and the contact surface on machine are clean and free from oxidation and foreign matter. Ensure part to be tested is rigidly supported. Position the part to be tested so that the distance from the center of an indentation to the edge of the part or another impression is at least 2.5 times the diagonal of the indentation. Unless otherwise indicated, select sufficiently even, flat specimen surface on part to be tested to enable the dimensions of the imprint to be accurately measured. OPERATOR SHOULD WEAR SAFETY GLASSES WHILE OPERATING TESTING EQUIPMENT.
(e)
WARNING: (2)
Apply the indicated load for 10-15 seconds unless otherwise specified. (a) (b) Do not use the first reading after changing machine setting. Make 3 impressions if possible.
(3) (4)
Remove part from machine. Measure the impression diagonals as follows: (a) (b) Use a measuring microscope. Measure both diagonal dimensions across each impression from corner-tocorner, and calculate the mean.
(5)
Determine the Vickers hardness number using the average of the diagonal means, Figure 2 (Sheet 1 of 3), Page 7 and Figure 3, Page 10, and the following examples: (a) Example 1: Using a 50 kgf test load, the average diagonal length measured is 0.644 mm. 1 2 In Figure 2 (Sheet 1 of 3), Page 7 read: 0.0644 mm diagonal length at one kgf results in a HV of 447.1. Using Figure 3, Page 10 find approximate length from step 1 in left hand column (0.600) and find placement of decimal for one kgf in HV number on right hand column (5.15). Apply this decimal placement to HV reading from Figure 2 (Sheet 1 of 3), Page 7 (4.471).
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STANDARD PRACTICES MANUAL AS907-1-1A 4 (b) Multiply HV4.471/one kgf by 50 kgf to arrive at HV=224 for 50 kgf test or 224HV50.
Example 2: Using a 50 kgf test load, the average diagonal length measured is 0.644 mm. 1 2 3 4 Using a 0.2 kgf test load the average diagonal length measured is 0.0311 mm. In Figure 2 (Sheet 1 of 3), Page 7 read: 0.0311 mm diagonal length at one kgf results in a HV of 1917. Using Figure 3, Page 10, note that there is no decimal placement for this approximate diagonal length. Multiply HV1917/one kgf, from step 2, by 0.2 kgf, test load, to arrive at HV383 for a 0.2 kgf test load.
(6)
When hardness tests are made on spherical or cylindrical surfaces use correction factors contained in Figure 4, Page 11, Figure 5, Page 12, and Figure 6, Page 13, and the following examples: (a) Example 1: (Hardness sphere). 1 Using a 10 kgf test load on a convex spherical surface with a diameter (D) of 10 mm, the resulting mean diagonal (d) of the impression measures 0.150 mm. Calculate d divided by D = 0.015 mm divided by 10 mm = 0.015 From Figure 2 (Sheet 1 of 3), Page 7 and Figure 3, Page 10 read and interpolate HV = 824. From Figure 4, Page 11, by interpolation, find the correction factor = 0.983. Hardness of sphere = 824 x 0.983 = 810HV 10.
2 3 4 5 (b)
Example 2: (Hardness of cylinder - one diagonal parallel to axis). 1 Using a 30 kgf test load on a concave cylinder with a diameter (D) of 5 mm, the resulting mean diagonal (d) by the impression measures 0.415 mm. From Figure 2 (Sheet 1 of 3), Page 7 and Figure 3, Page 10 read and interpolate HV = 269.2/one kgf. Calculate 269.2/one kgf x 30 kgf = HV8076. Calculate = d divided by D = 0.415 divided by 5 = 0.083. Using d divided by D from step 4 interpolate the correction factor Figure 6, Page 13 (1.075).
2 3 4 5
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STANDARD PRACTICES MANUAL AS907-1-1A 6 (7) Hardness of cylinder - 8076 x 1.075 = 8682HV30.
Record the hardness number using the Vickers hardness symbol and the following example: 400 HV 30 20 load applied for 20 seconds load of 30 kgf Vickers hardness symbol Vickers hardness of 400
Example:
NOTE: Record load time only if different from standard 10-15 second application. (8) Perform test on hardness test block of the same hardness range as part tested and compare results to ensure accuracy of readings.
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Vickers Hardness Numbers Sheet 1 Figure 2 (Sheet 1 of 3)
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Vickers Hardness Numbers Sheet 2 Figure 2 (Sheet 2 of 3)
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Vickers Hardness Numbers Sheet 3 Figure 2 (Sheet 3)
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Decimal Point Finder for Use with Figure 2 Figure 3
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Correction Factors for Use in Vickers Hardness Test Made on Spherical Surfaces Figure 4
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Correction Factors for Use in Vickers Hardness Test Made on Cylindrical Surfaces Figure 5
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Correction Factors for Use in Vickers Hardness Test Made on Cylindrical Surfaces Figure 6
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ROCKWELL HARDNESS TESTING - ROCKWELL HARDNESS TESTING TASK 70-34-03-220-009 1. Rockwell Hardness Testing SUBTASK 70-34-03-99G-009 A. General. (1) The Rockwell hardness test uses a calibrated machine to force a penetrator into the surface of the material being tested while measuring the permanent depth of the impression under minor and major loads. The machine supports the test specimen on an anvil. A variety of anvils are available as indicated in Figure 1, Page 3. The proper anvil should be selected to completely support the test part while the surface to be tested is parallel to the anvil surface and perpendicular to the penetrator. There are 2 types of stationary Rockwell hardness testers: (a) The regular tester applies a minor load of 10 kilo-grams force (kgf) and a major load of 60, 100, or 150 kgf and uses either a diamond sphero-conical penetrator or steel balls of 1.588, 3.175, 6.350, or 12.70 mm diameter ( Figure 2, Page 4). The superficial tester is a specialized form of the regular hardness tester. It operates by the same principle as the regular tester but uses a smaller minor load of 3 kgf and smaller major loads of 15, 30, and 45 kgf. This tester uses a steel ball penetrator 1.588 mm in diameter or a diamond sphero-cone. This tester is used in testing thin strips or sheet material or under conditions where large test machines or loads are destructive or undesirable. See Figure 2. NOTE: The ability to perform both regular and superficial testing may be combined in newer type equipment. (4) The scale and type of tester shall be specified in the applicable manual. The scale shall define the penetrator and load.
(2)
(3)
(b)
SUBTASK 70-34-03-220-091 B. Equipment. (1) Rockwell Hardness Tester (Regular). NOTE: The depth gage of the penetrator must be accurate to within 0.001 mm. (2) Rockwell Hardness Tester (Superficial). NOTE: The depth gage of the penetrator must be accurate to within 0.001 mm.
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ROCKWELL HARDNESS TESTING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (3) Penetrator (Regular). See Figure 1, Page 3. (a) (b) Diamond sphero-cone (regular configuration). Steel ball. 1 2 3 4 (4) 1.588 mm diameter. 3.175 mm diameter. 6.350 mm diameter. 12.70 mm diameter.
Penetrator (Superficial). (a) (b) Steel ball 1.588 mm diameter. Diamond sphero-cone (superficial configuration).
(5)
Anvil. See Figure 1, Page 3. (a) (b) (c) (d) (e) Plane anvil. Spot anvil. Shallow "V" anvil. Testing table. Cylindron Jr. anvil.
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Fixed Equipment Figure 1
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Various Hardness Scale Figure 2
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-34-03-220-092 C. Materials. (1) Hardness blocks for varied scales and ranges.
SUBTASK 70-34-03-220-093 D. Procedure. (1) Prepare and qualify the specimen for hardness testing: (a) (b) (c) Ensure that the surface of the part to be tested is perpendicular to the axis of the penetrator and parallel to the face of the anvil. Ensure that the test surface and machine contact surfaces are clean and free from oxidation and from foreign matter. Ensure that the part to be tested is thick enough to avoid having penetrator impression show on the anvil side of the part. Check Figure 3, Page 7, Figure 4, Page 8and Figure 5, Page 9 For thermal spray coatings, preparation of the surface is critical for successful hardness testing. 1 2 3 The coating must be ground to a matte finish with the coating aspirates removed. This can be accomplished using 120-320 grit metallurgical grinding papers using minimal pressure during removal. Coating removal should be a minimum of 0.001 inch (0.0254 mm) for the superficial 15T and 15N scales and a minimum of 0.005 inch (0.127 mm) for the 15Y scale. Care must be taken to provide even removal across the specimen. Flatness of the specimen should be 0.002-0.005 inches (0.05-0.127 mm). It is also important to prevent excessive coating removal, which would invalidate the test due to thickness concerns. With all thermal spray coatings, the thickness vs. hardness value charts ( Figure 3, Page 7, Figure 4, Page 8, and Figure 5, Page 9) should be reviewed to insure that the specimen has been coated with sufficient material for a valid hardness reading.
(d)
(2)
Establish general test conditions as specified in the process document and the following: (a) Position part so that the distance from the center of an impression to the edge of the part is at least 2-1/2 times the length of the impression and 3 times the diameter from another impression measured center-to-center. If not indicated, select an anvil to completely support the weight and shape of the part being tested.
(b)
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STANDARD PRACTICES MANUAL AS907-1-1A (c) (d) Inspect penetrator for defects and replace if necessary. If the surface to be tested is curved, the concave side of the curved surface should face the penetrator and Figure 6, Page 10 and Figure 7, Page 11 should be used for correction factors with the readings. OPERATOR SHOULD WEAR SAFETY GLASSES WHILE OPERATING TESTING EQUIPMENT.
WARNING: (3)
Perform test on hardness test blocks of known hardness which are in the same hardness range ( 5 hardness points for diamond penetrators and 10 hardness points for ball penetrators) as the test part. Compare test results with actual hardness of test block to ensure accuracy of test equipment and measuring technique. See Figure 8, Page 12. Apply major load for 2 seconds, unless otherwise specified. (a) (b) (c) Do not use the first reading after changing machine setting, anvil, penetrator, or testing at a different hardness range. Take a minimum of 3 hardness readings. If the load setting pointer is moved past either the set point or the major load point for the test, the load should be released and the test performed at a different position. Record the hardness value by indicating the scale used per the following example: NOTE: Time of major load application should be recorded if different from 2 second standard.
(4)
(d)
Example:
HR
60 Rockwell Hardness of 60
Rockwell Hardness Scale Rockwell Hardness Symbol
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Minimum Material Thickness Required for Regular Rockwell Scale and Selected Hardness Number Figure 3
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Minimum Material Thickness Required for Superficial Rockwell N Scale and Selected Hardness Number Figure 4
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Minimum Material Thickness Required for Superficial Rockwell T Scale and Selected Hardness Number Figure 5
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Corrections to be Added to Regular Rockwell Dial Readings for Cylindrical Parts Figure 6
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Corrections to be Added to Superficial Rockwell Dial Readings for Cylindrical Parts Figure 7
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Hardness Ranges used in Calibration/Verification by Standardized Test BLock Method Figure 8
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-34-03-220-094 E. Quality Assurance. WARNING: (1) OPERATOR SHOULD WEAR SAFETY GLASSES WHILE OPERATING TESTING EQUIPMENT.
If the tester is newly installed or rebuilt, calibrate the tester as follows: (a) Verify applied loads as follows: 1 2 3 Regular testing machines should be calibrated at loads of 60, 100, and 150 kgf. Superficial testing machines should be calibrated at loads of 15, 30, and 45 kgf. Check loads using standardized dead weights and proving levers or other approved methods. The tolerance under the major load must be within 1 percent. Verify machine at minor load before and after removal of the major load. Apply load and take 3 readings at each of the 3 positions of the power lever using standard hardness test block. Calculate mean for each group of 3 readings. The applied loads are calibrated if mean readings fall within tolerances of Figure 9, Page 14
4 5 6 (b)
Verify machine repeatability as follows: 1 2 Take 5 hardness readings on each of the 3 hardness test blocks of different hardness levels as indicated in Figure 8, Page 12. Calculate repeatability using R1, R2,...., R5 as hardness readings in increasing order. R5 minus R1 equals the repeatability of the hardness readings. If repeatability limits of Figure 10, Page 15 are met, machine is verified.
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Tolerances on Applied Loads Figure 9
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Repeatability of Testers Figure 10
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PORTABLE ROCKWELL HARDNESS TEST - PORTABLE ROCKWELL HARDNESS TESTING TASK 70-34-04-220-010 1. Portable Rockwell Hardness Testing SUBTASK 70-34-04-99G-010 A. General. (1) (2) Portable hardness testing equipment is used when the weight, shape, or condition of a test part prevents testing by other methods. The portable hardness tester is not considered to be a precise measuring device and should not be used as the only instrument for acceptance without meeting all requirements in the calibration section. The Rockwell hardness test uses a calibrated machine to force a penetrator into the surface of the material being tested while measuring the permanent depth of the impression under minor and major loads. Both regular and superficial Rockwell hardness tests can be performed on the portable machine. The regular hardness test applies a minor load of 10 kilograms force (kgf) and major loads of 60, 100, or 150 kgf. The superficial hardness test applies a minor load of 3 kgf and a major load of 15, 30, or 45 kgf. The portable hardness tester is equipped with a means of attaching it to the surface to be tested. The indenting force may be applied using a hydraulic cylinder equipped with a pressure gage or using a screw through a calibrated spring with a dial gage. The portable tester utilizes a diamond penetrator or a 1.588 mm steel ball. See Figure 1, Page 2. The machine backs up the part to be tested with an anvil. The 3 anvils available are shown in Figure 1. The proper anvil should be selected to completely support the test part while the surface to be tested is parallel to the anvil surface and perpendicular to the penetrator.
(3)
(4)
(5)
(6) (7)
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PORTABLE ROCKWELL HARDNESS TESTING Page 1 Dec 01/03
Accessories used with Portable Rockwell Hardness Testing Machines Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-34-04-220-101 B. Equipment. (1) (2) Portable Hardness Tester. Penetrator. (a) (b) (3) Anvil. (a) (b) (c) (4) (5) Plane anvil. Convex anvil. Shallow "V" anvil. Diamond sphero-cone. 1.588 mm steel ball.
Hardness Test Blocks. Calibrate Tester as Follows: CAUTION: PORTABLE HARDNESS TESTER IS VERY SENSITIVE AND SHOULD BE HANDLED WITH EXTREME CARE. (a) (b) (c) Take 5 readings on test block. Test blocks should be in the same hardness range (10) as the part to be tested. Adjust machine so that the median of the 5 readings will not differ from test block nominal value by more than 2.0 hardness points.
SUBTASK 70-34-04-220-102 C. Materials. (1) None required.
SUBTASK 70-34-04-220-103 D. Procedure. (1) Establish type of test (regular or superficial) and scale to be used from the process document. Load and penetrator are determined by the designated scale. See Figure 2, Page 5. Select an anvil to completely and rigidly back up the shape of the part being tested. Establish test conditions, if not otherwise specified in the applicable manual, as follows:
(2) (3)
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STANDARD PRACTICES MANUAL AS907-1-1A (a) Ensure that the part to be tested is thick enough to avoid having the penetrator impression show on the anvil side of the part. See Figure 3, Page 6, Figure 4, Page 7, and Figure 5, Page 8. Select sufficiently even, flat surface of part to enable the dimensions of the imprint to be accurately determined. If the surface of the part to be tested is curved, ensure that the concave side of the curved surface faces the penetrator. Use Figure 6, Page 9 and Figure 7, Page 10 for correction factors with the readings. Determine the number of readings to be taken according to Figure 8, Page 11, for the surface finish of the part. Inspect penetrator for defects and replace as necessary. Ensure that the surface of the part to be tested is perpendicular to the axis of the penetrator. Ensure that the test surface and machine contact surfaces are clean and free from oxidation and from foreign matter. Position part to be tested and tester so that indentations are no closer to each other or to the edge of the part than 2.5 indentation diameters.
(b) (c)
(d) (e) (f) (g) (h) (4)
Securely attach tester to surface to be tested. THE OPERATOR SHOULD WEAR SAFETY GLASSES. ANY MOVEMENT OF THE TESTER ON THE PART TO BE TESTED CAN CAUSE INJURY TO THE OPERATOR AND/OR DAMAGE TO TEST PART AND TESTER.
WARNING:
(5)
Perform test using scale indicated in process document. (a) (b) Do not use the first reading after changing machine setting, anvil, penetrator, or testing at a different hardness range. Apply major load for 2 seconds unless otherwise specified.
(6)
Record the hardness value by indicating the scale used and the following example: Example: HR C 50 In this example, the HR is the Rockwell harness symbol, the C is the scale used, and the 50 is the hardness value. NOTE: Time of load application should be recorded if different from 2 second standard.
(7) (8)
Remove tester from part. Take 5 readings on standard test block of same hardness range as part tested. Compare results with test readings to ensure uniformity of readings.
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Rockwell Hardness Scales Figure 2
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Minimum Material Thickness Required for Regular Rockwell Scale and Selected Hardness Number Figure 3
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Minimum Material Thickness Required for Superficial Rockwell N Scale and Selected Hardness Number Figure 4
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Minimum Material Thickness Required for Superficial Rockwell T Scale and Selected Hardness Number Figure 5
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Corrections Added to Superficial Rockwell Dial Readings from Cylindrical Specimens of the Diameters Indicated Figure 6
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Corrections Added to Regular Rockwell Dial Readings from Cylindrical Specimens of the Diameters Indicated Figure 7
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Surface Finish Requirements Figure 8
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-34-04-220-104 E. Quality Assurance. (1) None required.
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STAND DESIGN REQUIREMENTS - MULTIPLE PURPOSE AIRFLOW MEASUREMENT STAND DESIGN REQUIREMENTS TASK 70-35-00-930-001 1. Multiple Purpose Airflow Measurement Stand Design Requirements SUBTASK 70-35-00-99G-001 A. General. This document describes the requirements for the design and build of an airflow measuring system complete with a console type stand, air dryer, and all required hardware to measure and digitally display corrected airflow measurements in pounds per second. This document does not include part holding fixtures. SUBTASK 70-35-00-930-011 B. General Design Requirements. (1) The airflow stand shall incorporate quality components into a total system which shall have the capability of accurately measuring airflow, then correcting it to 708F (21.18C) and 29.50 inch Hg (100 kPa) barometric pressure, and finally digitally displaying the corrected airflow in pounds per second. (a) All components of the airflow stand shall be capable of withstanding the environment of an industrial shop and yet function properly with a minimum of maintenance. During a year, shop temperature normally varies from 608F (15.68C) to 858F (29.48C).
(2) (3)
All of the air piping of the stand shall be of corrosion resistant material such as galvanized steel, stainless steel or copper to insure a clean system. The stand shall be designed to require only a single connection for each of the required utilities. The vendor shall include a fused disconnect mounted on the stand as part of the facility. The airflow console stand shall be a self-standing unit. The stand shall have a connected 18.0 inch (457 mm) work table across the full width of the stand with 18.0 inch (457 mm) long by 18.0 inch (457 mm) wide wings for fixtures extending from the table on each side to give a "U" shaped area in front of the console. (a) The pressure regulating valves, pressure gages, switches, pushbuttons and digital flow read-out units, shall be panel mounted in the front panel(s) of the stand. All piping, directional valves and solenoid valves, not panel mounted, shall be enclosed. The console stand shall have rear-hinged, full-length doors to give full access for maintenance, an interior floor, and two filtered 6.0 inch (152 mm) by 6.0 inch (152 mm) vents, top and bottom in both ends.
(4)
(b)
MULTIPLE PURPOSE AIRFLOW MEASUREMENT STAND DESIGN REQUIREMENTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (5) The airflow measuring system shall include a self-standing, dual tower, heatless desiccant air dryer for drying the incoming 80-90 psi (552-621 kPa) air to less than a 08F (-17.88C) dewpoint prior to use in airflow measurement. (a) The dryer shall have a pre-filter and two after-filters with the last filter being sized to insure that any particulate matter in the air is less than 10 microns in size. It shall also have an automatic drain valve with muffler, a desiccant moisture indicator, and a drying tower venting muffler. The dryer shall be at least two times oversized for the maximum required airflow and shall allow for continuous airflow measurements at this rate with automatic switching of the drying towers.
(b)
(6)
There shall be a switch actuated on/off valve at the incoming air inlet point to the stand to allow pressure drop or leak checking of the 60 psi (414 kPa) piping. All test air piping shall be free of any leaks. (a) The operating air for valves, fixtures, etc. shall be separated from the 60 psi (414 kPa) and test air circuits.
SUBTASK 70-35-00-930-012 C. Other Requirements. (1) All pressure gages shall have temperature compensation, mirrored scales, and shall be large enough in size to be easily set and read accurately. (a) All pressure gages and pressure transducers shall be incorporated with the proper valving to allow each to be calibrated in place via a connection port mounted in the panel next to each one.
(2)
The inlet air pressure gage shall have a 0-100 psig (0-690 kPa gage) range, an 8.5 inch (216 mm) diameter face, 0.1 percent accuracy, and 500 divisions. This gage shall have an easily distinguished mark at the 60 psig (414 kPa gage) setting. The two part pressure gages (inlet pressure and exit pressure) shall have a range of 0-30 inches of Hg (gage) (0-102 kPa gage) an 8.5 inch (216 mm) diameter face, 0.1 percent accuracy, and 300 divisions. (a) Each of the part pressure gages shall have a pressure transducer/ transmitter mounted just below it which also measures the respective part pressure. Each pressure transducer shall have an accuracy of 0.25 percent (or better) of the calibrated span which includes the combined effects of linearity, hysteresis, and repeatability. The range of each transducer shall be 0-50 inch Hg (0-170 kPa) gage. The linear output or inches of mercury of the transducer shall be digitally displayed to 0.1 inch Hg (0.34 kPa) or less and also transmitted to the mini-computer for use in airflow correction. A pressure regulating valve shall be located near each pressure transducer so that an operator can easily see to regulate a setting on the gage as well as the digitally displayed pressure reading.
(3)
(b)
(4)
Part cavity pressure of the various cavities within the test subject (blade or vane) shall be sensed by a furnished probe and directed to a 0-30 inch Hg (0-102 kPa) pressure transmitter for digital display. A "probe" switch shall allow cavity
STANDARD PRACTICES MANUAL AS907-1-1A pressure to be directed to a pressure transmitter only while inlet part pressure can still be read on the 0-30 inch Hg (0-102 kPa) gage. While in the "probe" position, the computer shall not accept any pressure reading. (5) The airflow stand shall have two air temperature sensors. One shall be in the 60 psi (414 kPa) air pipe upstream of the airflow sensors, and the second one in the piping which has reduced pressure/part pressure air just prior to going to the part for airflow measurement. Only one sensor shall be used at a time or shall be plugged into a digital type temperature indicator which digitally displays temperature to 0.18F (0.068C). The digital temperature indicator shall have a BCD output which is transmitted to the computer for correcting part airflow measurements as to temperature. The stand shall also have an accurate barometer mounted in the panel which shall measure and digitally indicate barometric pressure to 0.01 inch Hg (0.003 kPa). The barometer shall have an acceptable output or one which can be converted for use in correcting airflow measurements as to barometric pressure. The airflow stand shall have a dewpoint instrument which has a single sensor probe for measuring the 60 psi (414 kPa) regulated air. This instrument shall be a Panametrics Model 600 Hygrometer or an equivalent unit. This hygrometer shall be housed in a EMA-4 instrument case mounted to the airflow cabinet end where the inlet air enters the stand. The hygrometer shall measure and digitally display the dewpoint in the range of -608F (-51.18C) to +308F (-1.18C;). The digital display meter shall be remote to the hygrometer unit and be mounted in the airflow stand front panel. Each of the following airflow ranges shall be measured within 1 percent and be repeatable to less than 1 percent. Each of the sensors shall have a linear voltage output signal or a non-linear computer controlled sensor. (a) The mass flow ranges shall be as follows: Inlet High Range 0.0090-0.045 lbsec (0.0041-0.0204 kg/sec) Inlet Log Range 0.0030-0.01500 lbsec (0.0014-0.0068 kg/sec) Exit Flow 0.005-0.025 lbsec (0.0023-0.0113 kg/sec) (b) (c) Each of the above mass flow ranges shall be the mid 60 percent of the total calibrated range of its flow sensor. Some turbine nozzle segments or "vanes" have two vanes, a leading vane and a trailing vane. Each vane will have two cavities, an aft cavity and a forward cavity. Other nozzle segments, primarily stage 2 vanes, have a leading vane and a trailing vane. Each vane has only one cavity, but requires controlling the air pressure and measuring the inlet and exit air flow. Turbine blades are usually tested as a single blade. Each blade will have at least two (2) major airflow circuits which must be evaluated.
(6)
(7)
(8)
(d) (9)
All airflow measurements shall be corrected to 29.50 inch Hg (100 kPa) barometric pressure and 708F (21.18C) prior to being digitally displayed in pounds/second or kg/sec on the console panel.
STANDARD PRACTICES MANUAL AS907-1-1A (a) A microprocessor based mini-computer shall be housed within the test stand which shall receive airflow measurements along with barometric pressure and air temperature inputs, process/calculate a corrected airflow reading, and subsequently transmit to a digital display unit. The mini-computer shall have non-volatile memory and shall also have the capability of withstanding an industrial environment temperature up to 1108F (43.38C). Functional operating environment is 60-858F (15.6-29.48C) ambient temperature. Stand shall demonstrate operating for 12 hours with a 100 percent reliability at a maximum temperature of 958F (35.08C). The mini-computer shall be loaded with the necessary airflow formulas. The stand shall have a selector switch to choose the proper formula for the part to be measured. NOTE: For information about the appropriate airflow formulas for use with the airflow test stand contact the following: Honeywell. Refer to the List of Suppliers in Step D of Subtask 70-8000-800-003. (c) The vendor shall design and incorporate, as part of the stand, a method which will allow the operator of the stand to utilize the mini-computer to perform the required addition or subtraction of measured airflows and subsequently display the resultant answer.
(b)
(10) The inlet test air to a fixtured part from the flow range circuits shall require an operator to only push a button to switch from one flow range to another flow range during flow measurement of a part. (11) The test stand shall have built-in calibrated sonic nozzles for each of the flow ranges and shall have the capability to allow the operator to only push a button to change from "test" to "calibrate" and read the corrected airflow on the digital readout unit in pounds/second or kg/sec. (a) Air pressure to the sonic nozzles shall be regulated and set by indication/ reading on a 75 psig (518 kPa gage) Heise gage and also by a pressure transducer which transmits an output to a digital readout unit which displays pressure to 0.1 psi (0.7 kPa) or better. Airflow through the nozzles shall be corrected only for air temperature and barometric pressure. The calibration system shall utilize sonic nozzles determined by the detail part airflow requirements. Size and quantity will be compatible with the airflow range required. Pushbutton actuated valves shall allow all sonic nozzles to be used in the calibration of each flow sensor.
(b)
(c)
(12) The test stand may (optional) have a "flow test loop" or "calibration loop" with identified ports under the console table to allow calibration checking upstream of the flow sensors by the users setmaster/calibrated flowmeter. User will determine need prior to contract with vendor. (13) The stand shall also incorporate a "fixture air clamp" piping circuit complete with an air regulator valve and gage and a female quick disconnect fitting on the
STANDARD PRACTICES MANUAL AS907-1-1A console panel for each fixture wing. The piping and disconnect should be 0.1250.1875 inch (3.175-4.763 mm) in size. (14) The vendor shall install and identify the female quick disconnect fittings appropriately to the function that the particular fitting is to perform and shall size them according to users requirements. (15) The vendor shall furnish the interconnecting hoses from the stand to the users fixture, each having a male disconnect fitting on each end and they shall be approximately 30 inch (762 mm) in length for part pressure, inlet air to the fixtured part, and fixture clamp air. The vendor shall also furnish a 30 inch (762 mm) long hose with a small diameter probe for checking cavity pressure. (16) The vendor shall calibrate the flow sensors and calibrated nozzles at the stand utilizing an accurate evaluating system traceable to the National Bureau of Standards. The vendor shall subsequently adjust each sensors digitally displayed output to "read" the same as the corrected flow of the evaluating system. Flows should be measured over each of the required mass flow ranges and recorded.
AIRFLOW MEASUREMENT - AIRFLOW MEASUREMENT TASK 70-35-01-720-001 1. Airflow Measurement SUBTASK 70-35-01-99G-001 A. General. (1) Inspection of certain engine parts such as air-cooled blades and vanes, requires accurate measurement of airflow characteristics. In order to establish whether parts conform to acceptable corrected airflow limits, they are mounted in an airflow test facility in which an accurately measured and controlled stream of air is directed through the engine part under testing. Whichever type of equipment is used, the property which is specified in repair documents for the pertinent parts as required limits is called the flow parameter. The flow parameter is a calculated relationship between the rate of airflow, its temperature and barometric pressure. This standard practice describes the requirements for the design, capacity and build of an airflow measuring system complete with a console type stand, air dryer, and all required hardware to measure and digitally display corrected airflow measurements in pounds (or grams) per second. The airflow operation shall be performed on approved equipment by qualified personnel using approved process sheets. Prior to airflow measurement of engine parts the repair source must meet the substantiation requirements for this operation. NOTE: Additional airflow measurement stand requirements can be found in Standard Practice TASK 70-35-00-930-001, Multiple Purpose Airflow Measurement Stand Design Requirements. SUBTASK 70-35-01-720-011 B. Equipment - Airflow Test Facility. (1) The airflow stand shall incorporate quality components into a total system which shall have the capability of accurately measuring airflow, then correcting it to 708F (218C) and 29.5 in Hg (749.3 mm Hg) barometric pressure, and finally digitally displaying the corrected airflow in pounds or grams per second. All components of the airflow stand shall be capable of withstanding the environment of an industrial shop and yet function properly with a minimum of maintenance. During a year, shop temperature normally varies from 608F (158C) to 908F (328C). All of the air piping of the stand shall be of corrosion resistant material such as galvanized steel, stainless steel, copper, etc. to insure a clean system.
(2)
(3)
(4)
(2)
(3)
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STANDARD PRACTICES MANUAL AS907-1-1A (4) There shall be a switch actuated on/off valve at the incoming air inlet point to the stand to allow pressure drop/leak checking of the 60 psi (414 kPa) piping. All test air piping shall be free of any leaks. The airflow measuring system shall include a self-standing dual tower, heatless desiccant air dryer for drying the users incoming 80-90 psi (552-621 kPa) air to less than a 08F (-188C) dewpoint prior to using in airflow measurement. The dryer shall have a pre-filter and two after-filters with the last filter being sized to insure that any particulate matter in the air is less than 10 microns in size. It shall also have an automatic drain valve with muffler, a desiccant moisture indicator, and a drying tower venting muffler. The stand shall also have an accurate barometer mounted in the panel which shall measure and digitally indicate baro-metric pressure to 0.01 in. Hg (0.25 mm Hg). The barometer shall have an acceptable output or one which can be con-verted for use in correcting airflow measurements. A microprocessor based mini-computer shall be housed within the test stand which shall receive uncorrected airflow measurements along with barometric pressure and air temperature inputs, calculate a corrected airflow reading, and subsequently transmit it to a digital display unit. The mini-computer shall have nonvolatile memory and shall also have the capability of withstanding a temperature up to 1108F (438C) in an industrial environment. Functional operating environment is 608F (158C) to 908F (328C) ambient temperature. Stand shall demonstrate 958F (358C) temperature operating for 12 hours with a 100 percent reliability. The mini-computer shall be loaded with all of the different formulas given by Honeywell Product Support Engineering, required to correct measured airflow to standard conditions. The stand shall have a multi-selector switch to allow an operator to select the proper formula for the part to be measured and shall have the capability to display the corrected airflow in lb/s (g/s).
(5)
(6)
(7)
(8)
(9)
(10) The airflow stand shall have two air temperature sensors. One shall be in the 60 psi (414 kPa) air pipe upstream of the airflow sensors, and the second one in the piping which has reduced pressure/part pressure just prior to going to the part for airflow measurement. Only one temperature sensor shall be used at a time or be plugged into a digital type temperature indicator. The indicator shall digitally display temperature to 0.18F (0.068C). The digital temperature indicator shall have a BCD output which is transmitted to the computer for correcting part airflow measurements for temperature. (11) The airflow stand shall have a capability to measure dew-point using an instrument which has a single sensor probe for measuring the 60 psi (414 kPa) regulated air. This instrument shall be a Panametrics Model 600 Hygrometer or equivalent. This hygrometer shall be housed in a NEMA-4 instrument case mounted to the airflow cabinet end where the inlet air enters the stand. The hygrometer shall measure and digitally display the dewpoint in the range of -608F (-518C) to +308F (-18C). The digital display meter shall be remote to the hygrometer unit and be mounted in the airflow stand front panel. (12) The test stand shall have built-in calibrated sonic nozzles for each of the flow ranges and shall have the capability to allow the operator to only push a button to
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STANDARD PRACTICES MANUAL AS907-1-1A change from "test" to "calibrate" and read the corrected airflow on the digital readout unit in lb/s (g/s). (13) The airflow console stand shall be a self-standing unit. The stand shall have a connected work table across the full width of the stand. The table should have wide wings for fixtures extending from the table on each side to give a "U" shaped area in front of the console. (14) The pressure regulating valves, pressure gages, switches, pushbuttons, digital flow read-out units, etc. shall be panel mounted in the front panels(s) of the stand. All piping, directional valves, solenoid valves, etc., not panel mounted, shall be enclosed. SUBTASK 70-35-01-720-012 C. Procedure. NOTE: Airflow system must be approved by Honeywell Product Support Engineering before implementation on production part. NOTE: Conditions and environment under which parts are to be airflow tested are delineated in the repair document, and shall contain but not be limited to the following: Flowing air dewpoint less than 08F (-188C) Particulate matter in flowing air less than 10 microns. Oil content less than 10 parts per million by weight. Ambient temperature may range from 608F (158C) to 908F (328C). Ambient barometric pressure may range from 28 in. Hg (711 mm Hg) to 32 in. Hg (813 mm Hg). (1) All tested parts shall be thoroughly cleaned internally and externally prior to installation on the flow check fixture. Refer to repair procedure for cleaning method. Check calibration of test equipment using Honeywell approved working master. This master may be a production part either new or repaired, with a known airflow repeatability and within the performance envelope of the part. Position part in testing fixture and record the raw test values of the airflow. This data must be converted to standard conditions 29.5 in. Hg (749.3 mm Hg) barometric pressure and 708F (218C) temperature of the test air and compared to airflow characteristics which are delineated in specific repair documents.
(2)
(3)
SUBTASK 70-35-01-720-013 D. Quality Assurance. (1) (2) The airflow stand and related equipment must be calibrated and traceable to the National Bureau of Standards and be accurate to 1 percent of point at calibration. The recommended calibration time cycles are as follows:
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STANDARD PRACTICES MANUAL AS907-1-1A (a) (b) (c) (d) Frequency of airflow test facility sonic nozzle calibration: minimum of once per year. Frequency of airflow test facility instrumentation calibration: minimum of once per 3 months. Frequency of working master recheck to proof test stand: minimum of once per shift and at the beginning and the end of each series of parts. Frequency of working master calibration: minimum of once per year.
SUBTASK 70-35-01-720-014 E. Substantiation for Airflow Measurement of Air Cooled Blades. (1) If airflow measurement is improperly accomplished, part life and or engine reliability could be affected. For this reason, each shop intending to perform this operation must prove its ability to perform such an operation before production implementation. The substantiation requirements for airflow measurement are available from Honeywell. Refer to the List of Suppliers in Step D. of SUBTASK 7080-00-800-003.
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WELDING AND BRAZING PRACTICES - WELDING AND BRAZING PRACTICES TASK 70-41-00-310-001 1. Welding and Brazing Practices SUBTASK 70-41-00-99G-001 A. General. (1) Repair welding is a safe, economical method to increase the service life of aircraft engine parts, when performed by qualified personnel using approved materials and techniques. The applicable manuals for specific engines control the limits within which welding is an acceptable repair procedure, and designate the parts to which it can be applied. This section contains descriptions of the standard procedures to be used in repairing the various alloys used in those parts. (Refer to TASK 70-41-01-310-002, Titanium Welding Procedure, for special titanium welding procedure.)
SUBTASK 70-41-00-310-011 B. Policy. (1) The primary factors to be considered in establishing repair welding procedures for any part include the following. (a) Risk. Repair welds are generally prohibited on rotating components where any failure starting at a repair weld could result in an in-flight shutdown and/or severe damage to the engine. Refer to the Engine/Shop Manual for specific exceptions. (b) Susceptibility of an Alloy to Repair Welding. While the alloys used in the engine require good control and care during repair welding, those parts designated in the Engine/Shop Manual can be safely and successfully repaired by the methods described in this section. (c) Welding Effect on Strength and Durability. When establishing repair welding procedures, every effort is made to maintain the original load-carrying strength of the part. (d) Welding Effect on Dimensions. One criterion of repair welding procedures is that parts must remain free of distortion. Several of the steps in this section are included for the purpose of maintaining dimensions within serviceable limits to avoid subsequent machining operations.
EFFECTIVITY: ALL
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WELDING AND BRAZING PRACTICES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-00-310-012 C. Preparation for Welding. DO NOT BREATHE THE PARTICLES FROM GRINDING OR LET THE PARTICLES TOUCH YOU. PARTICLES FROM GRINDING CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
WARNING:
(1) (2)
After inspection has disclosed repairable defects to be welded, the defects must be prepared for welding. Remove all paint, dirt, scale and carbon deposits from both front and back surfaces of the weld area, using a stainless steel rotary brush or 80-320 grit abrasive roll, disk or sheet. Remove all anodic or other chemical protective coating from front and back surfaces of aluminum parts within 0.50 inch (12.7 mm) of the weld area, using 160or 180- grit abrasive roll, disk or sheet. Standard carbide rotary files are available from the following distributors: Refer to Figure 1, Page 6. (a) (b) (c) (d) Arc Abrasives, refer to the List of Suppliers in Step D. of Subtask 70-80-00800-003. A.T. McAvoy, refer to the List of Suppliers in Step D. of Subtask 70-80-00-800003. Dixie Industrial Supply Company, refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. Manson Tool and Supply, refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003.
(3)
(4)
(5)
Vitrified abrasive mounted points are available from the following sources: (a) (b) Arc Abrasives, refer to the List of Suppliers in Step D. of Subtask 70-80-00800-003. Norton Company, refer to the List of Suppliers in Step D. of Subtask 70-80-00800-003.
(6)
Remove stock from both edges of the crack to the minimum depth and width that exposes sound metal, and to a length approximately 0.125 inch (3.18 mm) beyond each end of the crack. See Figure 2, Page 7 and Figure 3, Page 8. If a crack extends into a rivet hole, remove the rivet before welding. Grind or machine welds flush, and redrill or ream rivet hole before replacing rivet. If the crack extends through the entire thickness of the metal, remove stock to a depth proportional to the thickness, as follows:
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Metal Thickness To 0.045 in. (1.14 mm) 0.045-0.090 in. (1.14-2.29 mm) More than 0.090 in. (2.29 mm)
Depth of Stock Removal To one-half the parent metal To three-quarters of parent metal thickness To within 0.030 in. (0.76 mm) of opposite surface
Reference Figure Figure 4, Page 9 or Figure 5, Page 10 Figure 4, Page 9 or Figure 5, Page 10 Figure 4, Page 9 or Figure 5, Page 10
NOTE: A small hand-held air- or electric-powered grinder used with a small arbor mounted grinding wheel or a rotary file is recommended for crack preparation (see Figure 1, Page 6. Wire brush after grinding or filing to remove loose chips or grit.
WARNING:
NEVER ADD WATER TO ACIDS. ADD ACIDS TO WATER WHILE STIRRING VIGOROUSLY. LOCALIZED HEAT OF SOLUTION CAN CAUSE BOILING AND SPATTERING. WEAR CLOSE-FITTING GOGGLES OR A FACE MASK, RUBBER OR NEOPRENE GLOVES, AND PROTECTIVE CLOTHING.
(7)
Etch the prepared area per procedure and instructions in TASK 70-24-00-110-033, Etching Procedures for Fluorescent-Penetrant Inspection, and TASK 70-24-99-990005, Consumable Materials. Use appropriate etching solution per TASK 70-24-99-990-005, Consumable Materials, or Table 1, Page 3. Unless otherwise noted in TASK 70-24-00-110-033, Etching Procedures for Fluorescent-Penetrant Inspection, all etching solutions should be used as soon as they are made up. The 2 part solutions for super alloys are to be mixed just before use, and are good for approximately 5 minutes. The shelf life of the etchants is given in TASK 70-24-00-110-033, Etching Procedures for Fluorescent-Penetrant Inspection. Swab etching may remove approximately 0.0001 inch (0.0025 mm) per minute as a general rule. Table 1. Etchants
(8)
Etchant Low alloy steel etchant
Material Hydrochloric acid (36-38 percent) Water
Concentration 1 part 1 part 75 cc 15 cc 180 cc 50 cc

Stainless steel etchant (A-286, 17-4 PH, etc.) Water Sulfuric acid (95-98 percent) Hydrochloric acid (36-38 percent) Nitric acid (69-71 percent)
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Table 1. Etchants (Cont) Etchant Material Acetic acid (99.7 percent) Ferric chloride (FeC136H2O) Super-alloy etchants (stainless etchant type) Hydrochloric acid (36-38 percent) Stainless steel etchant (2) Super-alloy etchants (hydrogen peroxide type) Hydrochloric acid (36-38 percent) Hydrogen peroxide (30 percent) Aluminum alloy etchant (sodium hydroxide type) Sodium hydroxide pellets Water Aluminum alloy etchant (hydrochloric acid type) Hydrochloric acid (36-38 percent) Water Magnesium alloy etchant Tartaric acid Water Titanium alloy etchant Water Nitric acid (69-71 percent) Hydrofluoric acid (48 percent) 62 cc 35 cc 3 cc 100 grams 1000 cc 1 part 1 part 100 grams 500 cc 90 parts 10 parts 1 part 1 part Concentration 75 cc 45 grams
NOTE: Commercial grade or better is satisfactory as long as concentration/strength is as stated.
(9)
Reinspect prepared areas in accordance with TASK 70-32-03-230-002, SpotFluorescent-Penetrant Inspection, or TASK 70-32-19-220-001, Enhanced Visual Inspection, to be sure that cracks are properly ground. NOTE: In the case of through cracks, be sure that the prepared area extends 0.125 inch (3.18 mm) beyond each end of the crack indication.
(10) After repair welding, clean the weld per the applicable manual section to remove oxides, and inspect in accordance with TASK 70-32-03-230-002, Spot-FluorescentPenetrant Inspection, or TASK 70-32-19-220-001, Enhanced Visual Inspection, to be sure that the defects were properly welded. The acceptance inspection of the weld repaired area must be performed in accordance with TASK 70-32-03-230-002, SpotEFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Fluorescent-Penetrant Inspection, or other methods specified in the applicable manual so that the final inspection requirements of the applicable manual are complied with. WARNING: ACETONE AND MEK ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPORS AND CONTACT OF LIQUIDS WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME. OBSERVE ALL FEDERAL AND LOCAL REGULATIONS IN THEIR USE.
(11) Weld area should be cleaned with acetone C04-003 or Methyl-ethyl-ketone C04-001 using a clean cotton cloth just prior to etching.
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Standard Carbide Rotary Files Figure 1
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Non-through Cracks to be welded from One Side with One Pass Figure 2
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Non-through Cracks to be welded from One Side with Multiple Passes Figure 3
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Through Cracks to be welded from One Side with One Pass Figure 4
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Through Cracks to be welded with Multiple Passes Figure 5
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-00-310-013 D. Gas Backup. (1) Gas backing is a method of isolating the weld area from air, vapors, and other contaminants by surrounding it with an inert gas such as argon or helium. Flow and diffusion must be carefully controlled to prevent turbulence at the air/gas boundary, which can cause contamination of the shielding gas and result in lack of penetration or oxide line defects in the weld. Application of the gas should be restricted to the area of the repair weld by the use of contoured copper backup blocks or backup cups, if the back surface of the weld is inaccessible. Refer to Figure 6 (Sheet 1 of 3), Page 12. Perforated metal C10-095 or wire mesh cloth C10094 for gas backup cups and inlet tube may be obtained from: Catalog Number Catalog No. 9226Y Material-316SS C10-094 Catalog No. 9282Y Material - Low alloy steel or Catalog No. 9358Y14 Material - 304 Stainless Steel C10-095 Manufacturer McMaster Carr Refer to the List of Suppliers in Step D. of Subtask 70-80-00800-003. McMaster Carr Refer to the List of Suppliers in Step D. of Subtask 70-80-00800-003.
Order Data Wire Mesh Cloth
Perforated Steel
(2)
If a fitted, grooved copper backup block is used, the gas grooves must provide nonturbulent gas flow to the back surface of the part, and the contoured surfaces of the block must fit the part sufficiently well to prevent air mixing with the gas. The gas exit apertures should be recessed about 0.060-0.090 inch (1.52-2.29 mm) from the surface, and the groove width should be about 0.125 inch (3.18 mm). If a gas cup is used, the diffuser should be recessed about 0.25 inch (6.4 mm) from the surface of the part. If the back surface of the weld is not accessible, the part should be sealed at all ports except for those used for gas inlet and exhaust. When this method is used, the internal space must be purged with shielding gas for a sufficient time to exclude all air from the area to be welded. Flow of shielding gas should be regulated to produce a silver colored bead. The flowrate (cfh) depends upon the application.
(3) (4)
(5)
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Gas Backup Blocks and Cups Figure 6 (Sheet 1 of 3)
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Gas Backup Blocks and Cups Figure 6 (Sheet 2 of 3)
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Gas Backup Blocks and Cups Figure 6 (Sheet 3)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-00-310-014 E. Tack Welding. DO NOT WELD IF YOU ARE NOT APPROVED (TRAINED AND QUALIFIED); USE PERSONAL PROTECTION EQUIPMENT AND APPROVED SAFETY PROCEDURES.
WARNING:
(1)
Tacks are often used as an aid or alternate to fixturing prior to welding a joint to assist in joint alignment or for positioning of parts for brazing. During welding, tacks are used to counter the effect of lift-off that produces unacceptable offset conditions in the final weld. The use of tacks is minimal and often unnecessary with properly designed and built weld fixtures and with properly fitting component parts inputted to the weld station. (a) (b) Gas backing shall be provided during the tack welding operation. Heavily oxided tacks inhibit fusion during the subsequent welding operation. No cracks are allowed in the weld bead of the tack and defects must not exceed those permitted for the primary weld. Deviations from this requirement may be allowed by specific applicable manual repair. Filler material may be used to avoid crater cracks. However, where filler material is used the reinforcement of the weld bead normally should not exceed 15 percent of the nominal stock sheet thickness. Where the reinforcement exceeds this value, the tack welds should be reworked by a benching operation using a rotary file to remove the excess material. Extra care must be taken to avoid getting metal filings in the exposed joint adjacent to the benched tack. NOTE: Crater cracks are also avoided by the proper use of downslope control governed by the Arctrol. (d) Tack welds shall penetrate 20-100 percent of sheet thickness to avoid cracking during welding. The length and spacing of the tacks depend largely upon the alloy, fitup conditions, and specific application. Figure 7, Page 16 has lengths and spacings which, in the absence of specific information in the applicable manual repair, may serve as a guideline.
(c)
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Tack Weld Lengths and Spacing Figure 7
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-00-310-015 F. Welding Processes and Equipment. DO NOT WELD IF YOU ARE NOT APPROVED (TRAINED AND QUALIFIED). USE PERSONAL PROTECTION EQUIPMENT AND APPROVED SAFETY PROCEDURES.
WARNING:
CAUTION: WHEN WELDING ON THE ENGINE OR ASSEMBLIES, IT IS IMPERATIVE THAT THE WELDING GROUND SHOULD BE ATTACHED/CONNECTED TO THE PART BEING WELDED. WELD CURRENT SHOULD NOT FLOW FROM/ THROUGH ONE ENGINE PART TO ANOTHER. GROUND CONNECTION MUST BE LOCATED AS CLOSE TO WELD AREA AS POSSIBLE. (1) Repair welding should be performed only by qualified, trained personnel. The following process and equipment are recommended for welding steels and high temperature or corrosion resistant alloys. (a) (b) (c) Process: Inert-gas shielded arc (TIG, GTA, GTAW) Torch gas: Argon, 99.995 percent purity, is preferred; 10-15 cubic feet per hour. Electrode: 1/16-3/32 inch (1.6-2.4 mm) diameter, 2 percent throated tungsten or 1.5 percent lanthanum oxide tungsten, pointed. Zirtung is recommended for aluminum and magnesium. Control: A remote-control, variable-current device should be used to control heat input. Arctrol, or equivalent, is recommended. Refer to Cutler-Hammer Inc. in the List of Suppliers in Step D. of 70-80-00. Welding Machine: 1 2 For Steel and Steel Alloys: A DC type power source capable of being downsloped with a foot pedal control to low current is required to avoid craters, crater cracks and to adjust amperage during welding. For Aluminum and Magnesium Alloys: An AC type power source equipped with high frequency and capable of being downsloped with a foot pedal control to low current is usually required. D.C. reverse polarity welding with helium shield gas is also allowed. NOTE: Arc must be started on an adjacent copper strip if high frequency starting circuit is not incorporated in the welding machine. NOTE: Use of the P8P Plasma Arc melt-in (nonkeyhole) process mode is permitted as an alternate to the P8G (TIG) process unless otherwise prohibited.
(d)
(e)
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STANDARD PRACTICES MANUAL AS907-1-1A (2) If multipass welding is required, each bead should be thoroughly cleaned by grinding or rotary filing, followed by wire brushing to remove scale. ACETONE AND MEK ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPOR, AND CONTACT OF LIQUIDS WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME.
WARNING:
(3)
Where welding is performed from both sides, the root side shall be ground or rotary filed to sound metal by removing stock from both edges of the crack, and to a length approximately 0.125 inch (3.18 mm) beyond each end of the crack, etched per TASK 70-24-01-110-034, Swab Etching Procedure, and inspected in accordance with TASK 70-32-03-230-002, Spot-Fluorescent-Penetrant Inspection. See Figure 5, Page 10. Clean with stainless steel wire brush, and wipe area with a clean cloth moistened with acetone C04-003 before welding. The use of filler wire is recommended for most repairs. Unless otherwise specified in the process document, use Figure 8 (Sheet 1 of 2), Page 20 to determine the proper wire to be used. (a) Filler wire should be stored in such a manner as to protect it from contamination, dust, dirt, oil, etc., both in the filler storage area and the weld booth. It is recommended that used ends on the filler material be clipped before use to prevent the oxidized filler material from contaminating the weld pool.
(4)
(b) (5)
Amperage may vary with thickness and type of material to be repair welded. Table 2, Page 18 lists the suggested amperage for different thicknesses of materials by weld type categories. NOTE: Conditions and part configurations may require settings outside the suggested setting range. Table 2. Suggested Starting Amperage
Type of Welding Category I - DC, straight polarity
Thickness to 0.045 in. (1.14 mm) 0.045-0.065 in. (1.14-1.65 mm) 0.065-0.090 in. (1.65-2.29 mm) over 0.090 in. (2.29 mm) Castings
Amperage 30-40 40-65 60-100 60-120 (multipass) 50-150 35-45 50-60 60-85 80-105 90-150
Category II - DC, straight polarity to 0.045 in. (1.14 mm) 0.045-0.060 in. (1.14-1.52 mm) 0.060-0.080 in. (1.52-2.03 mm) 0.080-0.100 in. (2.03-2.54 mm) 0.100-0.125 in. (2.54-3.18 mm)
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Table 2. Suggested Starting Amperage (Cont) Type of Welding Thickness 0.125 in. (3.18 mm) and over Castings Category III - AC, high frequency to 0.045 in. (1.14 mm) 0.045-0.065 in. (1.14-1.65 mm) 0.065-0.080 in. (1.65-2.03 mm) Category IV - DC, straight polarity (titanium) to 0.045 in. (1.14 mm) 0.045-0.064 in. (1.14-1.63 mm) 0.065-0.090 in. (1.65-2.29 mm) over 0.090 in. (2.29 mm) castings 40-50 60-70 70-95 70-95 50-150 30-100 50-150 125-220 Amperage 90-150 (multipass) 50-150
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Repair Welding Figure 8 (Sheet 1 of 2)
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Repair Welding Figure 8 (Sheet 2)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-00-310-016 G. Approval of Welding Equipment. (1) The installation for fusion welding must be suitable for the nature of work to be performed, and must comply with specifications existing in the aircraft industry and the official regulations in force in the country where the repair shops are situated. The equipment must be checked periodically for correct operation and safety, at least once per year. Enter in a log document the detailed results of the approved tests, the dates of inspection and repairs on the equipment. Prior to carrying out a repair, it is necessary to check the capability of the equipment to do the job by producing a welding test specimen.
(2) (3)
SUBTASK 70-41-00-310-017 H. Qualification of Personnel. (1) All the welding personnel carrying out repairs by manual welding on aircraft engine components must be highly qualified and satisfy the following conditions: (a) (b) Possess a valid certificate of proficiency for the process and the metal employed. Have correctly carried out one or more test welds to demonstrate ability before producing any new component or each set of components. NOTE: The frequency of accomplishing these tests can be reduced by the repairer depending on the skill level acquired by its personnel. (2) The testing and certification requirements shall be in accordance with the appropriate national air regulation(s) and/or specifications existing in the aircraft industry. A typical standard used for the Qualification of Welding Personnel is MilStd-1595. Enter in a log document the level of proficiency results attained and their dates. The welder must ensure that his skill level always remains valid by obtaining acceptable results and when necessary, by submitting himself to a new examination for proficiency. NOTE: The frequency of such examinations shall be determined by the repair source or locally applicable welding specifications. SUBTASK 70-41-00-310-018 I. Welding and Brazing Symbols. (1) Joint Preparation Symbols. The joint preparation symbols ( Figure 9, Page 26) are used in conjunction with the appropriate welding symbols ( Figure 10 (Sheet 1 of 2), Page 27) to provide the necessary structural information on standard welds. When symbols are not
(3) (4)
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STANDARD PRACTICES MANUAL AS907-1-1A sufficiently explanatory, dimensions and notes pertaining to the weld may be used. Resistance welding and supplementary symbols are shown in Figure 11, Page 29. (2) Welding Symbols. The composite welding symbol, made up of the surface designating arrow, type of joint preparation, and various finish, spacing or positioning symbols, often includes a process designation in the tail of the symbol. The process designations cover the different types of operations used in welding, brazing and soldering. (3) Processing Designations. Process designations for various types of joints appear as symbols in the tail of the welding symbol. These designations are defined as follows: (a) Arc and gas welding. 1 P8B (Metal arc, coated electrode). In this process, the heat is obtained from an arc formed between the work and a coated metal electrode which supplies molten filler metal to the joint. The coating of the electrode consists of a flux which protects the weld metal. P8E (Gas welding). In this process, heat is produced by a gas flame. Flux can be used for protection of the molten puddle. P8F (Submerged arc). In this process, heat is produced by an electric arc between a consumable bare metal electrode and the work. Shielding is provided by a blanket of granular flux over the weld puddle or deposit. P8G (Gas-shielded tungsten arc). In this process, heat is obtained from an arc between a tungsten electrode and the work in a shielding atmosphere of inert gas. P8J (Gas shielded metal arc). In this process, heat is obtained from an electric arc between a consumable electrode and the work in a shielding atmosphere of inert gas. P8K (Electron beam welding). Electron beam welding is a fusion joining process in which the workpiece is bombarded with a dense focused stream of high velocity electrons where the kinetic energy of the electron particles is transformed into heat upon workpiece impact. Electron beam power is developed in a gun under high vacuum; however, actual welding can be performed either in vacuum (usually) or in the atmosphere. P8P (Plasma arc). In this process, heat is obtained from an electric arc in highly ionized gas called a plasma. The arc may be either transferred (between electrode and work) or nontransferred (between electrodes within the torch). Inert gas is used as the shielding medium. P8R (Resistance welding). A group of welding processes in which welds are made by heat resulting from the resistance of the work to the flow of electric current through it and by the simultaneous application of force.
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STANDARD PRACTICES MANUAL AS907-1-1A (b) Brazing. NOTE: When the general process designation, P9, is shown in the tail of the welding symbol, any of the brazing processes described below may be used. If the words braze weld are shown in the tail, the same is true. Braze weld is brazing without the requirement of capillary action to draw filler metal into the joint. 1 P9B (Resistance brazing). A process in which the brazing heat is obtained from resistance to the flow of electric current in a circuit of which the work is a part. P9D (Induction brazing). A process in which the brazing heat is obtained from resistance of the work to the flow of induced electric current from a surrounding coil. P9E (Arc brazing). A process in which the brazing heat is obtained from an electric arc. P9F (Furnace brazing). A process in which the brazing heat is obtained by placing the prepared work in a furnace. P9G (Gas-torch brazing). A process in which the brazing heat is obtained from gas flame. P9H (Metal-bath brazing). A process in which the brazing heat is obtained from a bath of molten filler metal. P9J (Flux-bath brazing). A process in which the brazing heat is obtained from a bath of molten flux. P9K (Heat lamp brazing). In heat lamp brazing, joining or coalescence of metallic materials is produced above 8008F (4278C) by use of radiant heat obtained from high temperature bulbs or lamps. Lamp heat output energy is usually focused on the workpiece by reflectors. Atmospheres surrounding the brazing alloy and base metal is usually obtained by use of a flux, inert gas or a combination of both.
3 4 5 6 7 8
(c)
Soldering. NOTE: When the general process designation, P18, is shown in the tail of the welding symbol, any of the processes listed below may be used. 1 P18B (Resistance soldering). A process in which heat is generated by resistance to the flow of electric current through the joint between 2 nonconsumable electrodes. Flux may be applied to the joint before heating. P18D (Induction soldering). A process in which heat is generated in the joint by resistance to an electric current by means of a surrounding coil. Both solder and flux are applied to the joint before heating.
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STANDARD PRACTICES MANUAL AS907-1-1A 3 P18E (Arc soldering). A process in which soldering heat is generated by an arc between the joint and a nonconsumable electrode. Solder may be added while the arc is maintained. P18F (Furnace soldering). A process in which soldering heat is obtained by placing the assembled joint (with flux applied and solder in place) in a furnace. P18G (Gas torch soldering). A process in which soldering heat is applied to the joint with a gas flame. Normally, flux is applied before heating, and solder applied in wire form when the joint is hot enough to melt it. Flux-cored solder may also be used. P18H (Metal-bath soldering). A process in which the joint is prepared, flux applied, then dipped into a bath of molten solder, or molten solder flowed over the joint. P18J (Flux-bath soldering). A process in which the joint is prepared, solder placed in position, and the joint dipped into a bath of molten flux. P18K (Soldering-iron, soldering-gun, or soldering-pencil soldering). A process in which the heated soldering tool transfers heat to the joint to raise it to soldering temperature. Flux may be applied before heating or added with the solder in cored wire form.
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Joint Preparation Symbols Figure 9
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Interpretation of Welding Symbols Figure 10 (Sheet 1 of 2)
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Interpretation of Welding Symbols Figure 10 (Sheet 2)
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Resistance Welding and Supplementary Symbols Figure 11
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-00-310-019 J. Weld Joint Geometry and Terminology. (1) The following describes weld geometries that are typical of all welded joints and may be used as a guide when the applicable manual repair calls for specific joint geometry requirements in terms of joint fitup and weld bead quality. The following depicts variations which may occur when performing butt welds and the terminology that applies to them. Weld joint preparation is per the specific applicable manual repair instructions and SUBTASK 70-41-00-310-012, Preparation for Welding. For purposes of clarity the illustrations show square butt joints but may be applied to any method of welding or any method of joint preparation. Joint fitup prior to welding is determined by the root gap opening and the mismatch conditions that exist between the mating surfaces after the parts have been tack welded together. Joint fitup is an extremely important factor in the fabrication of sheet metal components. In most cases, joint gap and mismatch prior to welding should be held to a minimum. In all cases where specified in a applicable manual repair, those values must be observed. (a) Equal Stock Thickness. Figure 12 (Sheet 1 of 2), Page 31 illustrates joint geometry and terminology as made between materials of equal nominal thickness at the joint interface and back to 4 times the thickness from the interface. Ideally, joint geometry without any of the deviations shown is desired. The allowable degree for each condition should be per the applicable manual repair. (b) Unequal Stock Thickness. Square butt joints may be made between materials of unequal thickness as directed by the applicable manual. It is important that the repair intent relative to sheet centerline alignment be clear. Sheet thickness ratio (thickto-thin) should not exceed 2.0, based on nominal thickness, unless otherwise directed by specific applicable manual repair. When sheet thickness ratio exceeds 2.0, the thicker sheet should be prepared such that the ratio at the interface does not exceed 1.2, unless otherwise directed by a specific repair. Figure 13, Page 33 illustrates joint possibilities between materials of unequal stock thickness. All of the definitions noted in step (a), above, and Figure 12 (Sheet 1 of 2), Page 31 also apply here, as applied to the thinnest member. (c) Effects of Stock Tolerance. The effects of stock tolerance on offset definition is illustrated in Figure 14, Page 34. Offset is measured in addition to known variation in actual stock thickness. The examples shown in Figure 14, Page 34 show the effects of stock tolerance on offset for 0.063 inch (1.60 mm) nominal 0.058-0.068 inch (1.47-1.73 mm) stock. All of the definitions noted in steps (1) and (2), above also apply here.
(2)
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Weld Joint Geometry Definition Figure 12 (Sheet 1 of 2)
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Weld Joint Geometry Definition Figure 12 (Sheet 2)
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Weld Joint Unequal Stock Thickness Figure 13
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Effects of Stock Tolerance Figure 14
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-00-310-020 K. Brazing. (1) General. (a) Brazing is a process where components are joined using a filler metal (alloy) which melts above 8008F (4278C) and below the melting point of the materials being joined. The filler metal is distributed between component joint surfaces by capillary attraction. To obtain good joint strengths from the brazing process, cleanliness of components, joint clearances, time at brazing temperature, and application of filler metal must be controlled. Filler metals from brazing are classified by solidus/ liquidus temperature. The solidus temperature is the highest temperature at which a metal is completely solid. The liquidus temperature is the lowest temperature at which a metal is completely liquid. The brazing temperature can vary from 15 to 1508F (8 to 838C) higher than the liquidus temperature and is dependent on the particular properties and application of each filler metal. The brazing temperature must be lower than the solidus of components being joined. Capillary attraction is that property of liquids which promotes self-sustained flow between mating surfaces and which proceeds until an equilibrium between weight of liquid and surface tension is reached or until the capillary gap is filled. Surface tension is an inherent characteristic of all liquids, including filler metals. The flow it produces is strongly influenced by cleanliness and surface finish of the components being joined, joint clearance, purity of atmosphere, cleanliness of filler metal, correct brazing temperatures as measured by actual part temperatures, and by proper placement of the filler metal at or within the joint. Total braze time must be determined for each application. The time required at brazing temperature to complete the flow of the filler metal is normally 5 to 15 minutes after the components to be joined have reached the required temperature.
(b)
(c)
(d)
(e)
(2)
Types of Brazing. Brazing processes are designated by the method of heating. The methods normally used are furnace brazing, torch brazing, and induction brazing. (a) Furnace brazing ( TASK 70-41-03-310-004, High Temperature Furnace Braze). 1 Furnace brazing is used extensively where the parts to be brazed can be assembled with the filler metal preplaced near or in the joint. The preplaced filler metal may be in the form of wire, foil, filings, slugs, powder, paste, tape, etc. Fluxing is usually employed except when an atmosphere is specifically introduced in the furnace to perform the same function. Some furnace brazing is accomplished in a reducing gas atmosphere such as hydrogen, and either exothermic or endothermic combusted gas. Pure, dry inert gases such as argon or helium are employed to
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STANDARD PRACTICES MANUAL AS907-1-1A obtain neutral atmospheric conditions. The brazing atmosphere is either maintained in a retort or the furnace itself. 3 The types of furnaces used are heated by either electrical resistance elements, gas, or oil and should have automatic time and temperature controls. Cooling is sometimes accomplished by cooling chambers which are either placed over the hot retort or are an integral part of the furnace design. Forced atmosphere injection is another method of cooling. Parts may be placed in the furnace singly or in batches. Some furnace brazing is performed in a vacuum. This prevents oxidation and often eliminates the need for flux. Vacuum brazing has wide application in the aerospace field where reactive metals are joined or where entrapped fluxes would be intolerable. If the vacuum is maintained by continuous pumping it will remove volatile constituents liberated during brazing. There are several base metals and filler metals, however, which can be harmed by brazing in a vacuum as their low boiling point or high vapor pressure constituents cause a part of the metal to be lost. Vacuum is a relatively economical method of providing an accurately controlled brazing atmosphere. Vacuum maintains the surface cleanliness needed for good wetting and flow of filler metal without the use of fluxes. Base metals containing chromium and silicon, which normally require very pure, low dewpoint atmosphere gas for brazing, are easily vacuum brazed. Super alloys containing highly reactive aluminum and titanium may be brazed in vacuum although prior surface plating is recommended to improve wet-out or braze flow characteristics.
(b)
Torch brazing ( TASK 70-41-02-310-003, Brazing of Joints in Formed Tubing). 1 As the name implies, torch brazing is accomplished by heating with a gas torch or torches. Depending upon the temperature and the amount of heat required, the fuel gas (acetylene, propane, natural gas, etc.) may be burned with compressed air or oxygen. Brazing filler metal may be preplaced in the forms of rings, washers, strips, slugs, powder, etc., or it may be fed from hand-held filler metal, usually in the form of wire or rod. In any case, proper cleaning and fluxing are essential. For manual torch brazing, the torch may be equipped with a single tip. Manual torch brazing is particularly useful on assemblies involving sections of unequal mass.
(c)
Induction brazing. 1 The heat necessary for brazing with this process is obtained from an electric current induced in the parts to be brazed, hence the name induction brazing.
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STANDARD PRACTICES MANUAL AS907-1-1A 2 When induction brazing, the parts are placed in or near an alternating current-carrying coil and do not form a part of the electrical circuit. The brazing filler metal is usually preplaced. Careful design of the joint and the coil set up are necessary to ensure that the surfaces of all members of the joint reach the brazing temperature at the same time. Flux is usually employed except when a atmosphere is specifically introduced to perform the same function. The three common sources of high-frequency electric current used for induction brazing are the motor generator, spark-gap converter, and vacuum tube oscillator. The depth of heating by induction depends primarily on the frequency of the alternating current. As the frequency is increased, both the depth of the current penetration and depth of the heated zone in the workpiece decreases. For example, the theoretical depth of current penetration is about 0.035 inch (0.89 mm) at a frequency of 3 kHz but decreased to about 0.003 inch (0.08 mm) at 500 kHz. Frequency ranges from 60 Hz to 460 Hz are used in induction brazing. The higher frequencies should be selected when shallow heat penetration is desired. For the majority of brazing applications, the frequencies used are seldom below 10 kHz, the peak frequency obtainable from motorgenerator power supply units.
(d)
Arc brazing. 1 Arc brazing is defined as a brazing process using a Gas Tungsten Arc (GTA) welding torch as the heat and inert gas shielding source. This process has also been called TIG brazing. This process provides a more localized heating than that which occurs with Torch Brazing (P9G). The filler metal is added to the braze joint using wire. The base metals are not melted, only the filler metal melts. Bonding takes place between the deposited filler metal and the hot unmelted base metals in the same manner as conventional brazing. Capillary action is not a factor in distribution of the brazing filler metal. The filler metal is melted and deposited in grooves and fillets exactly at the points where it is to be used. (Source: AWS Welding Handbook, Volume 2, eighth edition, pages 380 and 414). Braze fluxes are not used with this process. Prior to braze, the joint faces and adjacent surfaces of the base metal must be cleaned to remove all oxides, dirt, grease, oil, and other foreign material.
(3)
Filler Metals. Filler metals and brazing temperature will be specified in each repair. Figure 15, Page 38 lists the most common brazing alloys used in the repair of parts, their composition, brazing temperatures, and recommended usage.
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Common Brazing Alloys Used for Repairs Figure 15
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TITANIUM WELDING - TITANIUM WELDING PROCEDURE TASK 70-41-01-310-002 1. Titanium Welding Procedure SUBTASK 70-41-01-99G-002 A. General. (1) Parts made of titanium and its alloys require special handling throughout the repair welding process. Titanium absorbs atmospheric gases and surface contamination at elevated temperatures which permanently affect its physical and mechanical properties. For this reason it is mandatory that an effective inert gas atmosphere shield the weld puddle and heated base material during the welding operation and that the material surface be free of oxides, oil, dirt and other impurities of contamination. Once cleaned, the part should not be handled except with clean cotton gloves since even fingerprints may contaminate the weld sufficiently to cause weld or base metal defects. ACETONE AND METHYL-ETHYL-KETONE ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPOR, AND CONTACT OF LIQUIDS WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME.
WARNING:
(2)
Cleaning and acid pickling procedures as described in TASK 70-22-02-110-014, Special Cleaning Procedure No. 2 - Titanium Cleaning, are normally used before and after welding and heat treating. However, an alternate cleaning procedure may be used which consists of steam cleaning the weld repair area or part per TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning, (or alkaline cleaning in accordance with paragraph E.(2) in 70-22-02), and scrubbing the repair area with methyl-ethyl-ketone C04-001 or acetone C04-003. The weld repair area is considered to be the total area affected by high welding heat, including the back side of the material. The back side of the weld area must be steam cleaned, abrasive polished and solvent wiped as described below. If the surfaces are inaccessible for such cleaning, chemical cleaning of the entire case per TASK 7022-02-110-014, Special Cleaning Procedure No. 2 - Titanium Cleaning, using minimum allowable times in each chemical is required. The repair area is then prepared for welding by polishing with 150-320 grit silicon carbide abrasive and prepped with a high speed rotary file for defect removal. The polished area should extend 0.500 inch (12.70 mm) beyond the weld zone on both top or bottom surfaces as described above. After abrasive polishing, the use of a clean stainless steel wire brush is allowed to assure a clean smooth surface is obtained prior to weld repair.
(3)
(4)
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TITANIUM WELDING PROCEDURE Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: ACETONE AND METHYL-ETHYL-KETONE ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPOR, AND CONTACT OF LIQUIDS WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME.
(5)
Upon completion of mechanical cleaning, the areas to be welded should be given a final solvent wipe using methyl-ethyl-ketone or acetone and a clean lint-free cotton cloth.
SUBTASK 70-41-01-310-021 B. Crack Preparation. (1) Cracks should be prepared in general accordance with TASK 70-41-00-310-001, Welding and Brazing Practices; however, if grinding wheels have been used, the cut should be dressed with a high-speed steel or carbide rotary file to remove all traces of embedded abrasive before proceeding to the etching operation. Etch, using etchant described in item 6 of Table 1, Page 3 in paragraph C.(7) TASK 70-41-00-310-001, Welding and Brazing Practices, then rinse with potable or low mineral tap water. ACETONE AND METHYL-ETHYL-KETONE ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPOR, AND CONTACT OF LIQUIDS WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME.
(2)
WARNING:
(3)
Dry by blowing with clean shop air, or by wiping with a clean, lint-free cotton cloth moistened with acetone or methyl-ethyl-ketone.
SUBTASK 70-41-01-310-022 C. Procedure. (1) Welding of parts should be initiated within 12 hours after cleaning. If more than 48 hours have elapsed since cleaning of parts or more than 8 days since cleaning of filler wire or weld test strips, reclean in accordance with paragraph 1.C. to 1.E. of this procedure. WARNING: ACETONE AND METHYL-ETHYL-KETONE ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPOR, AND CONTACT OF LIQUIDS WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME.
(a) (b) (c)
Wipe all areas to be welded with acetone or methyl-ethyl-ketone and a clean lint-free cotton cloth. When practical, place parts in a welding chamber and begin gas purging with welding grade argon or helium. (Argon is preferred.) Test for adequacy of gas purging by welding test strips of titanium alloy. These strips shall be welded each time a chamber is loaded and when purging is interrupted.
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STANDARD PRACTICES MANUAL AS907-1-1A 1 Make bead-on-plate welds with or without filler wire on titanium alloy strips. The weld beads shall be at least 2 inches (51 mm) long and depth of the melt shall be at least as deep as the depth of the area being repaired. If the test strips show no color on the weld bead other than bright silver or light straw, the purge can be considered adequate. If other colors are present, continue or repeat purging procedure until test strips indicate that it is adequate. NOTE: A supplementary shielding-gas line may be required to purge air trapped in inverted cavities or recesses of the part to be welded. (d) The use of filler wire is recommended for most repairs. Unless otherwise specified in the process document, use TASK 70-41-00-310-001, Welding and Brazing Practices, to determine the proper filler wire to be used. Repair weld the part only after adequate purging has been verified. NOTE: If any color other than bright silver or light straw appears on the weld bead during welding operation, stop welding. Continue or repeat purging until test strips indicate that purging is adequate, then resume welding on the part. SUBTASK 70-41-01-310-023 D. Local Inert Gas Shielding. (1) In some instances, due to the size of the part, repair area access, or part geometry, use of a controlled atmosphere welding chamber may not be desired. Under this circumstance, the use of oversized torch gas cups, trailing shield, backup shields, and preplaced auxiliary shielding devices are permitted provided appropriate judgment and caution are exercised. The welding requirement and objective is to provide thorough and uninterrupted inert gas shielding of the heated area with a welding grade of argon. When this is accomplished, out-of-chamber welds can be produced with excellent results. (a) Welding inert gas cups and shielding devices should be designed and selected to provide required gas coverage for repair welding each application. The method chosen should be set up to duplicate the actual part condition and evaluated initially for adequateness of shielding gas by producing welds on scrap or sample titanium pieces. The welding procedure used should include provisions for adequately shielding any area at or adjacent to the repair that is exposed to welding heat. Typical types of gas backup cups are illustrated in TASK 70-41-00-310-001, Welding and Brazing Practices. Gas cups of similar configuration can be used as trail cups behind the weld torch to provide additional shielding gas at the top side of the joint. To improve weld torch gas shielding capability, an auxiliary torch cup may be used which encompasses the standard torch weld cup as illustrated in Figure 1, Page 4.
(e)
(b)
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Secondary Gas Cup Construction Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-01-310-024 E. Post Welding Preparation. (1) (2) (3) When welding has been completed, steam clean the part per TASK 70-21-03-160001, Cleaning Method No. 3 - Steam Cleaning, in preparation for heat treatment. Stress-relieve weld repaired parts as directed in the repair section for the specific part. Inspect in accordance with the fluorescent-penetrant method, as referenced for the specific part in the applicable manual.
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BRAZING OF JOINTS IN FORMED TUBING - BRAZING OF JOINTS IN FORMED TUBING TASK 70-41-02-310-003 1. Brazing of Joints in Formed Tubing SUBTASK 70-41-02-99G-003 A. General. (1) Joints in stainless steel tubing can be torch brazed when repair is authorized by applicable manual. Torch brazing of tube joints shall be performed only by personnel qualified by training and experience in the practice of torch brazing. Joints in nickel based alloy tubing (Inconel) cannot be repaired by torch brazing. Repair of this type of tubing must be accomplished by section replacement. The high temperatures required for re-melt and braze filler material flow make torch brazing impractical for nickel-based alloy tubing.
(2)
SUBTASK 70-41-02-310-031 B. Preparation of Joint. (1) If any part of the joint to be brazed has been used before, all residual filler metal must be removed from it before attempting to braze the joint. The residual metal could prevent proper assembly because of interference. Braze removal can be accomplished by 2 methods: chemical and abrasive. (a) Chemical Removal. Braze filler metal can be removed from part small enough to be immersed in an acid bath. This method can also be used by swabbing the acid solution onto large or unwieldy parts that cannot be immersed. Proceed as follows: 1 Protect workbench, tools, etc. with a plastic dropcloth before mixing or using the acid. WEAR RUBBER GLOVES AND APRON, AND FACE SHIELD, WHILE HANDLING OR USING THE ACID SOLUTION. IF ACID CONTACTS THE SKIN OR EYES, FLUSH IMMEDIATELY WITH COOL WATER, AND OBTAIN IMMEDIATE MEDICAL AID. NEVER ADD WATER TO ACID WHEN MIXING SOLUTIONS. HEAT OF REACTION CAN VAPORIZE WATER EXPLOSIVELY, CAUSING BOILING AND SPATTERING.
WARNING:
WARNING:
Prepare a 50 volume percent solution of nitric acid C04-072 by slowly pouring one part of nitric acid (428 Be) into one part of water while stirring vigorously.
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BRAZING OF JOINTS IN FORMED TUBING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A 3 Immerse the part in solution until residual braze filler metal is dissolved. If immersion is impractical, swab with a plastic cloth or swab affixed to a stainless steel or plastic rod. (Cotton swabs are acceptable for small areas.) Rinse part thoroughly with water to remove all acid residue.
CAUTION: SAND CAREFULLY TO AVOID UNDERCUTTING. (b) Abrasive Removal. Areas of high residual braze filler metal, such as original braze fillets, can be removed carefully with a silicon carbide sandroll or abrasive. Do not use aluminum oxide. After high metal is removed, the remaining filler metal can be removed manually, using 80 grit abrasive paper or cloth or chemicals, as described in paragraph B.(1)(a), above. (2) Gap Clearance. Trial fit the parts to be joined, and check to be sure that the clearance between faying surfaces does not exceed 0.005 inch (0.13 mm). On round tube joints, the diametral clearance should be 0.002-0.005 inch (0.05-0.13 mm). Too much clearance will prevent the filler metal from bridging the gap, even if both faying surfaces are wetted. If necessary, rework tube ends, couplings or fittings to obtain proper clearance. (3) Surface Cleaning. It is necessary to clean the surfaces of the joint immediately before brazing to ensure that filler metal will wet the faying surfaces. Flux will not remove oil or grease films, or surface oxides. Further, it is necessary to polish the surface to produce the capillary action required to cause the filler metal to flow into the joint. Clean and polish as follows: (a) (b) Insert plugs in ends of tubing to prevent entry of abrasive dust. Polish approximately 1.50 inches (38.1 mm) of each tube end with 180 grit abrasive paper or cloth. Use circumferential polishing strokes, rather than axial or longitudinal, to facilitate the flow of filler metal. ACETONE AND METHYL-ETHYL-KETONE ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID EXCESSIVE INHALATION OF VAPORS AND CONTACT WITH THE SKIN. TAKE PRECAUTIONS AGAINST FIRE.
WARNING:
(c) (d)
Remove abrasive dust completely from part by wiping the polished areas with a clean cloth wetted with acetone or methyl-ethyl-ketone. Remove plugs, being careful to avoid touching the cleaned areas with bare hands.
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-02-310-032 C. Brazing. (1) Mark the insertion depth of the tube, as specified in the appropriate assembly or repair section, by marking a light scribe mark. Braze as follows: WARNING: ACETONE AND METHYL-ETHYL-KETONE ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID EXCESSIVE INHALATION OF VAPORS AND CONTACT WITH THE SKIN. TAKE PRECAUTIONS AGAINST FIRE.
CAUTION: DO NOT HANDLE CLEANED AREA OF TUBING WITH BARE HANDS. USE CLEAN GLOVES, OR HANDLE ONLY AREAS THAT WILL NOT BE WETTED BY FILLER METAL. USE CLEAN TWEEZERS OR NEEDLENOSED PLIERS TO HANDLE RINGS OF FILLER METAL. (a) Clean rings of filler metal in acetone C04-003 or methyl-ethyl-ketone C04-001, and install in internal grooves in coupling. Surface oxides on braze filler may be removed mechanically using dry No. 00 grade steel wool. Apply a thin coating of flux to the entire inner surface of the coupling. If the joint is a simple lap joint in which the outer surface of one tube mates with the inner surface of another, lightly coat the entire inner mating surface of the female member with flux. Coat the cleaned external surface of the male tube member with flux, and insert it in the coupling or mating tube. Make sure that insertion depth, as previously marked on tubes, is correct. Braze Parameters. 1 2 Process - Oxy Acetylene. Acetylene - 5 psi (34.5 kPa). NOTE: Alternative fuel gasses such as MAPP gas or propane are permitted. The operator must be certified with the specific torch and technique and must be able to control the heat input. The operator must demonstrate with coupons that the process will make a good braze joint. 3 4 5 6 7 8 Oxygen - 12 psi (82.8 kPa). Tip sizes - No. 1 to No. 4 (dependent on stock thickness). Flame - neutral to slightly reducing. Filler - AMS 4770 (low temp) or AMS 4772 (high temp). Flux - AMS 3410 or AMS 3411 for AMS 4770 silver braze alloy. Flux - AMS 3411 for AMS 4772 silver braze alloy.
(b)
(c)
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STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: DO NOT USE OXIDIZING FLAME. DO NOT LET THE SMALL LIGHT BLUE CONE OF THE FLAME TOUCH THE METAL. ONLY THE DEEPER BLUE FLAME SHOULD CONTACT THE METAL OR BRAZE ALLOY. (d) Move the flame around the joint to distribute the heat evenly; stainless steel does not conduct heat readily, and all parts of the joint must be heated directly by the flame. If a coupling with internal rings of filler metal is used, watch for the filler metal to flow to the outer edges of the coupling. In a simple lap joint, force feed the filler metal until flow into the joint is observed and can be seen around the entire periphery of the exposed edge of the joint. Do not pile up excessive filler metal at the exposed edge.
CAUTION: FLUX RESIDUE IS HIGHLY CORROSIVE AND MUST BE REMOVED COMPLETELY. (e) Let the joint cool, then remove flux residue with a cloth saturated in warm water and a stainless steel wire brush. Flush the inside with hot water, or steam clean by blowing steam through the tube for 10 minutes minimum. Blow out residual water with filtered shop air. Where feasible, brazed tubes may be placed in boiling water for 10 minutes minimum to dissolve braze flux and blow dry with filtered shop air.
SUBTASK 70-41-02-310-033 D. Braze Acceptability Limits for Tubing. (1) Inspect finished joints as follows: (a) Acceptability Limits for Brazing. Visual indications are surface discontinuities which can be observed without magnification or aid of a non-destructive test process, that may indicate the presence of surface flaws. 1 The following acceptability limits apply to the braze filler material and are not applicable to the parent material. If type of imperfection is not assigned specific limits, the imperfection is not permitted. Exposed Edge Joints. The following imperfections in exposed edge joints as determined by visual inspection are permitted for all tubing braze joints when silver or gold braze filler material is specified. An exposed edge joint is defined as the external edge of the joint visible from the outside of the tube (See Figure 1, Page 8). a Maximum Linear Fillet Length. (See Figure 2, Page 9). For material thicknesses less than or equal to 0.2 inch (5.08 mm): DIM A maximum = material thickness. DIM B maximum = 125 percent of material thickness or 0.10 inch (2.54 mm), whichever is greater. For material thicknesses greater than 0.2 inch (5.08 mm):
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STANDARD PRACTICES MANUAL AS907-1-1A DIM A maximum = 0.25 inch (6.35 mm) or material thickness, whichever is less. DIM B maximum = 125 percent of DIM A. b Irregular Fillets. Irregular fillets (Type A) are defined as non-linear fillet edges where the external braze fillet varies as shown in Figure 3, Page 10. The fillet length (leg length) may not vary more than fifty percent of the maximum allowed fillet length [Ref para D.(1)(a) 2 a] within 0.25 inch (6.35 mm) of the periphery length for irregular fillet Type A. Irregular fillets Type B are defined as non-linear surfaces of exposed filler material (See Figure 4, Page 11). A maximum of 0.020 inch (5.08 mm) non-linearity above or below braze material surface is allowed for Type B irregular fillets. c Negative Fillet. A Negative fillet is defined as a lack of filler material at the edge of the materials being joined by brazing (See Figure 5, Page 12.) Localized concavity is when negative fillet length is not completely around the braze joint. Negative fillets or localized concavity are not allowed. d Pin Holes or Surface Porosity in Braze Fillets. Pin holes or surface porosity is defined as gas pockets or small holes in the surface of the braze material that has a depth which may extend totally through the filler material. e Acceptability Limits for Pin holes or Porosity. Pin holes with a maximum diameter of 0.030 inch (0.76 mm) are allowed with a minimum spacing of no greater than 2X the largest adjacent indication with a maximum of six pin holes allowed per linear inch (25.4 mm) of fillet. (b) Non-Exposed and/or Internal Edge Joints. Imperfection limits do not apply for internal edge joints. Non-exposed and/or internal edge joints do not require inspection. (c) Internal Joints Acceptability Limits. An internal joint is defined as the common mating surfaces of the pieces being joined by braze filler material (See Figure 6, Page 13). 1 Aggregate Area. a The total area of voids and unbonded areas compared to the total joint area shall not be greater than 35 percent for stainless steel tubing that utilize silver and gold alloys as braze filler material.
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STANDARD PRACTICES MANUAL AS907-1-1A The total area of voids and unbonded areas compared to the total joint area shall not be greater than 20 percent for nickel based alloy tubing that utilize nickel alloys as braze filler material. NOTE: Void is defined as a volume unfilled with braze filler material between the surfaces being joined. Unbonded area is defined as an area within a brazed joint in which the braze filler flowed, but did not bond to one or more of the surfaces being joined. 2 Maximum Length of a Single Imperfection. a The maximum length of a single imperfection compared to the total length (measured in the same direction) of the joint shall not be greater than 35 percent.
Tubing Joints with Pressure Differential. a When the braze joint is exposed to the tube internal pressure and if a pressure check requirement exists, then a continuous sound braze is required for a minimum of 0.060 inch (1.52 mm) in any direction. This requirement takes precedence over the four requirements of paragraph D.(1)(a) 2. The 0.060 inch continuous sound braze may be located any where within the required internal braze area (see Figure 7, Page 14).
Non-Pressure Differential Joints. a For non-pressure differential joints such as attachments for clamps, wear sleeves and brackets on formed tubing without a pressure differential between the internal and external environment of the joint, requirement for internal joint imperfections need only apply to an area of 0.150 inch (3.81 mm) width around the periphery.
Braze splatter/positive metal flashing and/or droplets of the braze alloy not part of the braze fillet and not exceeding 0.020 inch (0.51 mm) in height above the tube wall and/or fitting surface is acceptable up to 0.50 inch (12.7 mm) away from the braze joint. Braze splatter within 0.50 inch (12.7 mm) of the braze joint that exceeds 0.020 inch (0.51 mm) in height shall be removed to a height of 0.00 - 0.002 inch (0.0 - 0.51 mm) per SUBTASK 70-41-02-310-031, Preparation of Joint. Remove the splatter to produce a surface finish no greater than 32 microinches (0.85 micrometers) RMS. Visual comparison is an acceptable method for determining height of braze splatter. Braze splatter not exceeding 0.003 inch (0.8 mm) in height above the wall and/or fitting surface is acceptable if located 0.050 inch (12.7 mm) away from the braze joint. Braze splatter greater than 0.50 inch (12.7 mm) away from the braze joint must be removed to a height of 0.00 0.003 inch (0.0 - 0.51 mm) per SUBTASK 70-41-02-310-031, Preparation of Joint. Remove the splatter to produce a surface finish no greater than 32 microinches (0.085 micrometers) RMS.
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STANDARD PRACTICES MANUAL AS907-1-1A 7 Braze splatter is not allowed on sealing surfaces or threads of fittings (see Figure 8, Page 15).
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Examples of Exposed Edge Joints Figure 1
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Maximum Linear Fillet Length Figure 2
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Type A Irregular Fillet Figure 3
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Type B Irregular Fillet Figure 4
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Negative Fillet Figure 5
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Internal Joint Type Figure 6
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Internal Braze Area Figure 7
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Examples of Mating and Sealing Surfaces Figure 8
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HIGH TEMPERATURE FURNACE BRAZE - HIGH TEMPERATURE FURNACE BRAZE TASK 70-41-03-310-004 1. High Temperature Furnace Braze SUBTASK 70-41-03-99G-004 A. General. (1) Brazing is the term for a special group of welding procedures in which base metals are bonded by heating them to sufficient temperatures above 8008F (426.78C) and using a nonferrous filler metal with a melting point below that of the base metals. The filler metal is pulled between the closely fitted surfaces of the joint by capillary attraction. High temperature furnace brazing is usually done at 17508F (954.48C) or more in a vacuum. Because of the unique design and fabricating advantages of brazing procedures, they are used frequently to manufacture aircraft components. But the details of the procedure must be accurately controlled to make sure of consistently high joint strength. Requirements for specified conditions such as part cleanliness, joint clearance, and application of the brazing materials must be closely followed. Of the many fabrication repairs that are done with brazing processes, the replacement of honeycomb is most frequent. This Standard Practice does not give sufficient detail for a specific part application. When brazing is required and authorized, refer to the applicable manual repair for specific details.
(2)
(3) (4)
SUBTASK 70-41-03-310-041 B. Equipment. (1) Thermal Requirements. Furnaces used for brazing should meet with the minimum requirements for accuracy of temperature control, temperature uniformity within the hot zone, and temperature heat-up and cool-down rates when they are loaded with the maximum total mass of fixturing and parts for which they are qualified. Make sure that the furnaces agree with the requirements for temperatures through the maximum temperature at which they will be used and/or the temperatures that will be set as requirements for the specific repairs to be made. These minimum requirements are as follows: (a) (b) (c) Temperature Capability: Braze temperature + 1008F (568C). Maximum Thermal Nonuniformity: Nominal 208F (118C) in all areas of the furnace hot zone, as set on controller. Minimum Heat-up Rate: From 10008F (5388C) to braze temperature, 258F (148C) per minute.
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HIGH TEMPERATURE FURNACE BRAZE Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (d) (2) Minimum Cool-Down Rate: From braze temperature to 10008F (5388C), 108F (68C) per minute.
Vacuum Furnace Requirements. Furnaces which are qualified for vacuum brazing must agree with minimum vacuum performance requirements as follows: (a) Maximum pressure at room temperature, 12008F (648.98C), and at the maximum brazing temperature for which the furnace is qualified, shall be less than 10-3 torr (0.13 Pa) with the vacuum pumps in operation. The room temperature leak-up rate shall not be more than 30x10-3 torr (4 Pa) per hour. At the maximum brazing temperature, the leak-up rate shall not be more than 120x10-3 torr (16 Pa) per hour. Leak-up rates shall be determined when the equipment is empty and shall be checked by measuring the change in pressure which occurs during a minimum time span of 15 minutes with the valve between the pumping system vacuum and the chamber closed. Vacuum furnace brazing may require a pre-braze bake-out run before brazing starts to remove absorbed gas from porous materials. This removal prevents out-gassing from causing contamination of the parts before brazing. Insert gas may be put into the furnace for cooling if it agrees with the dew point requirements of paragraph (3). The inert gas may be argon (99.995 percent purity) or nitrogen (99.98 percent purity), but nitrogen may not be put into the furnace above 20008F (10938C).
(b)
(c)
(d)
(3)
Atmosphere Furnace Requirements. (a) Special brazing atmospheres are designed to minimize the formation of chromium and other stable oxides on the component surfaces during the brazing operation, and to remove superficial oxides which may form below brazing temperature. High purity and sufficient dryness (dew point) must be controlled. In some cases, vacuum brazing is used to better control the presence of surface oxides during the brazing operation. Equipment qualified for hydrogen or inert gas atmosphere brazing shall have a dew point of no wetter than -608F (-518C), as measured at the exhaust. This measurement shall be made at room temperature, at 12008F (6498C), and at maximum brazing temperature. These measurements shall be made after sufficient gas flow time at the test temperature has permitted the dew point to become stable. (This is to eliminate the effects of out-gassing and/or oxide reduction of the furnace load.)
(b)
(4)
Instrument Requirements. (a) Temperature measuring equipment shall have an accuracy of 0.5 percent of their span. Thermocouples measuring the part temperature are usually shielded from direct furnace radiation and are put as near to the braze joint as safely possible. Pressure measuring equipment shall be accurate to 0.2x10-3 torr (0.026 Pa) at a pressure of 1x10-3 torr (0.13 Pa) or less. This will require an ion gage type of instrument.
(b)
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STANDARD PRACTICES MANUAL AS907-1-1A (c) (d) Dew point measuring equipment shall be accurate to 108F (68C). Instruments that agree with these requirements should be in position during the equipment qualification testing and during brazing operations.
SUBTASK 70-41-03-310-042 C. Procedure. NOTE: Authorized repairs that use furnace brazing are given in the applicable manual. Always refer to the applicable manual repair for specific information on specific parts. If the applicable manual does not agree with this procedure, follow the applicable manual. (1) Cleanliness and Surface Preparation. (a) All part surfaces shall be free of oxides, oils, grease, dirt, paint and similar substances which may cause contamination of the furnace atmosphere and/ or the part joint during the brazing operation. It is important that no contamination be introduced to the base metal surfaces to be brazed or into the fluxes or atmospheres which are designed to protect them from contamination. This does not apply to the use of binders or stop-off, when required, but stop-off must be used carefully to make sure that none accidentally goes on the surfaces to be brazed. It will prevent the flow of the filler material through the joint. The primary function of fluxes and protective, reducing furnace atmosphere is to keep the formation of oxides at a minimum during the brazing operation. Thus, parts must be correctly cleaned before they are brazed. The cleaning of parts before brazing is usually done by mechanical or chemical methods, since many surface oxide layers are highly resistant. After all chemical treatments, thorough rinsing is required to remove all remaining cleaning agents from the component surfaces. Cleaning agents that remain from mechanical cleaning shall also be removed. Refer to the applicable manual repair for specific cleaning instructions. Wear clean white gloves when you touch parts after they are clean. The brazing operation should occur as soon as possible after cleaning, and parts should be stored in plastic bags during extended periods between cleaning and brazing. Base metal, atmospheric conditions, movement, storage, and other similar conditions have an effect on the time after which cleaning becomes necessary again. Plating of joint surfaces before brazing is controlled by the applicable manual procedure for the specific part being brazed.
(b)
(c)
(d)
(e) (2)
Joint Clearance. The gap (clear distance between the interfaces of the joint being brazed) is very important and must be controlled. This joint clearance has an important effect on the mechanical performance of the brazed joint. The clearance dimension is related to the capillary attraction that pulls the filler material into position after oxide films have been removed. Think of joint clearance in relation to conditions at a given moment, such as room temperature or brazing temperature, and the base
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STANDARD PRACTICES MANUAL AS907-1-1A metals being brazed. Refer to the applicable manual procedure for the gap required at the specific joint being brazed. (3) Application of Brazing Materials. (a) The filler material must be prepared properly to make sure that it does not move while it remains in the solid state, before and during the brazing operation. It must be put in a location from which it will flow through the joint area correctly. The location and quantity of the filler material is frequently controlled to limit the size or location of the fillet. The quantity of filler material used becomes very important when such parts as honeycomb seals are brazed. The size of the fillet can have an effect on mechanical strength of the seal, but it must be limited to prevent over-filling of the cells, which would have a detrimental effect on the function of the seal. If the filler material is put in the correct location, it will flow through and fill the joint, making fillets at all exposed joint edges. Follow the requirements for filler quantity and location that are given in the applicable manual procedure for the specific part being brazed. Stop-off materials, to control filler materials outside the joint area, and binders, to keep powder-type filler materials in the correct location, may be used as specified in the applicable manual repair. Use metallic shims, wire, or powders to correct insufficient joint fitup only if they are specified in the applicable manual.
(b)
(c) (4)
Braze Fixturing. (a) Brazing fixtures can have an effect on the part mechanically, and also on the brazing cycle. Refer to the applicable manual procedure for specific recommendations on specific parts.
(5)
Braze Run Procedure. CAUTION: FAILURE TO FOLLOW THE SPECIFIC HEATING AND COOLING STEPS IN THE APPLICABLE MANUAL COULD RESULT IN PART DISTORTION, STRAIN AGE CRACKING AND/OR MATERIAL PROPERTY CHANGES. (a) (b) Thermocouples shall be operational before the furnace is sealed. Set the overtemperature control at the brazing temperature +508F (+288C). Increase the temperature to the equilibration temperature as specified in the applicable manual. Make sure that thermocouples equalize at +208F (+118C) in less than 10 minutes. Continue the heating cycle to the brazing temperature in steps and times as specified in the applicable manual for the specific part being brazed. Cool to the furnace unload temperature, in the steps, at the rate, and in the atmosphere specified in the applicable manual.
(c) (d) (6)
Rebraze Cycles.
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STANDARD PRACTICES MANUAL AS907-1-1A (a) Rebraze cycles shall be done only as specified in the applicable manual repair.
SUBTASK 70-41-03-310-043 D. Quality Assurance. (1) Inspect the finished joint as follows: (a) (b) Visually inspect for continuity of braze alloy fillet around all exposed edges of the joint. Use 10-power magnification and sufficient lighting if necessary. Check the brazed joint for voids, porosity, discontinuities, erosion, and mechanical integrity. Use the amounts and methods that are specified in the applicable manual procedure. Make sure that all abrasive materials have been removed from the part.
(c)
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RESISTANCE WELDING - RESISTANCE WELDING - SPOT, SEAM, AND PROJECTION TASK 70-41-04-310-005 1. Resistance Welding - Spot, Seam, and Projection SUBTASK 70-41-04-99G-005 A. General. (1) Resistance welding is a group of welding processes in which welds are made by heat resulting from the resistance of the work to the flow of electric current through it and by the simultaneous application of force. This Standard Practice establishes the requirements for spot, seam and projection welded joints in products of iron, nickel, cobalt, titanium, aluminum and magnesium base alloys. This procedure does not include welds in foil thickness [0.008 inch (0.20 mm) or less], nor does it include techniques for welding or how to set up and operate a machine.
SUBTASK 70-41-04-310-051 B. Process. (1) Resistance Welding. (a) In resistance welding a very high amperage, low voltage current is applied to a concentrated area through copper alloy electrodes at a predetermined pressure. The faying surface (interface) reaches molten temperature due to the heat generated by the interface resistance of the material to the current flow, and fusion is concentrated by the applied pressure. A high forging pressure may be applied before, during and/or after the welding has occurred, thus deriving the proper metallurgical characteristics. Temperature peaks occur at the work surfaces and at the faying surface. Approximately the same amount of instantaneous heat is generated at these points, but electrode cooling and the high thermal conductivity of the electrodes maintains a lower temperature at the outside work surfaces. Maximum heat accumulation must be maintained at the faying surface, but generating heat only at the faying surface is impossible. The various techniques which can be employed to contain the generated heat at the interface area are as follows: 1 2 Electrode configuration concentrates the current and force. Weld force concentrates the current path, maintains good contact between the workpieces, confines the molten area and provides an efficient path to conduct the heat away.
(b)
(c)
Electrode cooling conducts the heat away from the weld surfaces, thus improving the life of the electrodes and confines the heat-affected zone of the weld to the smallest possible area.
(2)
Spot Welding.
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RESISTANCE WELDING - SPOT, SEAM, AND PROJECTION Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A Spot welding is a resistance welding process in which individually spaced welds (generally circular) are made by applying current and force using either stationary electrodes or wheels. A single point electrode spot welder must be raised off the workpiece for positioning each spot weld. Spot welding with a seam welder (roll spot welding) is faster and has the added advantages of accurate weld pitch and alignment, but cannot always be used due to access or faying surface heat balance difficulties. Where applicable, improved quality can be expected when spot welding with a seam welder (roll spot) due to reduced electrode wear and the advantage of maintaining constant joint force which minimizes distortion, indentation and sheet separation. (3) Seam Welding. Seam welding is a resistance welding process in which continuous welds are made either by making a series of overlapping spot welds using stationary electrodes or wheels or making continuous overlapping spot welds using rolling wheels. (4) Projection Welding. Projection welding is a resistance welding process localized by the part design. This is usually accomplished by projections, embossments or intersections. The electrode face is usually the largest diameter flat surface that the joint accessibility will permit. SUBTASK 70-41-04-310-052 C. Equipment. (1) There are 3 basic types of resistance welding equipment. One is single phase and two are three phase as follows. (a) Single-phase welding equipment operates from a single-phase AC input power of relatively high voltage and low amperage current and supplies a relatively low voltage, high alternating current for welding. A single pair of ignitor tubes are connected back-to-back acting as electronic on-off switches. The resulting secondary current wave form is a replica of the input wave form except the secondary voltage has been lowered and the available secondary amperage has been raised by the same amount. This change is dependent upon the turns ratio between the primary and secondary of the welding transformer. Three-phase resistance welding equipment is of 2 basic types: the frequency converter and rectifier type, both of which operate on a 3-phase AC input power of relatively low direct voltage and high direct current amperage for welding. The basic difference between the frequency converter 3-phase type machines is each weld pulse will be direct current, but of opposite polarity, while the rectifier 3-phase type, each weld pulse is a direct current of the same polarity. The welding of aircraft engine high-nickel alloys requires reduced-current amplitude but for longer times, thus permitting the short-duty cycle high-KVA (available current rating) welding transformer to be derated and modified to weld high-nickel alloys without replacement. The frequency converter type equipment must preferably be capable of delivering multiple pulses of DC current for sufficient duration to complete a weld.
(b)
(c)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-04-310-053 D. Preparation for Welding. (1) Cleaning. (a) The mating surfaces and the surfaces to be contacted by the welding electrodes must be clean and free of all foreign materials such as lubricants, marking materials, paint, etc. Cleaning may be either chemical or mechanical means. Refer to the applicable manual for individual part instructions. Chemical cleaning processes used should not result in intergranular attack or oxidation, or alloy depletion in the parent metal exceeding 0.001 inch (0.03 mm) in depth. Mechanical cleaning processes used must not leave any residue on the surface which interferes with welding. Blasting with aluminum oxide or with steel grit or shot should be specifically prohibited. NOTE: A portion of the weld force is required to break through a film of dirt or oxide; however, weld force should never be purposely used as a substitute for proper part cleaning. (c) Metal coupon or test pieces used for machine setup and weld checks should be cleaned with the same process used on parts to be resistance welded and in the same heat-treated condition or hardness.
(b)
(2)
Fitup. (a) Proper spot and seam welding fitup is most important and any applicable manual repair instruction should be closely followed. The fitup affects the selection of weld force when considering how much of the weld force is required, mainly to bring the mating parts together. The remaining force is actual weld force. NOTE: Weld force should never be purposely used as a substitute for improper fitup. (b) Detail parts may be located for resistance welding using resistance spot welds. See Figure 1, Page 5 and the instructions that follow in SUBTASK 7041-04-310-054, Resistance Spot and Seam Weld Geometry and Requirements. Arc tack welds ( TASK 70-41-00-310-001, Welding and Brazing Practices) should not be used unless specifically called for in the applicable manual repair.
SUBTASK 70-41-04-310-054 E. Resistance Spot and Seam Weld Geometry and Requirements. (1) In lieu of the applicable manual repair instructions, the centerline for spot or seam welds should be the centerline of the contacting overlap (see Figure 1, Page 5). Any displacement with respect to the centerline should not exceed one-half the spot diameter (or seam width) or 0.10 inch (2.5 mm), whichever is greater. The recommended minimum overlap is given in Figure 2 (Sheet 1 of 2), Page 6 for common sheet sizes.
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STANDARD PRACTICES MANUAL AS907-1-1A (2) When spot tack welds are used for assembly fitup the tack welds must be in alignment with the joint spot welds within one-half the spot diameter or 0.10 inch (2.5 mm), whichever is greater. Assembly spot tack welds for seam welding must be in alignment with the seam weld so that no indented or discolored surface extends more than 0.10 inch (2.5 mm) beyond the outer edge of the seam weld. See Figure 1, Page 5. Actual spot tack welds should be located so as to be contained within overlap spot or overlapping linear seam welds. Minimum penetration (see Figure 1, Page 5) into all sheets must not be less than 20 percent of the measured original thickness of the thinner outer sheet, over an area whose major axis is 80 percent of the weld diameter or width at the interface. Maximum penetration into either outer sheet must not be greater than 80 percent of its reduced thickness for aluminum and magnesium alloys, and 90 percent of its reduced thickness for all other alloys. Indentations should not exceed 10 percent of the measured original sheet thickness or 0.005 inch (0.13 mm), whichever is greater.
(3)
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Spot and Seam Weld Geometry Figure 1
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Weld Diameters, Widths and Overlap for Resistance Spot and Seam Welds Figure 2 (Sheet 1 of 2)
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Weld Diameters, Widths and Overlap for Resistance Spot and Seam Welds Figure 2 (Sheet 2)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-04-310-055 F. Quality Assurance. (1) Unless otherwise specified by the applicable manual repair, resistance welds should meet the following quality standards. (a) Cracks and Indications. 1 2 Outer surfaces of welds shall be free from cracks. Internal indications within spot and seam weld nuggets which do not extend more than one-third of the depth of penetration of the nugget from the faying plane toward the outer sheet, in a direction perpendicular to the interface, shall be acceptable. Internal indications within spot weld nuggets, measured in a direction parallel to the interface, which do not exceed one-quarter of the nugget diameter in length, shall be acceptable. Internal indications within seam weld nuggets, measured in a direction parallel to the interface, which do not exceed one-third of the nugget width as shown by a cross section, or one-third of the nugget spacing as shown by a longitudinal section, shall be acceptable.
(b)
Inspection Methods. Inspection of resistance welded parts coupons shall be by welding, cutting, polishing, etching, peel or tensile testing, and evaluating specimens to determine conformance to applicable requirements. 1 All coupons for welding test specimens shall be prepared from the same material, including heat treatment condition, thickness, surface finish and surface preparation, and by the same procedure used for preparation of parts to be welded. Specimens with a radius are required if the radius of curvature is less than 10 inches (254 mm). Sheet stock may be used for making coupons when the part is cast or machined, provided the surface finishes, resistances, and weld results are comparable. Coupons for aluminum and aluminum alloys should accompany parts through cleaning operations, and simulate cleaning methods and time limits placed on parts being welded. Specimens shall be welded with the overlap the same as the part weld. A minimum of 3 specimen welds should be prepared and evaluated, after a machine is setup for a specific weld operation, prior to making part weld, and upon completion of weld. Test specimens as follows: a Etch test. Two specimens are to be prepared by polishing and etching a cross section of the weld through the center of a spot weld, or perpendicular to the direction of welding of a seam weld, and perpendicular to the weld interface.
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STANDARD PRACTICES MANUAL AS907-1-1A b Peel test. One specimen is to be mechanically peeled apart with the resulting destruction of the parent material around the weld, or the weld itself. In seam weld specimens, peel from finishing end, not beginning of specimen weld. The size of the weld is measured at the faying surface and is the diameter or width of the button or of the fractured metal, if failure occurs along the faying surface. 4 Spot diameter or seam weld width or indication size are measured to the nearest 0.01 inch (0.3 mm). Indentation and base metal thickness shall be measured to the nearest 0.002 inch (0.05 mm). Penetration shall be measured to the nearest 0.002 inch (0.05 mm), or accuracy of measurement shall be such as to preclude acceptance of welds having penetration under minimum. Projection welds are inspected by peel testing. Etch testing is not required. The strength value for each projection weld should exhibit a tensile shear strength of 50 pounds (222 N) minimum, unless otherwise directed by a applicable manual repair. Weldments are acceptable if all specimen welds evaluated meet the requirements in paragraph E.(3) and Figure 2 (Sheet 1 of 2), Page 6, or the specific requirements of the applicable manual repair. See the requirements in paragraph E.(3). of SUBTASK 70-41-04-310-054, Resistance Spot and Seam Weld Geometry and Requirements.
SUBTASK 70-41-04-310-056 G. Weld Rework. (1) Rework of defects will be by TIG welding to the specific requirements of the applicable manual repair.
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ELECTRON BEAM WELDING - ELECTRON BEAM WELDING PROCEDURE TASK 70-41-05-310-006 1. Electron Beam Welding Procedure SUBTASK 70-41-05-99G-006 A. General. (1) Electron beam welding is a fusion welding process wherein the workpiece is bombarded with a dense stream of high velocity electrons. The stream of electrons is focused by use of electromagnetic or electrostatic fields into a narrow concentrated beam which impinges a small spot on the material to be welded. The resultant kinetic energy developed is transferred to heat, melting the material in a very localized area to form a fusion weld. Aircraft quality hardware is generally welded in a high vacuum environment to avoid presence of undesirable gas molecules which scatter the electron beam and contribute to weld contamination. Electron beam welding or aircraft quality joints shall be performed only on qualified equipment and by personnel qualified by training and experience on the type of electron beam welder being used. The electron beam weld process is not used interchangeably with other fusion weld processes.
(2)
(3)
(4)
SUBTASK 70-41-05-310-061 B. Equipment. (1) There are currently 2 basic types of electron beam welding machines commercially available: high voltage and low voltage. WARNING: THE ELECTRON BEAM WELD PROCESS MAY EMIT X-RAY RADIATION. IN THE CASE OF LOW VOLTAGE MACHINES, THE STEEL WORK CHAMBER AND LEADED GLASS VIEWING PORTS ARE DESIGNED TO RESTRICT X-RAY LEAKAGE. HIGH VOLTAGE MACHINES EMIT HIGHER LEVELS OF X-RAY RADIATION AND FOR THIS REASON ARE LEAD LINED TO PREVENT X-RAY LEAKAGE. ANY CHAMBER OR EXTERNAL EB GUN MODIFICATIONS SHOULD BE COORDINATED WITH THE MANUFACTURER TO AVOID POTENTIAL SAFETY PROBLEMS.
(a)
High Voltage. High voltage machines are acceleration voltages of 70,000 to approximately 150,000 volts. High voltage beams generally provide for deeper penetration and narrow welds, due to sharper focusing capability. Due to the intensity of the high voltage beam, weld spatter and weld undercutting are more pronounced then normally experienced on low voltage machines.
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ELECTRON BEAM WELDING PROCEDURE Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (b) Low Voltage. Low voltage machines use acceleration voltages in the range of 5,000 to 30,000 volts. They will produce welds of excellent quality but are usually somewhat wider than high voltage welds. Due to the increased weld width and lower beam intensity, welds tend to have minimized under-cut and spatter. SUBTASK 70-41-05-310-062 C. Process. (1) Process Mechanism. The electron beam is capable of such intense local heating that it has the capacity to generate a hole (keyhole) completely through the weld joint thickness. The walls of this hole are molten, and as the hole is advanced along the joint, metal head of the hole is melted which then flows around the bore of the hole and solidifies at the rear side of the hole to form the weld. However, a partial penetration weld can be accomplished merely by welding with lower beam power or intensity levels. The prime advantage of the electron beam weld process for repair of aircraft hardware is low weld distortion. (2) Filler Metal Addition. Filler metal may or may not be added to the weld. When used, it is usually positioned over or under the joint in the form of wire, sheet stock or an integral part of the weld joint design such as an overlapping lip or rib at the edge of one of the parts to be joined, or added using a cold wire feeder. Filler metal, if other than parent metal composition, is not allowed unless specified in the applicable manual. (3) Process Definition and Symbols. The basic weld symbols are interpreted in SUBTASK 70-41-00-310-018, Welding and Brazing Symbols. (a) (b) The welding process designation appears in the tail of the welding symbol. Process P8K (electron beam welding). In this process, the heat is obtained from an electron beam.
SUBTASK 70-41-05-310-063 D. Preparation for Welding. (1) Preweld Cleaning. WARNING: ACETONE AND METHYL-ETHYL-KETONE ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPOR, AND CONTACT OF LIQUIDS WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME.
(a)
The surfaces of all areas to be welded shall be free of dirt, paint, grease, oxide, soot, scale, or any other foreign matter. The entire assembly being placed into the vacuum welding chamber shall be suitably degreased and
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STANDARD PRACTICES MANUAL AS907-1-1A free of moisture to optimize vacuum chamber evacuation. Any process used to clean parts shall not cause intergranular attack, intergranular oxidation or alloy depletion of the base metal. Wire brushes or silicon carbide abrasives, Bright Boy, Cratex or Composition Wheels may be used for removal of coatings, surface scale or dirt followed by a solvent rinse with acetone or methyl-ethyl-ketone. CAUTION: DO NOT WET OR DRY ABRASIVE OR GLASS BEAD GRIT BLAST WELD AREA AS FINAL CLEANING OPERATION. (b) Silicon carbide abrasive cleaning may be used as a final surface cleaning method provided no undesirable residue remains on the weld joint after the cleaning operation.
(2)
Weld Samples. (a) Weld samples shall be used to qualify the machine and operator before welding on parts and shall meet the requirements of the applicable repair or of SUBTASK 70-41-05-310-065, General Requirements. Weld samples shall simulate the actual part in geometry, mass, and part heat treat condition. Where possible, fitup shall be simulated in the weld samples and stock thickness 10 percent of the actual joint thickness.
CAUTION: SURFACE FINISH OF THE MATING SURFACES IS IMPORTANT IN OPTIMUM CLEANLINESS AND WELD QUALITY. UNLESS OTHERWISE SPECIFIED THE MATING SURFACES SHALL HAVE A SURFACE FINISH OF 125 AA MAXIMUM AND MEET THE REQUIREMENTS OF PARAGRAPH 4.B. (3) Weld Fitup. (a) Parts shall be prepared so that a minimum weld joint gap is maintained. The maximum weld gap requirement is approximately 0.003 inch (0.08 mm) for material 1.500 inch (38.10 mm) or less in thickness and 0.005 inch (0.13 mm) maximum for material exceeding 1.500 inch (38.10 mm) in thickness. Weld joint gap exceeding these limits should not be welded. See TASK 70-41-00310-001, Welding and Brazing Practices, for joint geometry definitions.
(4)
Assemble for Weld. (a) Where fixturing is required, place parts in fixture and position joints for welding (weld fixtures to be made of non-magnetic materials to prevent beam deflection during weld operation). As an alternate to tooling or as a welding aid, parts may be carefully TIG tack welded together using the proper filler wire and gas backup specified in TASK 70-41-00-310-001, Welding and Brazing Practices, or TASK 70-41-01310-002, Titanium Welding Procedure. Tack weld size must be controlled so as not to interfere with electron beam welds, and shall be confined within the final weld unless otherwise specified. Where applicable, run-off and starting tabs shall be positioned at weld start and stop areas to minimize cracking and edge burn-back. Tabs shall be made of the same type metal as the parts being welded.
(b)
(c)
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STANDARD PRACTICES MANUAL AS907-1-1A (5) Use of Beam Stoppers. (a) On some parts, it is necessary to install a bar-type shield behind the weld joint to stop the path of the beam and prevent it from damaging the opposite side of the part, the tooling or the chamber itself. Material used for the beam stopper shall be the same type as the parts. The shield or beam stopper also serves to catch molten spatter and prevent it from contacting parts and equipment.
SUBTASK 70-41-05-310-064 E. Post Weld Processing. (1) Upon completion of electron beam weld repair, welds shall be examined for completeness and compliance with repair requirements. (a) Weld Repair. Unless otherwise specified, incomplete weld areas shall be ground with a rotary file and TIG repaired per TASK 70-41-00-310-001, Welding and Brazing Practices, or TASK 70-41-01-310-002, Titanium Welding Procedure, using the filler metal material specified for the base material being weld repaired. (b) Tab Removal. Run-off tabs or blocks shall be removed after electron beam welding and before inspection. Any imperfection noted at area where tab was removed shall be ground with a rotary file and repaired per TASK 70-41-00-310-001, Welding and Brazing Practices, or TASK 70-41-01-310-002, Titanium Welding Procedure, using the specified filler material, unless otherwise specified. SUBTASK 70-41-05-310-065 F. General Requirements. (1) Unless otherwise specified, electron beam welds and associated repaired joints shall meet the conditions specified herein. (a) Penetration. Weld joint penetration shall be 100 percent through the material thickness on butt welds which do not specify depth of penetration. Root fusion is required for all fillet and corner welds. CAUTION: THE NARROW WIDTH OF THE EB WELD CREATES THE POTENTIAL FOR MISSED JOINTS. MINIMUM WELD WIDTH AND JOINT TRACKING ACCURACY SHALL BE CONTROLLED TO ENSURE 100 PERCENT JOINT FUSION. (b) Fusion. There shall be uninterrupted fusion throughout the length of the weld joint. Refer to TASK 70-41-00-310-001, Welding and Brazing Practices, for definition. (c) Offset.
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STANDARD PRACTICES MANUAL AS907-1-1A Joint offset shall not exceed 10 percent of the nominal material thickness or 0.030 inch (0.76 mm), whichever is the smaller. For clarification, offset is interpreted as the misalignment of abutting surfaces after welding. Refer to TASK 70-41-00-310-001, Welding and Brazing Practices, for graphical illustration. (d) Undercuts. Undercuts are allowed, provided the minimum radius is as shown in Figure 1, Page 7 and the total of topside plus farside undercuts at any point along the weld does not reduce the nominal stock thickness by more than 10 percent. (e) Drop-Through. Drop-through shall not exceed the values listed below. See Figure 1, Page 7. Nominal Material Thickness (t) less than 0.375 inch (9.53 mm) 0.375 to 1.00 inch (9.53 to 25.4 mm) 1.00 inch (25.4 mm) and over (f) Low Weld. Welds are acceptable if the top surface is not more than 10 percent of the nominal material thickness below the surface of the parent material. See Figure 1, Page 7. (g) Contour Symbols. If contour symbols are used, the following tolerances apply. Flush Weld * Nominal Stock Thickness All Min -10% Max +10% Convex Weld Min +10% Max +30% Maximum Drop-Through 60 percent of t or 0.05 inch (1.3 mm), whichever is the lesser 0.10 inch (2.5 mm) as specified in repair or modification procedure
*Does not apply if surface is machined after welding. Percent (%) refers to percent of nominal stock thickness (h) Porosity. Porosity not in excess of that shown in the following shall be acceptable. The restrictions on size and number apply when inspecting visually or by an inspection process required by the specific repair.
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Nominal Material Thickness (t) Less than 0.027 inch (0.69 mm) 0.027 thru 0.065 inch (0.69 thru 1.65 mm) 0.066 thru 0.130 inch (1.68 thru 3.30 mm) 0.131 thru 0.260 inch (3.33 thru 6.60 mm) 0.261 inch (6.63 mm) and over
Max Pore Diameter 2t divided by 3 smaller of 0.4 t or 0.05 inch (1.3 mm)
Cumulative Length per Inch of Weld (See Note) 0.050 inch (1.27 mm) 0.100 inch (2.54 mm) 0.125 inch (3.18 mm) 0.150 inch (3.81 mm) 0.175 inch (4.45 mm)
NOTE: Indications must be separated by at least 2 diameters of the largest adjacent pore.
(i)
Equipment Requirements. 1 Suitable means for the measurement of each parameter setting which is to be controlled in order to make satisfactory welds must be available. Machines shall be maintained in good mechanical and electrical condition and their associated controls checked periodically. Instruments used for indicating current and voltage shall be checked for calibration on a regular schedule.
(j)
Radiographic Inspection. When required by the applicable manual, the X-ray techniques shall recognize the weld preparation angles and have the capability to accurately control that angle during inspection. To establish the best possible angle for exposure during X-ray inspection, a part tacked, clamped, or similarly assembled and ready for weld shall be X-rayed to determine what angle shows the non-fused joint the sharpest, commonly referred to as Black Line X-ray. This angle 28 shall then be used after welding for inspection.
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Weld Configuration Figure 1
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PLASMA ARC WELDING - PLASMA ARC WELDING PROCEDURE TASK 70-41-06-310-007 1. Plasma Arc Welding Procedure SUBTASK 70-41-06-99G-007 A. General. (1) Plasma arc is an arc welding process wherein coalescence is produced by heating with a constricted arc between a non-consumable tungsten electrode and the workpiece (transferred arc), or between the tungsten electrode and the metallic constricting nozzle or orifice (non-transferred arc). Weld puddle shielding is obtained from the hot, ionized inert gas issuing from the constricting orifice and is supplemented by an auxiliary source of inert gas shielding such as a conventional shielding gas cup similar to the types used in TIG welding. The highly energized columnar gas stream or plasma produces the characteristic narrow weld with deep penetration. Plasma arc repair welding should be performed only by trained and qualified operators and/or on qualified machines using certified weld schedules.
SUBTASK 70-41-06-310-071 B. Process Modes. (1) There are 2 basic modes of operation associated with the plasma arc welding process; keyhole and non-keyhole (melt-in). (a) Keyhole Welding. 1 In the keyhole mode, the material being welded is penetrated by the intense heat and high velocity energy of the plasma arc column which makes it possible to produce a keyhole effect in square groove butt welds in materials up to approximately 0.300 inch (7.62 mm) in thickness. As the keyhole is traversed along the weld joint, the surface tension of the melted metal allows the hole to close and solidify behind the direction of travel. The ability to form the keyhole is based on orifice hole size, orifice gas flow, welding current, arc voltage and precise travel speed. Use of the plasma arc keyhole mode is allowed only when specified in the applicable manual for a particular application. The keyhole mode produces less shrinkage and distortion compared with melt-in plasma or TIG welding.
(b)
Non-keyhole Welding. 1 When used with reduced orifice gas flow rates, the plasma arc welding torch can be operated in the nonkeyhole or melt-in mode which is moderately more penetrating than the TIG process. In this mode of operation, the process parameters can be adjusted to compare with the conventional TIG weld process and may be used interchangeably with the TIG process unless otherwise prohibited.
EFFECTIVITY: ALL
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PLASMA ARC WELDING PROCEDURE Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (c) Process Definition and Symbols. 1 The arc welding process designations appear in the tail of the welding symbol. See TASK 70-41-00-310-001, Welding and Brazing Practices for weld symbols. Process P8P (Gas shielded plasma arc). In this process, the heat is obtained from a constricted arc maintained between the parent metal and a tungsten electrode in a shielding atmosphere of inert gas.
SUBTASK 70-41-06-310-072 C. Equipment Requirement. (1) Any type of plasma arc welding equipment may be used provided satisfactory results are obtained. Equipment falls into 2 categories: manual and machine types. (a) Plasma Arc Welding Machine. A machine shall consist of the following basic components. 1 2 3 4 5 6 7 8 9 10 (b) Plasma welding torch. Control panel. DC power source. Welding control or programmer. Flow meters for shield and orifice gases. Cold wire feeder. Trail gas shield. Positioner or traverse facility. Pilot arc/high frequency arc starter. Water circulator for torch cooling.
Manual Plasma Arc Welding. Facilities for manual plasma arc welding shall include the following: 1 2 3 4 5 6 Manual type plasma arc welding torch. DC power source. Pilot arc power source/weld control. Flow meters for shield and orifice gases. Torch water cooling source. Foot operated remove current control.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-06-310-073 D. Preparation for Plasma Arc Welding. (1) Preweld Cleaning. (a) (b) The surface to be welded shall be free from dirt, paint, grease, oxides, soot, scale or any other foreign matter. Stainless steel wire brushes and silicon carbide abrasives may be used for removal of protective coatings or surface contaminants. ACETONE AND METHYL-ETHYL-KETONE ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPOR, AND CONTACT OF LIQUIDS WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME.
WARNING:
(c)
Following cleaning of weld joints with silicon carbide abrasives or stainless steel wire brushes, abraded surfaces should be wiped with methyl-ethylketone C04-001 or acetone C04-003 using a clean, lint-free cloth. No undesirable residue shall be permitted to remain on the surfaces after cleaning.
(2)
Joint Fitup. (a) Unless otherwise specified, metal joint contact should be obtained for keyhole welds. Gaps up to 0.015 inch (0.38 mm) or 15 percent of joint thickness, whichever is smaller, may be welded using the melt-in mode unless otherwise noted. See TASK 70-41-00-310-001, Welding and Brazing Practices, for joint geometry definitions.
(3)
Weld Backup. (a) Welds requiring 100 percent penetration through the joint shall be shielded on the backside with welding grade argon or helium shielding gas to prevent oxidation of the weld and base material. Shielding devices used shall be as shown in Figure 1, Page 4 and Figure 2, Page 5. Melt-in (nonkeyhole) plasma arc welding: Use same inert gas shielding as used for TIG in TASK 70-41-00-310-001, Welding and Brazing Practices.
(b) (4)
Weld Tooling. (a) Weld tooling shall hold the parts in alignment to meet the specified fitup requirements. Weld tooling should include a backup gas plenum chamber for keyhole welding or copper and inert gas backup for nonkeyhole welding when feasible in lieu of gas backup cups. When welding titanium, the plasma torch shall be equipped with a large torch gas cup or a trailer gas cup for outof-chamber welding applications.
(5)
Preweld Inspection and Defect Removal. (a) Inspection prior to repair weld operations and the removal of defects shall be performed in accordance with SUBTASK 70-41-00-310-012, Preparation for Welding, in TASK 70-41-00-310-001, Welding and Brazing Practices.
EFFECTIVITY: ALL
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Keyhole Plasma Arc Backup Cup for Curved Part Figure 1
EFFECTIVITY: ALL
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Keyhole Plasma Arc Backup Cup for Flat Material Figure 2
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-06-310-074 E. Quality Assurance. (1) Unless otherwise specified, the following requirements apply. Refer to TASK 7041-00-310-001, Welding and Brazing Practices, for nomenclature definition and illustration. (a) Offset. After welding, the offset of welds shall not exceed the limits in the following table. (b) Reinforcement. After welding, the reinforcement on welds shall not exceed the limits in the following table. (c) Drop-Through. After welding, the drop-through shall not exceed the limits in the following table. NOTE: When 2 different thicknesses of material are used, the tolerances apply to the thicker material. Nominal Stock Thickness 0.032 (0.81) 0.036 (0.91) 0.040 (1.02) 0.045 (1.14) 0.050 (1.27) 0.056 (1.42) 0.063 (1.60) 0.071 (1.80) 0.080 (2.03) 0.090 (2.29) 0.100 (2.54) 0.112 (2.85) 0.125 (3.18) 0.140 (3.56) 0.160 (4.06) 0.180 (4.57) 0.189 (4.80) 0.212 (5.39) 0.237 (6.02)
EFFECTIVITY: ALL
Offset 0.010 (0.25) 0.011 (0.28) 0.013 (0.33) 0.014 (0.36) 0.015 (0.38) 0.017 (0.43) 0.019 (0.48) 0.021 (0.53) 0.024 (0.61) 0.026 (0.66) 0.030 (0.76) 0.032 (0.81) 0.036 (0.91) 0.040 (1.02) 0.045 (1.14) 0.045 (1.14) 0.045 (1.14) 0.045 (1.14) 0.045 (1.14)
Inches (mm) Reinforcement 0.015 (0.38) 0.016 (0.41) 0.016 (0.41) 0.017 (0.43) 0.017 (0.43) 0.018 (0.46) 0.020 (0.51) 0.021 (0.53) 0.022 (0.56) 0.023 (0.58) 0.025 (0.64) 0.026 (0.66) 0.028 (0.71) 0.030 (0.76) 0.033 (0.84) 0.036 (0.91) 0.040 (1.02) 0.040 (1.02) 0.040 (1.02)
Drop-Through 0.016 (0.41) 0.016 (0.41) 0.017 (0.43) 0.018 (0.46) 0.018 (0.46) 0.019 (0.48) 0.020 (0.51) 0.022 (0.56) 0.023 (0.58) 0.025 (0.64) 0.027 (0.69) 0.029 (0.74) 0.031 (0.79) 0.033 (0.84) 0.037 (0.94) 0.040 (1.02) 0.040 (1.02) 0.040 (1.02) 0.040 (1.02)
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Nominal Stock Thickness 0.251 (6.38) 0.271 (6.88) 0.291 (7.39) (d)
Offset 0.045 (1.14) 0.045 (1.14) 0.045 (1.14) Undercuts.
Inches (mm) Reinforcement 0.040 (1.02) 0.040 (1.02) 0.040 (1.02)
Drop-Through 0.040 (1.02) 0.040 (1.02) 0.040 (1.02)
Undercuts are allowed provided the stock thickness is not reduced more than 10 percent and undercuts have a minimum radius of 0.01 inch (0.3 mm). (e) Penetration. Weld joint penetration should be 100 percent through the material thickness of the thinner material on square groove butt joints. In fillet welds meltthrough penetration shall be acceptable if it does not exceed 20 percent of the nominal stock thickness, except that for a total of 0.3 inch (8 mm) per linear inch of weld, the plus condition may be 40 percent of the nominal stock thickness. (f) Fusion. There shall be uninterrupted fusion of all abutting surfaces throughout the length of the joint. (g) Indications. Unless otherwise specified, allowable indications shall be as follows: 1 2 3 Maximum diameter or length of a single indication to be 50 percent of the thickness of the thinner material or 0.060 inch (1.52 mm) maximum. Minimum spacing between adjacent indications to be 3X the size of the largest adjacent indication. Accumulative length of indications per inch (mm) of weld to be no more than 0.100 inch/inch (2.54 mm/mm) and total accumulative length of no more than 6 percent of the weld length [weld over 6 inches (152 mm) in length].
(h)
Rework. Unacceptable indications detected at plasma arc weld repairs may be repaired by the plasma arc or TIG weld process per TASK 70-41-00-310-001, Welding and Brazing Practices.
(i)
Weld Parameters. Plasma arc weld parameters vary slightly from one equipment manufacturer to another depending on torch and orifice design. For this reason initial parameter development should be in accordance with equipment operating manual recommended settings and varied to suit qualification/certification criteria.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (j) Filler Addition. Filler wire may or may not be added to the weld depending on weld geometry and weld termination requirements. Depressions or keyholes remaining at a weld termination may be repaired using the melt-in plasma mode or by the TIG process per TASK 70-41-00-310-001, Welding and Brazing Practices.
EFFECTIVITY: ALL
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AUTOMATIC WELDING - AUTOMATIC WELDING FOR KNIFE EDGE SEAL REPAIR (FORMERLY DABBER TIG WELDING) TASK 70-41-07-310-008 1. Automatic Welding For Knife Edge Seal Repair (Formerly Dabber Tig Welding) SUBTASK 70-41-07-99G-008 A. General. (1) An automatic gas-shielded tungsten arc process is required for any weld buildup of a surface when a relatively low heat input is necessary to minimize the heat affected zone (HAZ) in the substrate. This process is particularly useful for weld buildup of seal serrations on rotating engine components, where the heat affected zone can be contained within the serration cross section, leaving the remaining component structure material properties unaffected. Since an unsatisfactory weld can lead to material failure or severe deformation of the part, it is essential that the process remain under control during repair of engine components. This welding procedure shall be performed only on qualified equipment using certified weld schedules by personnel qualified by training and experience on the type of welder being used. Prior to welding on engine parts the repair source must meet the pre-qualification requirements of this procedure. See SUBTASK 70-41-07310-086, Repair Source Substantiation for Automatic Weld Repair.
(2)
SUBTASK 70-41-07-310-081 B. Equipment and Process. (1) Automatic Welding System. (a) An automatic welding system which conforms to Hobart Specification No. 200592 (Hobart Bros. Co., Hobart Square, Troy, Ohio 45373) is the equipment which is considered the minimum required to perform a satisfactory repair. The use of alternate fusion welding equipment may be allowable, provided it meets or exceeds these requirements and is approved by the Honeywell. in writing.
(2)
Gas Shielding Equipment. (a) In this procedure, proper inert gas shielding is essential to success. The following shielding equipment is required: 1 2 Gas Lenses: Commercially available gas lenses for gas tungsten arc welding torches, such as the Linde HW-27, must be used. Gas Trailers: Gas trailers must be used to protect the heated weld deposit and base material after the torch has passed. If not commercially available, fabricate one per Figure 1, Page 3. The bottom screening may be either a firm, close meshed screen or hole punches
EFFECTIVITY: ALL
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AUTOMATIC WELDING FOR KNIFE EDGE SEAL REPAIR (Formerly Dabber Tig Welding) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A sheet metal. If too tightly packed, the steel wool or Fiber-Frax material may inhibit gas flow. 3 Skirts: It is important to ensure that the gas flow is delivered from the trailer smoothly and with no appreciable turbulence. Turbulence may create low pressure areas or vortex-like effects which pull air into the weld zone. Additionally, heat resistant tape should be used as a skirt around the gas cup and trailer, just contacting the coupon or part. This will shield against stray currents of air and will provide a better protective atmosphere for the weld.
(3)
Materials. (a) Filler material will be specified in the applicable Shop Manual procedure. Filler material for automatic weld buildup must be clean, free of surface oxides and exhibit acceptable flow characteristics. All filler wire material must be certified. The repair source should verify the filler material alloy prior to welding on engine parts.
EFFECTIVITY: ALL
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Typical Gas Trailer Figure 1
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-07-310-082 C. Preparation for Welding. (1) Preweld Machining. (a) Preweld machining removes damaged material and provides a uniform surface to initiate weld buildup. Machining should continue to cleanup; or until in-process dimensional limits specified in the applicable manual procedure are met. Further material removal is not recommended. Preweld machining on seal serrations will usually provide a sufficiently wide base to initiate weld buildup. See SUBTASK 70-41-07-310-083, Weld Procedure.
(2)
Preweld Inspection (a) The in-process diameter of the preweld machining and the inside wall diameter of the shell shall be inspected and recorded. See SUBTASK 70-4107-310-085, Quality Assurance. When specified in the applicable manual, non-destructive inspection shall be performed.
(3)
Preweld Cleaning (a) The surfaces of all areas to be welded shall be free of dirt, paint, grease, oxide, soot, scale, machining coolants and any other contaminants that may adversely affect the weld. After preweld machining, unless otherwise specified in the applicable manual, the part should be cleaned as follows: WARNING: CLEANING SOLVENTS ARE HIGHLY FLAMMABLE, VOLATILE AND TOXIC. THEY SHOULD BE USED WITH ADEQUATE VENTILATION. AVOID PROLONGED BREATHING OF VAPORS AND REPEATED OR PROLONGED CONTACT WITH SKIN. OBSERVE PRECAUTIONS AGAINST FIRE.
Vapor degrease non-titanium parts per TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing. Titanium parts shall be rinsed or wiped with acetone C04-003, methyl-ethyl-ketone (MEK) C04001 or isopropyl alcohol C04-035. Dry abrasive clean per TASK 70-21-04-120-001, Dry Abrasive Blast Cleaning - Method 4A, except use 0.002-0.006 inch (0.05-0.15 mm) diameter glass beads at 30-50 psig. Solvent rinse with acetone C04-003, MEK C04-001 or isopropyl alcohol C04-035.
3 (4)
Setup for Welding
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STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: WHILE LOCATING AND CLAMPING THE PART ON THE ROTARY FIXTURE, THE CLEANED WELD AREA MUST NOT BE CONTAMINATED. IN PARTICULAR, TITANIUM SEAL SERRATIONS SHOULD NOT BE TOUCHED BECAUSE CONTAMINANTS FROM THE SKIN MAY PROMOTE WELD DEFECTS, ESPECIALLY POROSITY. (a) Tooling should firmly hold the part to meet specified alignment requirements. Some parts to be repaired may require special fixturing for dimensional restraint and will be prescribed in the applicable manual procedure. In general, the part should be setup with specified repair datums concentric to axis of rotation 0.005 inch (0.13 mm) and perpendicular to axis of rotation within 0.005 inch (0.13 mm).
SUBTASK 70-41-07-310-083 D. Weld Procedure. (1) Successful weld repair requires strict adherence to the applicable manual procedures for specific parts. These established procedures have resulted from extensive development, inspection, mechanical property testing and component/ engine testing. Deviations require prior approval of the Honeywell. (Refer to Table 1, Page 5 for definition of parameters). (a) Autogenous Weld Pass (Meltdown Pass). 1 When seal serration machining removes the defect before reaching the minimum in-process dimensions, the weld land may be too small to initiate welding and an autogenous weld pass (meltdown pass) may be used to generate a weld band width sufficient to support the weld bead. This technique utilizes the established parameters and makes a weld pass without using filler wire. The resulting meltdown and mushroom created by the weld pass will provide a base to support subsequent weld buildup.
(b)
Parameter Adjustments. 1 Operator training and experience will dictate what parameter settings (within the specified ranges) are required. Parameter settings at the extremes may produce undesirable results unless related parameters are also adjusted. Normally, adjustments should be made as follows: a If a meltdown pass is required, it should be done at a lower power setting. This will keep the heat affected zone to a minimum. The first pass, where filler wire is deposited, will normally be accomplished at a medium power setting.
EFFECTIVITY: ALL
70-41-07
Table 1. Definition of Parameters Used in Automated Welding Parameter Electrode Extension: Wire Clearance: Definition The distance the electrode extends beyond the torch cup (see Figure 2, Page 7). The clearance between the electrode and the fully extended filler wire (see Figure 2, Page 7). This clearance con-tributes to determining the arc length for a given voltage setting on the arc voltage control unit. The total distance the tip of the filler wire moves in a reciprocating motion (see Figure 2, Page 7). The number of times per second the filler wire is placed into the weld puddle and withdrawn. The distance from the tip of the wire feed nozzle to the weld puddle (see Figure 2, Page 7). The angle between the vertical center-line of the plane of motion and the welding torch or filler wire feed nozzle, measured clockwise (CW) or counterclockwise (CCW) from vertical centerline (see Figure 3, Page 8). The angle between the torch or wire feed nozzle and a plane through the point of weld deposit parallel to the weld positioner face plate, measured CW or CCW (see Figure 3, Page 8). The angle between the wire feed nozzle and a plane through the point of weld deposit parallel to the weld positioner face plate, measured CW or CCW (see Figure 3, Page 8). The angle between a vertical plane and the part weld positioner face plate measured CW or CCW from vertical plane (see Figure 3, Page 8). c Should the parameter sheet provide a large latitude for weld current settings, lower current should be used in conjunction with lower part travel speeds, lower wire feed speeds and/or shorter arc lengths. Higher current settings require higher part travel speeds, higher wire feed speeds and/or longer arc lengths. Torch and Wire Angles (see Figure 3, Page 8) have an affect on heat dissipation and/or heat transfer to adjacent part surfaces and should be dealt with by increasing or decreasing power or shielding of adjacent surfaces as required. Increases in part travel speed may require an increase in trail gas rate.
Stroke Length:
Stroke Rate: Wire Nozzle Setback: Pitch Angle:
Roll Angle:
Yaw Angle:
Part Roll Angle:
EFFECTIVITY: ALL
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Torch and Wire Feed Nozzle Figure 2
EFFECTIVITY: ALL
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Definition of Torch, Wire Feed Nozzle, and Part Angles Figure 3
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-07-310-084 E. Post Weld Processing. (1) Welds shall be examined for completeness, compliance with specific repair requirements in the applicable manual and the requirements of this procedure as specified in SUBTASK 70-41-07-310-085, Quality Assurance. Unacceptable indications or other defects in the welds shall be repaired by machining to remove the defective weld and reprocessing using an automatic weld process. Do not exceed the minimum allowable applicable manual in-process machining limits.
(2)
SUBTASK 70-41-07-310-085 F. Quality Assurance. (1) Unless otherwise specified, all automated weld repairs shall meet the conditions specified herein. (a) Records: 1 Accurate records must be maintained for each part by serial number. Record in-process dimensions and fusion zone depth. Maintain heat treatment charts, filler wire certification, NDT results and shotpeen data (if applicable).
(b)
Indications: 1 Allowable indications shall be defined in the applicable shop manual repair procedure. Indications interpreted as cracks are not allowed.
(c)
Fusion: 1 There shall be uninterrupted fusion throughout the weld buildup area. On seal serrations, measure distance from fusion line to shell outer wall with a depth gage or take a wax impression. Fusion zone (meltdown of serration parent metal from the in-process starting diameter) shall be contained within 0.020 to 0.050 inch (0.5 to 1.3 mm) (see Figure 8, Page 22).
(d)
Undercuts: 1 Undercuts are not allowed (see Figure 4, Page 11).
(e)
Weld Overlay: 1 Weld overlay is not allowed (see Figure 4, Page 11).
(f)
Parameters: 1 The weld parameters must be adhered to and recorded by part and serial number.
(g)
EFFECTIVITY: ALL
X-ray:
70-41-07
STANDARD PRACTICES MANUAL AS907-1-1A 1 For weld repairs on large cross sections (cross sections other than seal serrations), an X-ray Radiographic inspection is required. Refer to applicable shop manual repair for allowable limits.
EFFECTIVITY: ALL
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Weld Undercut and Overlay Figure 4
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-41-07-310-086 G. Repair Source Substantiation for Automatic Weld Repair. (1) This paragraph contains the substantiation requirements for components repaired by this weld process. Substantiation by part number is required. NOTE: The pre-qualification and substantiation requirements stated herein are based on the use of the automatic weld equipment/system designated in SUBTASK 70-41-07-310-081, Equipment and Process. The use of alternate fusion welding equipment will necessitate additional pre-qualification requirements which are outlined in this paragraph. Release of the repair source will be granted in two steps, Pre-qualification Release and Full Repair Source Release by the Honeywell. (2) Production Approval and Repair Source Release. Refer to Steps (a), (b) and (c). (a) Approval for use of alternate fusion welding equipment should be obtained from the Product Support Department of Honeywell prior to the prequalification approval process. Submit data to prove equipment manufacturing specifications and machine controlling parameters will yield equivalent welds and control of process as follows: 1 2 Base machine type, original manufacturer and model number. A brief description of modifications made to permit low heat input welding and typical heat affected zones achieved. Include control parameters and machine repeatability data. Method of maintaining a protective atmosphere on part during welding operations, type and composition of atmosphere and control parameters. A brief description of the method for feeding filler metal, repeatability data and control parameters. Repeatability of setup method or positioning of part prior to initiating weld bead. Part positioner shall be of the rotary drive type with a speed control capable of providing reproducible and consistent speeds. Face runout should not exceed 0.002 inch (0.05 mm) FIR. Other information deemed necessary by the Product Support Department.
4 5 6
7 (b)
Pre-qualification Release is Honeywell approval to proceed with repair of first production part/lot. Repair source shall complete and satisfy the following requirements prior to submitting data for full release. Requirements include: 1 2 Honeywell.approval (in writing) from the Customer Support Department for use of equipment other than Hobart Spec. No. 200592. Technical plan per paragraph G.(3).
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A 3 4 Quality plan per paragraph G.(3)(a) 6 and SUBTASK 70-41-07-310-085, Quality Assurance. A pre-qualification weld sample for Inco 718 alloy and all supporting documentation for the generation of the alloy sample, including variable dimensional data. For weld sample preparation instructions and evaluation requirements refer to SUBTASK 70-41-07-310-087, Procedure for Preparation and Evaluation of Representative Weld Sample. Results of the evaluation by Honeywell product support department will be communicated to the repair source in writing, constituting the Prequalification Release.
(c)
Full Repair Source Release is Honeywell approval to proceed with full production repair program on one part number only. A Full Repair Source Release must be obtained for each part repaired, by part number. Requirements for Full Repair Source Release include: 1 Requirements of pre-qualification release per paragraph G.(2)(b). Include copy of written pre-qualification release from Honeywell when submitting data for full release. Process sheets and/or router indicating the repair scheme for the part number in question. This is in addition to the technical plan. First production part inspection including variable dimensional data per the applicable shop manual procedure and SUBTASK 70-41-07310-085, Quality Assurance. Heat treat charts of first part. Shotpeen information, if applicable. Operation audit per paragraph G.(3)(d). First piece visual by the Product Support Department of Honeywell prior to application of any metal spray materials. Destructive analysis per paragraph G.(3)(e). (optional). Technical audit per paragraph G.(3)(c).
2 3
4 5 6 7 8 9 (3)
Definition of Terms. (a) Technical Plan. The Technical Plan is a documented, detailed plan which is prepared by the Repair Source for Honeywell approval. The technical plan specifies the facilities, tooling, materials, processes, process control, quality control, metallurgical evaluation and testing and any other factor that could affect the integrity of the repaired product. The contents of a technical plan to be prepared by the Repair Source shall include:
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A 1 Facilities: All facilities utilized in the repair process shall be defined and, as applicable, calibration and control of these facilities shall be documented. Tooling: All tooling and fixtures utilized in the repair process shall be defined. Materials: All materials, their sources of supply, and the quality control provisions utilized by the Repair Source in their procurement shall be defined. Repair Processes: Manufacturing processes to be utilized by the Repair Source in performing the repair shall be defined in detail process sheets, and any allied processing, such as, but not limited to: cleaning, machining, welding and thermal spraying shall be provided. Process Sequence: A document or series of documents which specifically defines the individual operations that effect the total repair shall be provided. Quality Control Plan: A document which specifically defines control of the process steps shall be provided. These steps must include controls over special processes unique to these repairs, i.e., cleaning methods, welding, heat treatment operations, etc. This document shall define the integration within the process sequence, or may itself be integrated into the process sequence. Pre-production Process Qualifications: Processes such as, but not limited to: stripping, cleaning, machining, etc., require pre-production qualification. Such processes require a series of trial runs to be performed by the repair source to prove the process prior to a first production repair. Pre-qualification Welding Schedules: Pre-qualification welding shall be performed in accordance with SUBTASK 70-41-07-310-087, Procedure for Preparation and Evaluation of Representative Weld Sample. Metallurgical and Non-destructive Testing (NDT) Evaluation: This evaluation will be performed on a ring specimen as defined in SUBTASK 70-41-07-310-087, Procedure for Preparation and Evaluation of Representative Weld Sample. Investigation of the microstructure, weld consistency and defect levels is required and shall demonstrate acceptability to Honeywell standards.
2 3
(b)
Changes to Technical Plan. 1 Any changes to the technical plan shall be approved by the prime technical service organization of the Honeywell prior to implementation in production.
(c)
Technical Audit.
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STANDARD PRACTICES MANUAL AS907-1-1A 1 A technical audit of the procedures as approved by Honeywell and used in the first production run, shall be performed at the repair source by the Honeywell.
(d)
Operation Audits. 1 Operation audits shall be performed by the Repair Source Quality organization, independent of the normal work force conducting the repair process. Such audits shall include: a b c Verification that the operations are performed to the process sheets. Verification that metallurgical evaluation, NDT and other requirements are performed. All data shall be forwarded to the Honeywell for evaluation and approval prior to any further activity.
(e)
Destructive Analysis. 1 Metallurgical evaluation of representative parts from the first production run may be made to assure that processing problems that might affect part integrity do not exist. All such parts shall have been subjected to all steps or repair.
(f)
Quality Control Plan Implementation. 1 Maintenance of the Quality Control Plan for the proper control of the Repair Source process after qualification by Honeywell. shall be the responsibility of the Repair Source subject to approval by the customer, if applicable. In further regard to this plan, the Honeywell shall have the right to perform technical audits in the facilities of the Repair Source as Honeywell deems necessary to ascertain the repair process complies with the one evaluated, tested and approved by Honeywell.
SUBTASK 70-41-07-310-087 H. Procedure for Preparation and Evaluation of Representative Weld Sample. (1) Repair source automatic welding requires evaluation and correlation to determine and ensure repair design intent. This evaluation and correlation is performed on a sample welded by the repair source. The work content shall include: (a) Produce an Inco 718 weld sample consistent with Figure 5, Page 19 (Ring Specimen). Representative Inco 718 seal (scrap part) with seal diameters pre-machined 0.110-0.130 inch (2.8-3.3 mm) below finish diameter may be used in lieu of ring specimen. Weld specimens shall be in the aged condition prior to welding and shall not be post-weld heat treated in any way. Scribe marks on ring specimen 22.5 degrees apart per Figure 5, Page 19 or on corresponding area of representative seal.
(b)
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STANDARD PRACTICES MANUAL AS907-1-1A (c) Dimensionally inspect and record diameters A, B, and C of ring specimen ( Figure 5, Page 19) at the end tooth and adjacent to scribe marks (8 places) or on corresponding diameters of representative seal. Automatic weld seal teeth diameter A on ring specimen or seal teeth diameters on representative seal 0.110-0.150 inch (2.8-3.8 mm) above premachined diameter. Recommended parameters in Table 2, Page 16 are for Dabber TIG welds. Do not repair defects in the welded ring specimen. Dimensionally inspect and record diameter B on ring specimen ( Figure 5, Page 19) or corresponding diameter on representative seal at the same locations measured and recorded before weld. Submit welded seal specimen and all recorded dimensional data to Product Support Department of the Honeywell. Results of the evaluation by Honeywell will be communicated to the repair source in writing. The evaluation of the ring specimen will be conducted to the following specifications: 1 Resulting Shrinkage. a Shrinkage measurements are calculated by averaging ring seal specimen diameter B recordings (8 places) before weld and subtracting average diameter B recordings (8 places) after weld. Allowable as-welded shrinkage of the specimen is 0.005 inch (0.13 mm) or less.
(d)
(e)
(f) (g)
Consistency of Weld. a Unacceptable welds are a result of incorrect parameters, insufficient shielding gas or dirty filler wire. Consistency of weld will be evaluated as follows: Skips and misses not allowed (see Figure 9, Page 23 and Figure 11, Page 25). Weld filler deposits shall be uniform (see Figure 10, Page 24).
Table 2. Weld Parameters for Pre-qualification Specimen Utilizing Dabber TIG Welding Equipment Base Alloy Filler Wire Wire Diameter (inch) Stroke Length (inch) Stroke Rate (Hz) Wire Nozzle Setback (inch) Electrode Material Electrode Diameter (inch) Inco 718 AMS 5832 0.045 in. (1.14 mm) 0.15-0.20 in. (3.8-5.1 mm) 3-4 0.150 in. (3.81 mm) 2% Thoriated Tungsten 0.094 in. (2.39 mm) Pointed
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Table 2. Weld Parameters for Pre-qualification Specimen Utilizing Dabber TIG Welding Equipment (Cont) Base Alloy Electrode Extension (inch) Cup Size Torch Gas Rate (Argon) (CFH) Trail Gas Rate (Argon (CFH) Wire Feed Speed (IPM) Part Travel Speed (IPM) Wire Voltage -Ref- (Volts) Weld Current (Amps) Arc Length Wire Angle, Pitch (degrees) Wire Angle, Yaw (degrees) Torch Angle, Pitch (degrees) Torch Angle, Roll (degrees) Part Angle, Roll (degrees) Inco 718 0.5-1.0 in. (13.0-25.0 mm) No. 8-10 50 CFH (1.4 m3/S) 75-100 CFH (2.1-2.8 m3/S) 3 3 8.2-8.7 Volts 10-14 Amperes 0.05-0.10 in. (1.3-2.5 mm) 158-458 CCW 08 158-458 CW 08 08 Amount of weld deposits (see Figure 7, Page 21 and Figure 8, Page 22) must be sufficient to allow finish machining with 100 percent cleanup on cross section, 360 degrees around part. Any welds which indicate a process out of control are not allowed (see Figure 9, Page 23 and Figure 10, Page 24). 3 Total Heat Input: a Total heat input from welding will be determined as follows: Meltdown of seal tooth parent metal from the in-process or starting diameter shall be contained within 0.020-0.050 inch (0.5-1.3 mm) (see Figure 8, Page 22). This will be measured from fusion line to shell with metallograph. Heat affected zone is determined for Inco 718 as-welded specimen and is measured by a microhardness traverse of the seal teeth. The microhardness measurements will be taken in 0.005 inch (0.13 mm) maximum steps, starting at the fusion line and progressing through the heat affected zone until full base metal hardness is achieved. A typical example is shown in Figure 12, Page 26 (see Figure 8, Page 22 for fusion line definition). 4
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Defect Content of Weld:

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STANDARD PRACTICES MANUAL AS907-1-1A a Defect content of weld shall be assessed with typical sections taken at locations of suspected weld abnormalities (see Figure 6, Page 20). A parting out will be made and seal teeth will be removed, individually from seal. An X-ray Radiographic inspection will be performed normal to and through each seal tooth. Areas of suspected weld abnormalities will be selected from radiographic results for metallographic examination. A metallographic evaluation will be performed at locations of suspected defects per Figure 7, Page 21. No cracks, oxide inclusions or lack of fusion are permitted. Scattered porosity is permitted.
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Weld Specimen for Repair Source Pre-Qualification Figure 5
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Minimum Metallography Required for Weld Pre-Qualification Figure 6
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Typical Sections of Welds on Pre-Qualification Test Specimens Figure 7
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Weld Cross Section Showing Measurements for Determination of Serration Meltdown Figure 8
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Automated Equipment Welds Demonstrating Process Out of Control Figure 9
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Automated Equipment Welds on Pre-Qualification Test Specimens Showing Process Under Control Figure 10
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Weld Skip/Miss on Serration Buildup Figure 11
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Microhardness Traverse of Gas Tungsten Arc Weld on Pre-Qualification Figure 12
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PREPARATION PROCEDURE - PREPARATION PROCEDURE FOR FLUX-AIDED GAS TUNGSTEN ARC WELDING TASK 70-41-08-310-009 1. Preparation Procedure for Flux-Aided Gas Tungsten Arc Welding SUBTASK 70-41-08-99G-009 A. General. (1) This procedure gives the necessary instructions to use a backing flux to do a weld repair on parts where it is not possible to supply inert gas shielding to the back (root) of the weld.
SUBTASK 70-41-08-310-091 B. Tools, Equipment and Consumable Materials. (1) Code No. C04-014 C06-030 Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Consumable Materials. Description Methyl Alcohol Solar Flux, Type I Grinding Wheels Abrasive Cloth Paper Cup Clean Shop Cloth Paint Brush Shim Stock 0.010 -0.030 in. (0.25 - 0.76 mm) Use Cleaning Solvent/Thinner GTAW/TIG Backing Flux Grinding Cracks Surface Preparation Mixing Flux Solvent Wipe Flux Application Flux Application
SUBTASK 70-41-08-310-092 C. Procedure. CAUTION: THIS PROCEDURE IS TO BE USED ONLY AS A SINGLE PASS WELD REPAIR, DO NOT USE MULTIPLE PASS WELDS. (1) Sand an area 0.5 in. (13 mm) beyond the crack in all directions to remove the oxides around the crack.
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PREPARATION PROCEDURE FOR FLUX-AIDED GAS TUNGSTEN ARC WELDING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: PARTICLES FROM THE GRINDING OPERATION CAN DAMAGE EYES AND RESPIRATORY TRACT. EYE AND RESPIRATORY TRACT PROTECTION IS REQUIRED.
CAUTION: DO NOT LET THE GRINDER TOUCH ANY OTHER AREA OF THE PART OR ANY OF THE PARTS ADJACENT TO THE CRACK. (2) Grind through the crack with a 0.030 in. (0.76 mm) abrasive wheel. Extend the ends of the crack 0.125 in. (3.18 mm). WARNING: WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG (206 KPA). WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS.
(a)
Remove the grinding residue from the surface of the part with a dry air compressor or vacuum. METHYL ALCOHOL C04-014 IS FLAMMABLE AND TOXIC TO SKIN, EYES, AND RESPIRATORY TRACT. SKIN AND EYE PROTECTION IS REQUIRED. AVOID REPEATED AND PROLONGED CONTACT. USE IN A WELL VENTILATED AREA.
WARNING:
(b) (3)
Wipe the area of the crack with a clean cloth moistened with methyl alcohol C01-014.
Put one tablespoon of the Solar Flux, C06-030 Type I powder in a paper cup.
CAUTION: FLUX MUST BE APPLIED QUICKLY. METHYL ALCOHOL C01-014 WILL EVAPORATE MAKING APPLICATION DIFFICULT. (4) Mix methyl alcohol (methanol) C04-014 to the Solar Flux, C06-030 Type I in the paper cup. Add the methyl alcohol slowly while gently stirring the mixture. Continue to stir the mixture until it resembles a thick cream. Apply the flux mixture to the area in and around the crack. Use a paint brush to apply a generous amount of the flux mixture to the crack. (a) Push the moist flux mixture into and through the crack with a piece of metal 0.010 - 0.030 in. (0.25 - 0.76 mm) shim material. NOTE: If possible, apply the flux directly to back (root) side of the crack. (6) (7) Remove the flux mixture from the area around the crack with a clean dry cloth. Do not remove the flux mixture from inside the crack. Do the repair weld. Make sure you follow all instructions in the specific repair document and TASK 70-41-00-310-001, Welding and Brazing Practices. An 0.060 in. (1.52 mm) diameter filler wire is recommended. Clean and inspect the repair weld. Make sure you follow all instructions in the specific repair document. If the repair weld fails inspection do the weld repair again as follows:
(5)
(8) (9)
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STANDARD PRACTICES MANUAL AS907-1-1A (a) (b) (c) Grind to remove all the weld and open the crack again. Make a new flux mixture. Do not use the flux mixture from the first weld repair. Prepare a new flux mixture. Weld the crack again.
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BLENDING AND REMOVAL OF HIGH METAL - BLENDING AND REMOVAL OF HIGH METAL PROCEDURES TASK 70-42-00-350-002 1. Blending Procedures SUBTASK 70-42-00-99G-002 A. General. (1) Blending is a repair procedure that is used to remove stress concentrations caused by nicks, scratches, or other sharp-edged damage marks on critical parts. Removal of the material surrounding the stress concentration, so that the sharp edges are blended into a smooth contour, relieves the stress concentration and permits further use of the part by lessening the danger of cracking. Blending is also used to remove sharp edges resulting from machining, drilling, etc., and to restore the original contour and/or surface finish to parts that have been repaired by welding, brazing, etc. Defects more then 0.25 inch (6.4 mm) apart shall be blended separately. Those less than 0.25 inch (6.4 mm) apart (except splines) shall be blended together. Splines that are closer together than 0.25 inch (6.4 mm) and defects shall be repaired separately. The finish on the blended area must be as close as possible to the original finish of the part.
(2)
(3)
(4)
SUBTASK 70-42-00-350-021 B. Hand Blending. DO NOT BREATHE THE PARTICLES FROM BLENDING OR LET THE PARTICLES TOUCH YOU. PARTICLES FROM BLENDING CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
WARNING:
NOTE: Refer to the specific manual section or Service Bulletin for the blend limits of the piece part under review. Use the limits in this procedure only when no specific limits are specified for the component in the applicable manual or applicable Service Bulletin. (1) Sharp edges can be blended out, using abrasive stones or papers, files, or crocus cloth. Coarse grades of abrasives or files may be used for fast metal removal, but the parts must then be given a smooth surface finish with fine grades of abrasives or crocus cloth. (a) When blending compressor rotor blades, stator vanes, turbine blades, and similar parts, blend in a radial direction in relation to the engine. Avoid removing metal from leading and trailing edges of airfoil sections in such a
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BLENDING AND REMOVAL OF HIGH METAL PROCEDURES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A way that the edges become thin or sharp; blend so as to maintain approximately the original contour. NOTE: Refer to the inspection and repair limits for specific instructions on blending limits applicable to each part of the engine. (b) (c) (d) When blending a cylindrical part, blend in a circumferential direction, not along the axis of the part. The finish on the blended area must be as close to the original finish as possible. When blending on a part involving a radius, keep the radius as specified in the repair section. If the radius is not specified, keep it as close as possible to the original contour. Refer to a similar part, if necessary to determine original radius. After blending, etch the reworked area per TASK 70-24-00-110-033, Etching Procedures for Fluorescent-Penetrant Inspection. Inspect per TASK 70-3203-230-002, Spot-Fluorescent-Penetrant Inspection.
(e)
SUBTASK 70-42-00-350-022 C. Power Blending. DO NOT BREATHE THE PARTICLES FROM BLENDING OR LET THE PARTICLES TOUCH YOU. PARTICLES FROM BLENDING CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
WARNING:
CAUTION: POWER BLENDING OF AIRFOIL SECTIONS MAY BE DONE ONLY WHEN SPECIFIED BY INDIVIDUAL PART INSTRUCTIONS. (1) Blending on most parts may be done by using a power-driven polishing wheel or rubber-bonded abrasive points. Special instructions for the individual part must be followed. CAUTION: WHEN DOING POWER BLENDING, BE SURE TO AVOID BUILDING UP EXCESSIVE HEAT AND RESULTING THERMAL STRESSES IN THE PART. (a) Rough-out defects using coarse grades of resilient flexible abrasive impregnated wheels, brushes, or points. Use fine or extra fine grades to finish the blend areas. When doing power blending, follow the requirements described in SUBTASK 70-42-00-350-021, Hand-Blending. NOTE: After power blending of a titanium part is completed, hand-blend the same area approximately 0.002 inch (0.05 mm) deeper to remove residual stresses in the surface material.
(b)
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STANDARD PRACTICES MANUAL AS907-1-1A (c) After blending, etch the reworked area per TASK 70-24-00-110-033, Etching Procedures for Fluorescent-Penetrant Inspection. Inspect per TASK 70-3203-230-002, Spot-Fluorescent-Penetrant Inspection.
SUBTASK 70-42-00-350-023 D. Component Specific Requirements. DO NOT BREATHE THE PARTICLES FROM BLENDING OR LET THE PARTICLES TOUCH YOU. PARTICLES FROM BLENDING CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
WARNING:
NOTE: The instructions in the applicable Engine/Shop Manual section or applicable Service Bulletin take precedence over the following procedures. Use the instructions that follow with the applicable Engine/Shop Manual or Service Bulletin criteria, or when no criteria are specified. (1) Blending Airfoils. (a) The types of airfoil damage described below may be repaired by handblending or by power-blending. Always refer to applicable part inspection paragraph for a description of airfoil defect limits as follows: 1 2 3 4 Nick. A V-shaped depression in the airfoil made by a sharp-edged object pushing the metal inward. Pit. A round, sharp-edged hole with a rounded bottom caused by corrosion. Scratch. A V-shaped line or furrow in the airfoil, such as would be made by dragging a sharp object across the surface. Dent. A smooth, rounded depression in the airfoil made by impact with a rounded object. If there is a noticeable sharp discontinuity in the depression, it should be considered a nick. Waviness of leading or trailing edge is to be treated as a dent. Erosion. A sand- or shot-blasting effect on the leading edges or the leading portion of the concave side, caused by sand or dust going through the engine. Torn Metal. A separation or pulling apart of material by force, leaving jagged edges.
6 (b)
Hand-blending of airfoils may be done as specified below: 1 Blending is done to remove stress caused by nicks, pits and scratches to prevent blade failure. Remove high metal and straighten dents (where permitted) to restore the airfoil shape as closely as possible to its original aerodynamic contour. Blending shall be finished with fine stone or crocus cloth. Coarser tools may be used for the initial removal of material. Finish the blending in a
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STANDARD PRACTICES MANUAL AS907-1-1A direction along the length of the blade or vane, and remove all evidence of marks across the airfoil that may have been made during initial blending. 3 Defects more than 0.25 in (6.4 mm) apart shall be blended separately; those 0.25 in (6.4 mm) or less apart may be blended together. All blends must have a minimum radius of 0.25 in (6.4 mm). The total reduction in chord width may be taken on either side or divided between the sides. The amount of rework is controlled by the minimum chord width limit. The minimum allowable chord is given for the root and tip of airfoil, and the minimum chord at other points is proportional. To minimize the possibility of having the engine stall, keep the shape of the blended airfoil leading edge as close as possible to the original contour. Refer to Figure 1, Page 6. Blending limits are given as depth dimensions to make it easier to see how much can be repaired. Experience has shown that depth limits are used for most rework. However, the minimum chord limit is the most important dimension; it should be checked in borderline cases or where previous rework is evident in the same area. For convenience, the depth limits and minimum chord limits are given in both decimals and fractions. In borderline cases where depth limits and minimum chord limits conflict with one another, use the decimal minimum chord dimension to decide if the part is usable. Defect limits are given as depth dimensions since this is the dimension that affects strength. However, accurate depth measurements require special equipment not normally available. Comparing the depth of a defect with the thickness of a thickness gage leaf, or with the thickness of a piece of safety wire, is a reasonably accurate way of measuring depth. Refer to Figure 2, Page 7. Swab-etch the reworked area per TASK 70-24-00-110-033, Etching Procedures for Fluorescent-Penetrant Inspection. Inspect per TASK 70-32-03-230-002, Spot-Fluorescent-Penetrant Inspection. Brush or swab on penetrant where air passages are present, to prevent excessive penetrant entrapment.
(c)
Power-blending of rotor blades, variable vanes, and vane segments may be done as follows: 1 2 To avoid damaging the airfoil, use masking tape and mask off the airfoil next to the rework area. Use coarse grade, silicon-carbide-impregnated rubber wheels and points for the initial benching of the blades and vanes. NOTE: During finish-blending of defects, make a radius on both the leading and trailing edges of the airfoil. To do this, apply light pressure with the rubberized abrasive wheel, and let the cushion action of the wheel do both the blending of the radius and the buffing of the defect.
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STANDARD PRACTICES MANUAL AS907-1-1A 3 Finish blending the defects, using the fine and extra fine grade of rubberized abrasive wheels. Remove only enough material to repair the defect. Swab-etch the reworked areas per TASK 70-24-00-110-033, Etching Procedures for Fluorescent-Penetrant Inspection. Inspect per TASK 70-32-03-230-002, Spot-Fluorescent-Penetrant Inspection. Place the repaired blades and vanes in separate containers to prevent damage during handling. Carefully inspect the blades and vanes.
5 6 (2)
Blending Minor Indications in Tubing. (a) (b) Use a fine abrasive stone, a small needle file with fine teeth, emery cloth, or crocus cloth for blending. Blend around the circumference of the tubing. The finished blend shall be as close as practical to the original finish of the part.
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Airfoil Leading Edge - Blending Figure 1
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Airfoil Defect - Measurement Figure 2
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-42-00-350-024 E. Removal of High Metal. DO NOT BREATHE THE PARTICLES FROM BLENDING OR LET THE PARTICLES TOUCH YOU. PARTICLES FROM BLENDING CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
WARNING:
NOTE: The instructions in the applicable Engine/Shop Manual section or applicable Service Bulletin take precedence over the following procedures. Use the instructions that follow with the applicable Engine/Shop Manual or Service Bulletin criteria, or when no criteria are specified. (1) High metal is caused by the displacement of metal above a surface. It is found around defects like nicks and scratches. Remove high metal as follows: (a) (b) Use a fine abrasive stone, emery cloth, or crocus cloth to remove high metal. Remove only the material that is projecting above the original surface contour. Refer to Figure 3, Page 9.
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Defect - Blending and High Metal - Removal Figure 3
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POLISHING BOLT HOLE SURFACES - POLISHING BOLT HOLE SURFACES TASK 70-42-01-350-003 1. Polishing Bolt Hole Surfaces SUBTASK 70-42-01-99G-003 A. General. (1) This procedure provides instructions for polishing bolt hole surfaces to eliminate tool marks, scratches, and other minor surface defects.
SUBTASK 70-42-01-350-031 B. Equipment. (1) An air- or electric-powered rotary tool having a minimum speed of 4000 rpm is necessary. One having a speed of 5000-8000 rpm is recommended.
SUBTASK 70-42-01-350-032 C. Materials. NOTE: Equivalent substitutes may be used instead of the following items. Consumable Product A. Polishing Compound. (1) 240 grit aluminum oxide in soft grease C10-096 NOTE: Any equivalent polishing compound must be removable by vapor degreasing. B. Wire Brushes. (1) 0.003 inch (0.08 mm) wire C10-097 NOTE: Brush diameter range of sizes should be about 0.031 inch (0.79 mm) larger than bolt hole to be polished. No.
SUBTASK 70-42-01-350-033 D. Procedure. (1) Polish internal surface as follows: (a) Mount a steel wire brush of the proper diameter in the chuck of the rotary tool.
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POLISHING BOLT HOLE SURFACES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (b) With the tool rotating at 4000 rpm minimum, pass the wire brush completely through the hole, and charge the brush with polishing compound in that position. Withdraw the rotating brush slowly and evenly. Repeat step D.(1)(b) until defects are eliminated or oversize limit is reached. Do not exceed limit. NOTE: The brush itself is not used to polish, but to carry the polishing compound. Nevertheless, the brush should be changed often enough to retain full size. It is suggested to change the brush after polishing one complete bolt circle. (d) Examine the hole after polishing as follows: 1 2 3 Check surface finish of wall to be sure that it meets detail part specifications. Swab etch the affected area per TASK 70-24-00-110-033, Etching Procedures for Fluorescent-Penetrant Inspection. Inspect surface per TASK 70-32-03-230-002, Spot-FluorescentPenetrant Inspection. No indications are permissible.
(c)
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POLISHING BOLT HOLE SURFACES Page 2 Dec 01/03
REPAIR PRACTICES - REPAIR PRACTICES FOR HOLE REWORK TASK 70-42-02-320-001 1. Repair Practices for Hole Rework SUBTASK 70-42-02-99G-001 A. General. (1) This procedure defines the process to be used for the rework of holes in rotor components and critical static parts. It will be used when specified by the process document. This rework includes the removal of damaged material, nicks, dents, gouges, etc., as well as enlargement of the hole for life extension purposes. This procedure may also be used to make new holes with a length (L) to depth (D) ratio (L/D) of less than 1. For holes with L/D ratio greater than or equal to 1, specific Source Substantiation requirements will be issued. This procedure incorporates steps to ensure that the rework of a hole does not result in damage to the substrate and subsequent loss in design life for that component.
SUBTASK 70-42-02-320-051 B. Equipment. (1) Hones and honing supplies can be obtained from the following manufacturers: (a) (b) Micromatic Textron, refer to the List of Suppliers in Step D. of Subtask 70-8000-800-003. Sunnen Products Co., refer to the List of Suppliers in Step D. of Subtask 7080-00-800-003.
SUBTASK 70-42-02-320-052 C. Materials. (1) Honing stones shall be silicon carbide of the following grades: (a) (b) (c) (2) C150JVQ2 C320NVQ2 XIC180JVA
Honing Oil. (a) (b) Sunnen; Oil MV-30, C02-073 Micromatic; Oil PMC 9214, C02-073
(3)
General Purpose Coolants.
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REPAIR PRACTICES FOR HOLE REWORK Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (a) (b) Master Chemical; VHP-210. C10-75 Master Chemical; Trimsol, C10-75
SUBTASK 70-42-02-320-053 D. Procedure. (1) Documented annual operator awareness training is required for those operators who will perform this process. The following is an outline of the subjects that must be addressed by the operator training program. (a) (b) (c) (d) (e) (2) Awareness of the effect on the part life of this Standard Practice. Significance of speed, coolant application, and tool wear controls. Significance of edgebreak requirements. Methods of recording unusual events or part defects. Provision for annual retraining.
Tool Definition and Control. A Tool Control System must be in place to control the tooling used for this process. This system must address the following at a minimum: (a) (b) (c) (d) (e) Detailed tool drawings. Supplier control. Method of issuing tools. Regrind control. Method of handling tool geometry variations.
(3)
Equipment Speed and Feed Verification. (a) (b) (c) (d) Measure machine tool spindle speeds under no load conditions to verify that actual speeds are within 10 percent of nominal speeds. Perform spindle speed measurements across the applicable range of spindle speeds for the operations performed on a specific machine. Measure machine tool feedrates under no load conditions to verify that actual feedrates are within 10 percent of nominal feedrates. Perform feedrate measurements across the applicable range of feedrates for the operations performed on a specific machine. NOTE: These measurements must be taken at regular intervals. Initially, it is recommended that these checks be performed and documented every six months, and annually thereafter.
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STANDARD PRACTICES MANUAL AS907-1-1A (e) (4) Keep records of the inspections in accordance with the repair shops calibration system requirements.
Multi-step Process Requirements. (a) When machining new holes, use a multi-step process such as drilling followed by reaming or boring. A minimum of 0.006 inch (0.16 mm) must be removed by the secondary reaming or boring pass. Measure this 0.006 inch (0.16 mm) radially, 0.012 inch (0.31 mm) on the diameter. When you rework holes, the depth of the cut (measured radially) must be no more than 0.015 inch (0.38 mm) for each pass. For both processes above [both machining new holes (a) and reworking holes (b)], the last 0.002 inch (0.05 mm) must be removed by honing. Measure this 0.002 inch (0.05 mm) radially, 0.004 inch (0.10 mm) on the diameter.
(b) (c)
(5) Maching Process Drilling
Maximum Cutting Speeds and Feedrates.
Hole Lgth/ Diameter Ratio 3 >3 >3
Tool Diameter inches > 0.150 0.150
Max Cutting Speed (SFM) Power Met./ All Others 35 30 30 60 60 30 30 20 100 30 40 30 60 60 30 45 40 35 80 80 45 45 30 120 45 50 35 60 60 30
Max. Chip Load 0.0015 0.0015 0.0015 0.0015 0.0006 0.0005 0.0015 0.0010 0.0030 0.0015 0.0010 0.0010 0.0010 0.0010 0.0010
Coolant Fed Gun Drilling Gun Reaming Drillbore Ream and End Mill Hole Sizing Single Pt. Boring Center Bore Spotfacing Peripheral Milling Plunge Milling Chamfer Milling Countersinking Hand Fed Radius or Countersink (6)
Coolant Application Instructions. (a) You must use a continuous flow of coolant throughout the machining process except for manual edgebreak operations.
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STANDARD PRACTICES MANUAL AS907-1-1A (b) (7) Direct the coolant toward the tool cutting edge along the tool shank or submerge the part in coolant.
Tool Wear Limits. (a) Method of Measuring Tool Wear: 1 Use a hand held Bausch & Lomb Brinell glass or equivalent to estimate the width and length of the tool wear land at the cutting edge. NOTE: A Bausch & Lomb (B & L) Brinell glass is used to measure the diameter of the ball impression from a Brinell hardness test. The B & L eyepiece has a graduated scale with gaps between lines at 0.004 inch (0.10 mm). Any equivalent 7 to 50x magnifier with a 0.003 to 0.005 inch (0.08 to 0.13 mm) gap between lines is also acceptable. (b) Use the maximum tool wear values listed below to determine tool change values. Wear Land Length Inch 0.008 0.006 0.006 0.010 0.006 0.005 0.004 0.008 0.005 0.008 0.005 0.005 0.005 Edgebreak, Handbenching Definition. (a) Edgebreak: 1 Ensure that the edgebreaks of holes is free of burrs and high metal and is performed in accordance with the process document unless otherwise specified. Perform chamfer corner rounding as the last metal removal operation in making the holes. MM 0.20 0.15 0.15 0.25 0.15 0.15 0.10 0.20 0.13 0.20 0.13 0.13 0.13
Tool Type Drill Gun-drill Gun-reamer Bore portion of drill-bore Reamer End mill (hole sizing) Single point bore (hole sizing) Counterbore/spotface Peripheral mill Plunge mill Chamfer mill Counter sink Radius cutter (8)
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STANDARD PRACTICES MANUAL AS907-1-1A 3 Ensure that corners are chamfered by milling unless otherwise specified in the process document and that the corners are free of burrs and high metal. NOTE: Chamfer corner rounding must be done with soft tools, i.e., Cratex C10-043. (b) Handbenching: 1 Use soft tools, i.e., Cratex C10-043, to remove surface imperfections in holes. NOTE: The use of hard tools (i.e., abrasive stones) is allowed only when specified in the process document. (9) Post-finish Machining Requirements. (a) Post-finish reworked holes by honing, jig-grinding, or abrasive flow processes to remove 0.002 inch (0.05 mm) minimum radial material after conventional machining is performed. The following requirements apply to the processes used for post-finishing: 1 Abrasive Flow. a b 2 Maximum grit size shall be 710 micron (36 grit). Grit type shall be silicon carbide or aluminum oxide.
(b)
Honing. a b c d Maximum grit size shall be 122 micron (150 grit). Maximum tool expansion rate shall be 90 microns/minute. Minimum stroke rate shall be 120/minute. Grit type shall be silicon carbide or cubic boron nitride (CBN).
Jig Grinding. a b c Maximum grit size shall be 66 micron (220 grit). Maximum tool speed shall be 3500 SFM. Maximum feed rate shall be 150 microns/minute.
(10) Shotpeen Requirements. (a) Re-shotpeen all holes reworked per this instruction according to the requirements of the process document.
(11) Process Approval Responsibility.
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STANDARD PRACTICES MANUAL AS907-1-1A (a) Internal approval is required for this section of the Standard Practice Manual. The internal approval must be based upon the following: 1 2 3 4 Documentation of the Operator Training Program. Definition of Tooling Control System. Results of calibration of the machine tool as defined in the procedure. Documentation of the speeds and feeds used for the rework of the hole(s).
EFFECTIVITY: ALL
70-42-02
TOUCH-UP SILICONE-ALUMINUM PAINT - TOUCH-UP SILICONE-ALUMINUM PAINT TASK 70-43-01-380-001 1. Touch-Up Silicone-Aluminum Paint SUBTASK 70-43-01-99G-001 A. General. (1) Touch-up silicone aluminum paint can be used for touching up spots that have been repaired, or spots from which the original paint has been worn or removed. Silicone-aluminum paint should be used for this touch-up.
SUBTASK 70-43-01-380-051 B. Description Solvent, General Solvent, General Paint, Silicone Aluminum Solvent, General SUBTASK 70-43-01-380-052 C. Procedure. (1) Prepare the surface by removing loose particles and flakes of paint with a stainless steel wire brush. Feather-edge the sound paint surrounding spots to be touched up, using medium-fine wettable abrasive paper, wipe dry, and clean with a clean cloth moistened with general solvent, C04-002, C04-003, C04-035, or equivalent. Do not touch or otherwise contaminate areas to be painted. (a) Brush or spray cleaned areas with one coat of silicone aluminum paint, stir well before using. Refer to silicone aluminum paint C03-030. Air-dry for 30 minutes and bake for 2 hours at 4508F 258F (2328C 148C). Check adherence and appearance of paint as follows: 1 2 Finish must be uniform in appearance, and free from pin holes, blisters, runs and thin spots. Paint must not strip when a piece of cellophane tape is pulled rapidly from a clean surface of the part. The adherence of slight amounts of pigment to the tape may be disregarded. Materials. Consumable Code C04-002 C04-003 C03-030 C04-035
(b)
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70-43-01
TOUCH-UP SILICONE-ALUMINUM PAINT Page 1 Dec 01/03
EFFECTIVITY: ALL
70-43-01
TOUCH-UP SILICONE-ALUMINUM PAINT Page 2 Dec 01/03
PAINT ONE-COAT PROCESS - SILICONE-ALUMINUM PAINT ONE-COAT PROCESS TASK 70-43-02-380-002 1. Silicone-Aluminum Paint One-Coat Process SUBTASK 70-43-02-99G-002 A. General. (1) The one-coat refinishing process is used on specific parts, designated in the repair manual, for over-all surface protection. Refer to silicone aluminum paint C03-030 for consumable information. NOTE: Refer to the repair section on an individual part for special instructions concerning the painting and preparation of the part before using this procedure. SUBTASK 70-43-02-380-051 B. Description Paint, Silicone Aluminum SUBTASK 70-43-02-380-052 C. Procedure. (1) Clean the surface thoroughly to ensure a tight bond between the paint and the surface to be finished. Old paint can be stripped by using TASK 70-23-02-110-019, Stripping Method No. 2 Stripping Sermetel W Paint, if the part is a ferrous or high-temperature alloy. CAUTION: OTHER CLEANING METHODS MAY BE USED, BUT DO NOT USE SHELL, SAND OR SHOT BLASTING. DO NOT TOUCH OR OTHERWISE CONTAMINATE THE SURFACE TO BE PAINTED. (a) Dry abrasive blast as directed in TASK 70-21-04-120-0010, Dry Abrasive Blast Cleaning, Cleaning Method No. 4A, using 120-220 mesh aluminum oxide grit. This procedure cleans the part and leaves the surface in condition for good adherence of the paint. After abrasive blasting make sure that all dust and abrasive residue is removed by blasting with clean, dry shop air or by vacuum cleaning. Within one hour of cleaning the part, spray or brush silicone aluminum paint C03-030 on the part to form a uniform coating. Air dry for 30 minutes, then cure in an oven for 4508F 258F (2328C 148C) for 2 hours. Check adherence and appearance of paint as follows: Materials. Consumable Code C03-030
(b)
(c)
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70-43-02
SILICONE-ALUMINUM PAINT ONE-COAT PROCESS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A 1 2 Finish must be uniform in appearance, and free from pin holes, blisters, runs and thin spots. Paint must not strip when a piece of cellophane tape is pulled rapidly from a clean surface of the part. The adherence of slight amounts of pigment to the tape may be disregarded.
EFFECTIVITY: ALL
70-43-02
SILICONE-ALUMINUM PAINT ONE-COAT PROCESS Page 2 Dec 01/03
PAINT TWO-COAT PROCESS - SILICONE-ALUMINUM PAINT TWO-COAT PROCESS TASK 70-43-03-380-003 1. Silicone-Aluminum Paint Two-Coat Process SUBTASK 70-43-03-99G-003 A. General. (1) The two-coat refinishing process is used on specific parts, designated in the repair manual, for over-all surface protection. Refer to silicone aluminum paint C03-030 for consumable information. NOTE: Refer to the repair section on an individual part for special instructions concerning the painting and preparation of the part before using this procedure. SUBTASK 70-43-03-380-051 B. Description Paint, Silicone Aluminum SUBTASK 70-43-03-380-052 C. Procedure. (1) Clean the surface thoroughly to ensure a tight bond between the paint and the surface to be finished. Old paint can be stripped by using TASK 70-23-02-110-019, Stripping Method No. 2 Stripping Sermetel "W" Paint, if the part is a ferrous or high-temperature alloy. CAUTION: OTHER CLEANING METHODS MAY BE USED, BUT DO NOT USE SHELL, SAND OR SHOT BLASTING. DO NOT TOUCH OR OTHERWISE CONTAMINATE THE SURFACE TO BE PAINTED. (a) Dry abrasive blast as directed in TASK 70-21-04-120-001, Dry Abrasive Blast Cleaning - Cleaning Method No. 4A, using 120 or finer mesh aluminum oxide grit. This procedure cleans the part and leaves the surface in condition for good adherence of the paint. After abrasive blasting make sure that all dust and abrasive residue is removed by blasting with clean, dry shop air or by vacuum cleaning. Materials. Consumable Code C03-030
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70-43-03
SILICONE-ALUMINUM PAINT TWO-COAT PROCESS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (b) Within one hour of cleaning the part, spray or brush silicone-aluminum paint C03-030 on the part to form a uniform coating. Air dry for 30 minutes. NOTE: Relative humidity must be below 60% or second coat may not adhere properly. If humidity cannot be controlled, and is over 60%, the first coat of paint can be oven-dried at a temperature not to exceed 1508F (668C) for 30 minutes, or dried under a heat lamp for 30 minutes. (c) Apply second coat of silicone-aluminum paint C03-030 in the same manner as the first. Let air dry for 30 minutes, then cure in an oven at 4508F 258F (2328C 148C) for 2 hours. Check adherence and appearance of paint as follows: 1 2 Finish must be uniform in appearance, and free from pin holes, blisters, runs and thin spots. Paint must not strip when a piece of cellophane tape is pulled rapidly from a clean surface of the part. The adherence of slight amounts of pigment to the tape may be disregarded.
(d)
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70-43-03
SILICONE-ALUMINUM PAINT TWO-COAT PROCESS Page 2 Dec 01/03
EPOXY PAINTING - EPOXY PAINTING TASK 70-43-04-380-004 1. Epoxy Painting SUBTASK 70-43-04-99G-004 A. General. (1) Epoxy enamel paint is a surface coating that protects parts against erosion and corrosion. The following is a general procedure and should be put together with refinishing requirements in repair procedures for specific parts.
SUBTASK 70-43-04-380-051 B. Description Reducer, Epoxy Paint, Epoxy, Aircraft Gray 283E200 Solvent, General Paint, Polyurethane, Aircraft Gray SUBTASK 70-43-04-380-052 C. Preparation for Painting. CAUTION: OLD PAINT OR GRIT REMAINING ON THE PART MAY PREVENT NEW PAINT FROM BONDING SATISFACTORILY. GRIT-BLAST AGAIN AND AIR-BLAST AGAIN TO REMOVE REMAINING GRIT. (1) Prepare the part. (a) Strip the old paint from the part. Refer to TASK 70-23-01-110-018, Stripping Method No. 1 - Stripping Epoxy, Polysulfide, and Polyurethane Paint Systems (Hot Tank Method). Clean the part. Refer to TASK 70-21-22-110-042, Cleaning Method No. 22, Light Duty Aqueous Cleaning - Method 1, or TASK 70-21-22-110-050, Cleaning Method No. 22, Light Duty Aqueous Cleaning - Method 2. Grit-blast the part lightly. Refer to TASK 70-21-04-120-001, Cleaning Method No. 4 - Dry Abrasive Blast Cleaning. Air-blast the part to remove the remaining grit. Materials. Consumable Code C03-035 C03-034 C04-036 C03-080
(b)
(c)
(2)
Do not touch the cleaned parts with your bare hands; wear clean cotton gloves. Apply paint in less than three hours.
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70-43-04
EPOXY PAINTING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (3) Mask the areas that are not to be painted, following the detailed part instructions.
SUBTASK 70-43-04-380-042 D. Procedure. (1) (2) (3) Spray paint C03-034 to a thickness of 0.0005-0.0015 inch (0.013-0.038 mm) on the surface to be coated. Let the coating air-dry for a minimum of 30 minutes. Inspect the coating for a smooth appearance. It must be free of bubbles, build-up on edges, sags, runs and other defects. Minor pits and voids may be touched up, then air-dried. Surfaces that are not coated correctly must be stripped of the coating and coated again. Use thinner C03-035 to remove defective coating. Apply a second coat to a final coating thickness of 0.001-0.002 inch (0.025-0.050 mm). Bake the final coating for a minimum of 30 minutes at 4008-4258F (2048-2188C). Inspect the coating to make sure that the specified area is covered, and that it is continuous, smooth, and free of bubbles. NOTE: Touch-up is permitted if the affected area is baked, and if it agrees with inspection and test requirements. (7) Test the coating for a full cure by quickly rubbing an area with a clean white cloth moistened with thinner C03-035. There must be no indication that the coating has been removed or made soft. If the coating is not fully cured, bake the part and test it again. If the coating continues to be not fully cured, strip the coating from the part and coat the part again. Refer to TASK 70-23-01-110-018, Stripping Method No. 1 - Stripping Epoxy, Polysulfide, and Polyurethane Paint Systems (Hot Tank Method).
(4) (5) (6)
(8)
SUBTASK 70-43-04-380-043 E. Touch-up Procedure. (1) Use this procedure for touch-up of small areas with damaged or missing paint on steel parts, particularly when heat-curing is not practical or desirable. CAUTION: THE SOLVENTS USED FOR SURFACE PREPARATION, SUCH AS C04036 OR AN EQUIVALENT THINNER, AND THE SOLVENTS USED IN THE PAINT AND THE CATALYST, ARE FLAMMABLE AND SHOULD BE KEPT AWAY FROM HEAT OR OPEN FLAME. AVOID PROLONGED BREATHING OF THE VAPORS. TREAT SOAKED CLOTHS AND BRUSHES AS FIRE HAZARDS. (a) Remove loose particles of paint and foreign material with a wire brush, and wipe the area clean with a clean cloth soaked with C04-036 or equivalent paint thinner. Do not touch the cleaned area with your bare hands; wear clean cotton gloves.
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STANDARD PRACTICES MANUAL AS907-1-1A (b) Use a small, clean artists brush to apply the paint C04-036. Mix the paint and catalyst together in a 1-to-1 ratio by volume. Wait 10 minutes before usage. USE PROPER PRECAUTIONS WHEN TOUCHING THE CATALYST. CONTACT OF THE CATALYST WITH THE SKIN OR EYES CAUSES SKIN BURNS AND SEVERE EYE INJURY. IF THE CATALYST CONTACTS THE SKIN, FLUSH THOROUGHLY WITH WATER. IF THE CATALYST CONTACTS THE EYES, SEEK MEDICAL AID IMMEDIATELY.
WARNING:
(c) (d)
Let the paint cure at room temperature for 24 hours. After the paint has cured, rub the area for 20 seconds or longer with a clean cloth soaked with acetone. If the coating is not removed or softened, the rough-up is acceptable. ACETONE IS HIGHLY FLAMMABLE, AND ITS VAPOR IS TOXIC. AVOID PROLONGED INHALATION OF ITS VAPOR, AND KEEP IT AWAY FROM HEAT OR FLAME.
WARNING:
(e)
No oil, grease or solvent may come into contact with the touch-up painted areas during the 24 hour cure time.
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EFFECTIVITY: ALL
70-43-04
PROTECTIVE COATING - INORGANIC ALUMINUM PROTECTIVE COATING TASK 70-43-05-380-005 1. INORGANIC ALUMINUM PROTECTIVE COATING SUBTASK 70-43-05-99G-005 A. General. WARNING: THESE COATINGS CONTAIN ALUMINUM PARTICLES IN THE 5 TO 10 MICRON RANGE, WHICH REACT LIKE PURE ALUMINUM POWDER IN THE DRY STATE, FORMING EXPLOSIVE MIXTURES WHEN DISPERSED IN AIR. TAKE PRECAUTIONS TO AVOID THE ACCUMULATION OF OVERSPRAY AND THE FORMATION OF DUST CLOUDS. ALUMINUM COATINGS REACT WITH ALKALINE SOLUTIONS AND MANY ACIDS TO LIBERATE HYDROGEN, WHICH FORM EXPLOSIVE MIXTURES WITH AIR. BE SURE THAT PAINTSTRIPPING TANKS ARE THOROUGHLY VENTILATED BY A FORCED-AIR EXHAUST SYSTEM WHILE PROCESSING ALUMINUMCOATED PARTS. THE UNCURED BINDER OF THESE COATINGS CONTAINS HEXAVALENT CHROMIUM, IS TOXIC IF INGESTED AND REQUIRES CARE IN HANDLING. AVOID CONTACT WITH SKIN, EYES, AND MUCOUS MEMBRANES. IN CASE OF CONTACT, IMMEDIATELY IRRIGATE AFFECTED AREA WITH RUNNING WATER. IF CONTACT IS SEVERE, OBTAIN MEDICAL ATTENTION. WHILE SPRAYING AVOID BREATHING THE MIST OF THE ATOMIZED COATING. WELL VENTILATED SPRAYING AREAS WITH A HIGH EXHAUST RATE (150 FEET PER MINUTE OR GREATER) SHOULD BE USED AND RESPIRATORS SHOULD BE WORN.
WARNING:
(1)
These coatings are applied to surfaces that are subject to corrosion.
SUBTASK 70-43-05-380-051 B. Equipment and Settings. (1) The following spray equipment (a) and settings (b) or equivalent are recommended for this coating procedure. (a) Equipment. 1 Spray Gun, Devilbiss Model JGK IN-641FX with nylon tipped needle and either air cap number 263 for 6-8 inch (152-203 mm) spray pattern or number 265 for 8-12 inch (203-305 mm) spray pattern. Pressure Tank, Devilbiss Model QMR-HTS 1414-55p stainless steel fitted 5 gallon (19 liter) pot with high efficiency stainless steel mixer and air motor drive.
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70-43-05
INORGANIC ALUMINUM PROTECTIVE COATING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A 3 4 5 (b) Fluid Hose Devilbiss H-1996-PHC-4548-XX (specify length) 0.375 inch (9.5 mm) ID nylon lined. Air Hose. Devilbiss H-1641-PNC-4527-XX (specify length) 0.312 inch (7.9 mm) ID with static grounding wire. Grounding Wire For Pressure Pot. Justrite 8-501, 3 grounding wires with clamps.
Settings. 1 2 3 4 Pressure Tank: 10-12 psi Fluid Pressure: 5-7 psi Atomizing Air Pressure: 40 psi Spray Distance: 5-8 inches (127-203 mm) from the part while making upand-down passes. Do not make passes in a circular motion.
SUBTASK 70-43-05-380-052 C. Materials. (1) Description Paint, SermeTel Paint, Inorganic Aluminum Paint, SermeTel Paint, Inorganic Aluminum Paint, Inorganic Aluminum SUBTASK 70-43-05-380-053 D. Preparation Procedure. (1) (2) Strip the old coating. Refer to TASK 70-23-02-110-019, Stripping Method No. 2 Stripping SermeTel W Paint. If the part has been inspected or repaired after the coating was stripped, clean the part. Refer to TASK 70-21-22-110-042, Cleaning Method No. 22, Light Duty Aqueous Cleaning - Method 1, or TASK 70-21-22-110-050, Cleaning Method No. 22, Light Duty Aqueous Cleaning - Method 2. Mask all areas not to be coated, following the detailed part instructions. Grit-blast the part. Refer to TASK 70-21-04-120-001, Cleaning Method No. 4 - Dry Abrasive Blast Cleaning. Use aluminum oxide grit particles in the 120-240 mesh Inorganic Aluminum Coating Ref No. C03-038 C03-055 C03-039 C03-091 C03-093
(3) (4)
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70-43-05
STANDARD PRACTICES MANUAL AS907-1-1A range as the abrasive material. Remove the remaining grit particles by air-blasting the area with clean, dry shop air. NOTE: Do not handle prepared parts with your bare hands; wear clean, white cotton gloves. Unless the parts are to be coated in less than 4 hours, they should be stored in clean, sealed polyethylene bags. SUBTASK 70-43-05-380-054 E. Spray Application and Cure Procedure. (1) Apply a minimum of 2 separately cured spray coats of C03-038, C03-055, C03-091, or C03-093 to get the required thickness. The total thickness after curing is to be 0.0015-0.0030 inch (0.038-0.076 mm) unless otherwise specified in the detailed part instructions. For coating material, refer to SUBTASK 70-43-05-380-052, Materials. NOTE: When it is possible, apply the coating in shop areas where the relative humidity is not more than 60. If humidity is more than 60, special drying procedures are required after spraying. Refer to Step E.(4) Mix the coating material thoroughly before and during the procedure to make sure that solids do not collect in the bottom of the tank. Viscosity shall be 16-18 seconds, as measured with a Model S-2 Meylon stop watch and a No.2 Zahn cup. (2) (3) (4) Unless otherwise specified, use the spray parameters and method specified in the applicable manual to apply the coating. Refer to , Equipment and Settings. Remove the masking, plugs, caps and sealing fixtures from the part. Air-dry the coating at room temperature until the coating is a uniform gray-white color. When the relative humidity is more than 60%, air-drying in an oven at 1751858F (79-858C), or with heat lamps at a maximum coating surface temperature of 1858F (858C), may be necessary to accelerate the drying time. If dark green areas exist and will not dry, remove the coating by pressure-rinsing with cold water. Dry the part thoroughly. Replace the required masking, plugs, caps, and sealing fixtures, grit-blast the part, and then re-coat the part. Ignore light green or brown areas. NOTE: Dark green areas indicate that the coating is too wet or too thick, and that it may flake during final baking. (6) (7) Bake the part a minimum of 15 minutes at a part temperature of 6258F 258F (3298C 148C). Make sure that the coating is sufficiently cured by quickly rubbing a small area with a swab soaked in water. If the coating does not change color, it is cured; if the coating color becomes green, repeat Step E.(5) until the coating is cured. Use the same procedure to apply additional coats as required to get the specified thickness. Cure each coat separately before you apply the next. Visually check the final coating to make sure that it is free from cracks, pin-holes, runs, sags, inclusions of foreign material, or other defects.
(5)
(8) (9)
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70-43-05
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-43-05-380-055 F. Quality Tests. (1) Test panels shall be coated and tested as required by the local quality control organization. Panel configurations and tests are recommended as follows: (a) Test panels shall be approximately 3 X 4 X 0.063 inches (76.2 X 101.6 X 1.6 mm) in size, they shall have smooth edges and rounded corners, and they shall be annealed. The panels should be of the same material as the parts. Test panels should be coated in the same manner and with the parts. Bend the coated test panels through an angle of 908, around a 0.125 inch (3.18 mm) bend radius. Spring-back to less than 908 is permitted. Inspect the test panels. No less than 90% of the coating along the axial lines on the convex panel surface shall be free from chipping or peeling. If the panels do not agree with this requirement, strip and refinish the engine parts that they represent.
(b) (c) (d)
SUBTASK 70-43-05-380-056 G. Touch-up Procedure. (1) Defective areas may be touched up with SermeTel paint C03-039, full strength from the can. Keep the can tightly covered when not in use. Refer to SUBTASK 70-43-05380-052, Materials. NOTE: Not more than 5% of total coated area may be touched up. This touch-up procedure does not give the same corrosion protection as the original coating. (a) Clean and prepare the alloy surface by grit-blasting the area to be touched up. Refer to TASK 70-21-04-120-001, Cleaning Method No. 4 - Dry Abrasive Blast Cleaning. An alternative method is to expose only clean metal by sanding the surface with 180 grit aluminum oxide abrasive cloth or paper. Remove the remaining grit particles by air-blasting the area with clean, dry shop air. Make sure all organic solvents are removed from the surface. Wipe the cleaned area with a clean, lint-free cloth. Brush or spray the touch-up coating onto the prepared area. Shake the container thoroughly before use to keep the material from collecting rapidly at the bottom. Let the touched-up part dry for 8 hours at room temperature to cure fully. Check the bond and cure of the touch-up coating as follows: 1 Flush the repaired and cured surface by immersing it in roomtemperature water, or by flowing water over the repaired surface, for one minute. If the surface is not removed or softened, it is satisfactory.
(b) (c) (d)
(e) (f)
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A 2 Rub the touched-up areas with a rag soaked with Jet-B fuel or lubricating oil (MIL-L-7808) for one minute. If the repaired surface is not removed or softened, it is satisfactory. NOTE: The surface is also resistant to steam cleaning. The touch-up coating may not be an exact color match for the original coating, but the color is very close to that of the original coating after it cures.
EFFECTIVITY: ALL
70-43-05
EFFECTIVITY: ALL
70-43-05
CLEAR EPOXY COATING - CLEAR EPOXY PAINTING TASK 70-43-06-380-006 1. Clear Epoxy Painting SUBTASK 70-43-06-99G-006 A. General. (1) Clear epoxy paint is used to touch up repaired parts from which areas of the original paint have been removed.
SUBTASK 70-43-06-380-051 B. Description Paint, Epoxy Clear Reducer, Epoxy SUBTASK 70-43-06-380-052 C. Procedure. (1) Prepare part for touch-up with clear epoxy paint C03-041 as follows: (a) (b) (c) Remove loose paint and feather-edge with stainless steel brush or abrasive cloth, 200 grit or finer. Clean with bristle brush or soft cloth moistened in solvent, to remove oil, fingerprints, residues or dust. If the part is magnesium, call your Honeywell contact for instructions before application of the paint. Materials. Consumable Code C03-041 C03-035
SUBTASK 70-43-06-380-053 D. Application. (1) Apply clear epoxy paint C03-041 to prepared areas with brush or spray. NOTE: Reducer C03-035 may be used to thin paint as required. (2) Let paint air-dry for 30 minutes or more before handling. Baking is permissible, but is not required. Air-drying can be accelerated by the use of a heat lamp.
EFFECTIVITY: ALL
70-43-06
CLEAR EPOXY PAINTING Page 1 Dec 01/03
EFFECTIVITY: ALL
70-43-06
CLEAR EPOXY PAINTING Page 2 Dec 01/03
CHEMICAL TOUCH-UP FOR ALUMINUM - CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM TASK 70-43-07-380-007 1. CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM SUBTASK 70-43-07-99G-007 A. General. WARNING: THE SOLUTIONS USED IN THIS PROCESS ARE HIGHLY CORROSIVE. USE RESPIRATORS, GOGGLES OR FACE SHIELD, RUBBER OR NEOPRENE GLOVES, BOOTS AND APRONS WHEN HANDLING OR APPLYING THE SOLUTION. WASH OFF IMMEDIATELY IF SOLUTION CONTACTS THE SKIN. IF SOLUTION CONTACTS THE EYES, FLUSH THEM WITH CLEAR WATER, IRRIGATE WITH BORIC ACID SOLUTION, AND SEEK IMMEDIATE MEDICAL AID.
(1)
Aluminum surfaces from which the original anodized protective finish has been removed must be touched up or refinished to restore the protective film. The following treatment is used for spot touch-up, and the solution may be brushed, sprayed, or sponged on the prepared area.
SUBTASK 70-43-07-380-071 B. Materials. CAUTION: YOU CANNOT MIX ONE COATING MATERIAL WITH ANOTHER. IF YOU MIX TWO DIFFERENT COATING MATERIALS TOGETHER, THE RESULT COULD GIVE UNSATISFACTORY PROTECTION. (1) Interchangeability. You can use the materials specified by MIL-C-81706 listed in QPL-81706 as alternatives to the materials in the table that follows if: (a) (b) (c) - they are from the same class, and - they use the same method of application. The materials in QPL-81706 and the materials in the table that follows will give equivalent protection if they are from the same class and method of application.
EFFECTIVITY: ALL
70-43-07
CHEMICAL TOUCH-UP SURFACE REFINISHING PROCESS FOR ALUMINUM Page 1 Dec 01/03
Description Description Conversion Coating, Chromated Conversion Coating, Chromated (MIL C 5541, Yellow) Conversion Coating, Chromated Conversion Coating, Chromated Solvent, General Solvent, General Solvent, General SUBTASK 70-43-07-380-072 C. Procedure. (1) Refinish exposed areas as directed in the following steps. (a) Clean surface with liquid solvent degreaser such as C04-002, C04-003, C04035, or other approved non-hazardous solvent, using a clean brush or lintfree cloth. CHLORINATED HYDROCARBON SOLVENTS ARE TOXIC AND SHOULD BE USED IN A WELL- VENTILATED AREA. AVOID PROLONGED BREATHING OF VAPORS. REPEATED OR PROLONGED CONTACT WITH THE SKIN WILL DISSOLVE FAT AND SKIN OILS AND MAY CAUSE SEVERE DERMATITIS. Consumable Code Consumable Code C03-081 C03-082 C03-084 C03-092 C04-002 C04-003 C04-035
WARNING:
CAUTION: DO NOT PERMIT SURFACE COATING SOLUTION TO CONTACT ORGANIC SOLVENTS: IT CAN IGNITE THEM. (b) Sand area lightly, using 180-grit, aluminum oxide abrasive paper.
CAUTION: IF YOU USE AN INTERCHANGEABLE MATERIAL, OBEY THE MANUFACTURERS INSTRUCTIONS TO MIX AND APPLY THE MATERIAL. IF YOU DO NOT USE THE MANUFACTURERS INSTRUCTIONS, THE RESULT COULD BE DAMAGE TO THE PART OR UNSATISFACTORY PROTECTION. (c) Alternative procedure available. If using C03-081 or C03-082, apply the refinishing solution as follows: 1 Apply the refinishing solution with an acid-resistant nylon-bristle brush or cellulose sponge. Keep part wet with solution until coating is fully formed - usually from one to 10 minutes.
EFFECTIVITY: ALL
70-43-07
STANDARD PRACTICES MANUAL AS907-1-1A (d) Alternative procedure. If using C03-084, apply the refinishing solution as follows: 1 2 Mix parts A and B together in equal volume, stirring thoroughly. Apply refinishing solution C03-084 with an acid-resistant nylon-bristle brush or cellulose sponge. Keep part wet with solution until coating is fully formed - usually from one to 10 minutes
(e)
Check the color and texture of the coating. The coating is usually a golden iridescent color, although the color may vary with different alloys and processing conditions. If coating is powdery, the treatment time was longer than necessary. Powdery coating should be removed and coating redone.
CAUTION: BE CAREFUL TO PREVENT SPLASHING OR SPRAYING OF REFINISHING SOLUTION ONTO METALS OTHER THAN ALUMINUM. THE SOLUTION IS HIGHLY CORROSIVE. (f) Rinse off the refinishing solution thoroughly by flushing with clear water, by immersion in overflowing water (1208-1408F or 498C-608C), or by removing excess solution with a wet sponge. Do not rinse with the jet from a hose or with a pressure-spray, and do not permit liquids to remain in cavities or depressions in the part. A blast of clean shop air may be used to blow liquids from the part.
CAUTION: WHEN WIPING, BE CAREFUL TO AVOID SCRATCHING OR RUBBING OFF THE COATING, WHICH IS DELICATE WHEN FRESHLY FORMED. (g) Dry the part with shop air or with a clean, soft cloth.
CAUTION: DO NOT PERMIT SWABS, CLOTHS, PAPER, ETC., USED FOR APPLYING OR REMOVING THE SURFACE COATING SOLUTION TO DRY OUT. THESE MATERIALS ARE COMBUSTIBLE WHEN DRY, AND CONSTITUTE A FIRE HAZARD. IMMEDIATELY AFTER USE, SOAK THE ITEMS THOROUGHLY IN WATER BEFORE DISCARDING. (h) (i) If the part is to be painted, let the surface coating set for at least 30 minutes to cure before applying the paint. Store touch-up solution in plastic container. It will deteriorate in plain glass or steel containers.
EFFECTIVITY: ALL
70-43-07
EFFECTIVITY: ALL
70-43-07
CHEMICAL FILM COATING FOR ALUMINUM - CHEMICAL FILM COATING FOR ALUMINUM TASK 70-43-08-380-008 1. CHEMICAL FILM COATING FOR ALUMINUM SUBTASK 70-43-08-99G-008 A. General. WARNING: THE SOLUTIONS USED IN THIS PROCESS ARE HIGHLY CORROSIVE. USE RESPIRATORS, GOGGLES OR FACE SHIELD, RUBBER OR NEOPRENE GLOVES, BOOTS AND APRONS WHEN HANDLING OR APPLYING THE SOLUTION. WASH OFF IMMEDIATELY IF SOLUTION CONTACTS THE SKIN. IF SOLUTION CONTACTS THE EYES, FLUSH THEM WITH CLEAR WATER, IRRIGATE WITH BORIC ACID SOLUTION, AND SEEK IMMEDIATE MEDICAL AID.
(1)
Aluminum or aluminum alloy parts from which all or most of the original anodized finish has been removed must be refinished to restore the protective film. The following treatment is used for over-all refinishing by immersing the parts in the chemical solution.
SUBTASK 70-43-08-380-081 B. Materials. CAUTION: YOU CANNOT MIX ONE COATING MATERIAL WITH ANOTHER. IF YOU MIX TWO DIFFERENT COATING MATERIALS TOGETHER, THE RESULT COULD GIVE UNSATISFACTORY PROTECTION. (1) Interchangeability. You can use the materials listed in QPL-81706 as alternatives to the materials in the table that follows if: (a) (b) (c) - they are from the same class, and - they use the same method of application. The materials in QPL-81706 and the materials in the table that follows will give equivalent protection if they are from the same class and method of application. Consumable Code C03-006 C03-046 C03-083
Description Conversion Coating, Chromated (MIL C 5541, Yellow) Conversion Coating, Chromated Conversion Coating, Chromated (MIL C 5541, Yellow)
EFFECTIVITY: ALL
70-43-08
CHEMICAL FILM COATING FOR ALUMINUM Page 1 Dec 01/03
Description Solvent, General Solvent, General Solvent, General Acid SUBTASK 70-43-08-380-082 C. Procedure. (1)
Consumable Code C04-002 C04-003 C04-035 C04-072
Refinish parts as directed in the following steps: WARNING: SOLVENTS CAN BE TOXIC, AND SHOULD BE USED IN A WELL VENTILATED AREA. AVOID PROLONGED BREATHING OF VAPORS. REPEATED OR PROLONGED CONTACT WITH THE SKIN WILL DISSOLVE FAT AND SKIN OILS, AND MAY CAUSE SEVERE DERMATITIS.
CAUTION: IF YOU USE AN INTERCHANGEABLE MATERIAL, OBEY THE MANUFACTURERS INSTRUCTIONS TO MIX AND APPLY THE MATERIAL. IF YOU DO NOT USE THE MANUFACTURERS INSTRUCTIONS, THE RESULT COULD BE DAMAGE TO THE PART OR UNSATISFACTORY PROTECTION. CAUTION: DO NOT PERMIT SURFACE COATING SOLUTION TO CONTACT ORGANIC SOLVENTS: IT CAN IGNITE THEM. (a) Clean parts thoroughly with liquid solvent degreaser such as C04-002, C04003, C04-035, or other approved non-hazardous solvent, using a clean brush or lint-free cloth. Immerse parts in coating solution for 5-10 minutes at ambient temperature to 1008F (388C). Refer to the table below for solution mixing/chemistry. Mixing Instructions Solution Sheet S1173 Check the color of the coating. The coating is usually a golden iridescent color, although the color may vary with different alloys and processing conditions. If coating is powdery, the treatment time was longer than necessary; however, the powder can be wiped off with a soft cloth without damage to the coating.
(b)
Consumable Code C03-006 or C03-083 (c)
EFFECTIVITY: ALL
70-43-08
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: BE CAREFUL TO PREVENT SPLASHING OR SPRAYING OF REFINISHING SOLUTION ONTO METALS OTHER THAN ALUMINUM. THE SOLUTION IS HIGHLY CORROSIVE. (d) Remove parts from solution; drain. Rinse off the re-finished solution thoroughly by flushing with clear water, by immersion in overflowing water 1208-1408F (408-608C) or by removing excess solution with a wet sponge. Do not rinse with the jet from a hose or with a pressure-spray, and do not permit liquids to remain in cavities or depressions in the part.
CAUTION: DO NOT PERMIT SWABS, CLOTHS, PAPER, ETC., USED FOR APPLYING OR REMOVING THE SURFACE COATING SOLUTION TO DRY OUT. THESE MATERIALS ARE COMBUSTIBLE WHEN DRY, AND CONSTITUTE A FIRE HAZARD. IMMEDIATELY AFTER USE, SOAK THE ITEMS THOROUGHLY IN WATER BEFORE DISCARDING. (e) Rinse parts thoroughly and quickly in acidified solution C03-046. See table below for mixing instructions. Allow to drain dry. Do not permit liquids to remain in cavities or depressions in the part. NOTE: All chemically cleaned and treated aluminum parts shall not be handled until they are completely dry and then only with clean cotton gloves to avoid scuffing or scratching. Consumable Code C03-046 (f) Mixing Instructions Solution Sheet S1174 If the part is to be painted, let the surface coating set for at least 30 minutes to cure before applying the paint.
EFFECTIVITY: ALL
70-43-08
EFFECTIVITY: ALL
70-43-08
REPLACEMENT OF DRY-FILM LUBRICANT - REPLACEMENT OF DRY-FILM LUBRICANT TASK 70-43-09-640-001 1. Replacement of Dry-Film Lubricant SUBTASK 70-43-09-99G-001 A. General. (1) Locknuts and other threaded parts that are re-usable in other respects must be coated with a film of dry lubricant before they are used again. The following treatment is used to restore the lubricating film.
SUBTASK 70-43-09-640-011 B. Materials. (1) ESNA 382 C02-006
SUBTASK 70-43-09-640-012 C. Procedure. (1) Recoat threads as directed in the following steps. (a) Steam clean per TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning, to remove dirt and grease. Special care must be taken to clean the threads. Parts to be coated must be free of heat-treat oxides, grease, oil and other foreign matter. Clean per TASK 70-21-06-110-004, Cleaning Method No. 6 - Heavy-Duty Alkaline Cleaner (Without Inhibited Phosphoric Acid). Blow threads dry with clean shop air. Apply dry-film lubricant C02-006 as follows: 1 2 Stir lubricant thoroughly before using. Lubricant settles out of the mixture rapidly, and the mixture should be agitated during use. Coat threads with lubricant mixture, taking care to coat threads completely. Use a swab, if necessary, to break air pockets and obtain complete coverage. Air-dry the coating for at least 15 minutes, then bake for 2 hours at 1508F (668C) followed by 2 hours at 4008F (2048C) using an air circulating type oven.
(b) (c)
EFFECTIVITY: ALL
70-43-09
REPLACEMENT OF DRY-FILM LUBRICANT Page 1 Dec 01/03
EFFECTIVITY: ALL
70-43-09
REPLACEMENT OF DRY-FILM LUBRICANT Page 2 Dec 01/03
COLLOIDIAL GRAPHITE COATING - COLLOIDAL GRAPHITE COATING - C02-028 TASK 70-43-10-640-002 1. Colloidal Graphite Coating - C02-028 SUBTASK 70-43-10-99G-002 A. General. (1) Colloidal graphite coatings are effective in preventing chafing, fretting, and other types of wear between moving parts. See C02-028 for consumable
SUBTASK 70-43-10-640-051 B. Description Coating, Colloidal Graphite Solvent, General Solvent, General SUBTASK 70-43-10-640-052 C. Procedure. WARNING: SOLVENTS CAN BE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPOR AND CONTACT WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME. Materials. Consumable Code C02-028 C04-001 C04-003
(1)
Clean the surface to be coated by wiping with a cheesecloth pad saturated with a general solvent C04-001 or C04-003. Refold pad to expose clean surface, and continue to rub or wipe until cloth remains clean. Use masking tape to mask-off areas that are not to be coated. Spray surface to be coated, using C02-028, which is available in pressurized containers. Before spraying, shake container vigorously until agitator ball strikes the inside freely, indicating thorough mixing of graphite and vehicle. Shake container periodically during spraying to keep graphite in suspension. Hold nozzle of spray container about 8-10 inches (203.2-254.0 mm) from part, and apply an even coat of uniform thickness. After completion, invert the container and press spray button for 1-2 seconds to clear nozzle for future use. Let coating air-dry at room temperature for at least 30 minutes.
(2) (3)
(4)
(5)
EFFECTIVITY: ALL
70-43-10
COLLOIDAL GRAPHITE COATING - C02-028 Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: (6) (7) OBSERVE PRECAUTIONS AGAINST FIRE AND EXCESSIVE BREATHING OF SOLVENT VAPORS.
Remove masking. Wipe off any superfluous coating, using a cloth moistened in a general solvent C04-001 or C04-003. Examine coating before assembling part. Coating must be continuous, homogeneous, of uniform thickness, tightly bonded to the base metal, and free of oil. Coating must not peel, chip, or crack when scratched with fingernail.
EFFECTIVITY: ALL
70-43-10
COLLOIDIAL GRAPHITE COATING - COLLOIDAL GRAPHITE COATING - C02-030 TASK 70-43-11-640-003 1. Colloidal Graphite Coating - C02-030 SUBTASK 70-43-11-99G-003 A. General. (1) Colloidal graphite coatings are effective in preventing chafing, fretting, and other types of wear between moving parts. C02-028 may be applied to parts by brushing, spraying, or dipping.
SUBTASK 70-43-11-640-051 B. Description Coating, Colloidal Graphite Solvent, General Solvent, General Solvent, Blend SUBTASK 70-43-11-640-052 C. Process. (1) Thoroughly clean the surface to be coated, so that it is free of oil, grease, rust or scale, to ensure a tight bond. Apply the colloidal graphite coating within 3 hours after cleaning. NOTE: If the cleaning process removes the corrosion preventative from areas of the bare metal that are not to be coated, reapply the corrosion preventative immediately after curing the new colloidal graphite coating. (2) Spray, brush, or dip the part to apply the colloidal graphite coating, according to the following directions: (a) Spraying: Mask areas not to be coated. Spray a uniform coating of colloidal graphite onto the part, using the material undiluted as it comes from the can. Air pressures of 25-40 psi (172.4-275.8 kPa) are recommended. SOLVENTS ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPOR AND CONTACT WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME. Materials. Consumable Code C02-030 C04-036 C04-230 C04-231
WARNING:
(b)
Brushing: Thin the material, using a 50:50 mixture of C04-036 and C04-230 or C04-231 as the thinner, to not more than 1:1 dilution. Agitate frequently to
EFFECTIVITY: ALL
70-43-11
STANDARD PRACTICES MANUAL AS907-1-1A keep material in suspension. Apply multiple coats with a soft-bristle brush until proper thickness of coating is attained. WARNING: TOLUOL AND CELLOSOLVE ACETATE ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPOR AND CONTACT WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME.
(c)
Dipping: Thin the material, using a 50:50 mixture of C04-036 and C04-230 or C04-231 as the thinner, to not more than one part of thinner to 2 parts of colloidal material. Agitate frequently to keep the colloidal graphite in suspension. Either manual or mechanical dipping methods may be used.
(3) (4) (5)
Let coating dry for 15-30 minutes. Cure coating at 3758-4258F (1918-2188C) for 30 minutes minimum. Examine coating to make sure that it is free from cracks, blisters, and foreign matter; it shall be a continuous, homogeneous coating of uniform thickness, and shall not chip, crack or peel when scratched with the fingernail.
EFFECTIVITY: ALL
70-43-11
BLACK OXIDE FINISH - BLACK OXIDE FINISH TASK 70-43-12-380-009 1. Black Oxide Finish SUBTASK 70-43-12-99G-009 A. General. (1) Black oxide finish is applied to low-carbon alloy steels as a surface treatment, and conforms to AMS 2485. Typical parts protected by black oxide finish are gears and bearing housings.
SUBTASK 70-43-12-380-091 B. Materials and Equipment. (1) The application of black oxide finish is a 2-tank process requiring the materials listed below. Consumable Code C03-043 C02-048 Equipment (a) For conversion coating molten salts or equivalent: Mild steel tank; Gas-fired heating equipment; Mechanical agitator, exhaust fan and hood; Automatic temperature- and level-control equipment (recommended). (b) For Rust Inhibitor: Mild steel tank; Mild steel heating coils; Temperature-control equipment; Mechanical or air supplied agitation. (3) Strength of Solutions: CAUTION: ADD SALTS TO WATER SLOWLY WHILE AGITATING THE SOLUTION. TOO RAPID AN ADDITION CAN CAUSE THE SOLUTION TO BOIL OVER. (a) Black oxide tank: 10 percent solution Fill tank half full of water. Add 6 pounds of conversion coating molten salts per gallon of water, and heat until solution just boils (2858-2958F or 14081468C). Adjust solution level with water to maintain a moderate boil at that temperature.
Description Conversion Coating Molten Salts Rust Inhibitor (2)
EFFECTIVITY: ALL
70-43-12
BLACK OXIDE FINISH Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (b) Rust Inhibitor tank: 10 percent solution Fill tank half full of water, and heat to 1308-1408F (548-608C). Add approximately 1 gallon of Rust Inhibitor to 10 gallons of water, and stir thoroughly. Bring solution level to desired height at this concentration, and maintain temperature at 1308-1408F (548-608C). SUBTASK 70-43-12-380-092 C. Procedure. (1) (2) Clean parts thoroughly per TASK 70-21-06-110-004, Cleaning Method No. 6 Heavy-Duty Alkaline Cleaner (Without Inhibited Phosphoric Acid). Immerse parts in the hot black-oxide solution for 30-45 minutes at 2858-2958F (14081468C). WEAR FACE SHIELD AND PROTECTIVE CLOTHING. IF BLACK OXIDE SOLUTION CONTACTS THE SKIN, FLUSH WITH COLD WATER.
WARNING:
(3) (4) (5) (6)
Cold-water rinse thoroughly. Scrub off with soft-bristle brush if necessary to remove salt residue and scum. Hot-water rinse for one minute. Immerse in Rust Inhibitor tank for 2 minutes. Drain and blow dry. NOTE: Finished parts must be deep black, although deep plum color, discoloration or mottling is acceptable if ground portions are deep black. Red deposits or discoloration resulting from air pockets during processing are not acceptable.
EFFECTIVITY: ALL
70-43-12
BLACK OXIDE FINISH Page 2 Dec 01/03
ELASTOMER COATING - ELASTOMER COATING, ABRASION RESISTANT TASK 70-43-13-380-010 1. Elastomer Coating, Abrasion Resistant SUBTASK 70-43-13-99G-010 A. General. (1) This procedure describes the materials and process for applying erosion-resistant urethane coating to parts specified in the overhaul manuals.
SUBTASK 70-43-13-380-101 B. Description Reducer, Epoxy Primer, Epoxy, Yellow Polymer, Elastomer Polyurethane Abrasion Resistant Catalyst Coloring Pigment, Lamp Black Solvent, General Solvent, General Solvent, General Acid Solvent, General Abrasive Grit Abrasive Grit Abrasive Grit Chemical Abrasive Pad Sandpaper SUBTASK 70-43-13-380-102 C. Procedure. (1) Parts to be coated must be clean and dry. Prepare panels for coating by manual removal of old coating, or by chemical stripping, to minimize plugging of panel holes. Materials. Consumable Code C03-011 C03-017 C03-027 C03-028 C03-029 C04-001 C04-003 C04-035 C04-101 C04-102 C04-112 C04-113 C04-114 C04-229 C10-010 C10-105
EFFECTIVITY: ALL
70-43-13
ELASTOMER COATING, ABRASION RESISTANT Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (a) Manual Removal. Remove old coating manually, as follows: 1 2 Peel off as much of the urethane coating as possible, using fingers and plastic scraper. Hand-sand the exposed support surface lightly to roughen the surface, using 180-240-grit abrasive paper.
CAUTION: USE CARE TO AVOID EXPOSING OR CUTTING INTO GLASS FIBERS OF THE SUPPORT SURFACE. CAUTION: ACETONE AND METHYL-ETHYL-KETONE ARE TOXIC AND EXTREMELY FLAMMABLE. USE IN A WELL VENTILATED AREA, AND TAKE PRECAUTIONS AGAINST FIRE. 3 Clean the surface, using Abrasive Pad C10-010 or equivalent. Follow up with a clean, lint-free cloth saturated with C04-001, C04-003, or C04-035. Let dry completely.
(b)
Chemical Stripping. If manual removal is not satisfactory, strip coating as directed in paragraph C.(2) in TASK 70-23-10-110-025, Stripping Urethane Coating from Unperforated Metal and Plastic Parts. Vigorous scrubbing with a stiff nylon brush will facilitate removal of the old coating from perforations. 1 Following removal of old coating with cloths, etc., steam clean as directed in TASK 70-22-04-110-016, Special Cleaning Procedure No. 4 Cleaning Urethane-Coated Acoustic Panels. Rinse with clear water, drain, and let dry. NOTE: Ultrasonic cleaning for approximately three minutes, using the same solution as for steam cleaning, followed by the rinse, drain and dry cycle, may be used instead of steam cleaning if desired. 3 Sand panel lightly, and clean refer to paragraphs C.(1)(a) 2 and C.(1)(a) 3.
(c)
Preparation of Surface. Prepare surface by one of the following methods: 1 2 In accordance with AMS 2470. Grit blasting, (Titanium, Aluminum, Steel and Rein-forced Plastics). WARNING: THE DRY ABRASIVE EQUIPMENT USED FOR TITANIUM AND TITANIUM ALLOYS SHALL BE CLEANED REGULARLY TO PREVENT FIRE HAZARDS DUE TO THE ACCUMULATION OF METALLIC PARTICLES.
Degrease with a clean oil-free, non-halogenated organic solvent, such as C04-001, C04-003, or C04-035.
EFFECTIVITY: ALL
70-43-13
STANDARD PRACTICES MANUAL AS907-1-1A b Grit blast the surface to be adhesive bonded with 150-400 mesh aluminum oxide grit C04-112, C04-113, or C04-114 at a nozzle pressure of 70-90 psi (482.6-620.5 kPa). Nozzle shall be held at a minimum of two inches (50.8 mm) from surface and time shall be controlled to prevent distortion or thinning of the substrate. After grit blasting, the surface shall not be contaminated by oil, foreign material, or touched by bare hands. Clean with clean cheesecloth wetted with C04-001, C04-003, or C04-035. NOTE: Metallic parts must either be protected by primer coat of adhesive or in bond cycle within 4 hours after completion of surface preparation. Surface shall not be contaminated by oil, foreign material, or touched by bare hands. Primer should be applied within 8 hours after surface preparation or surface preparation shall be repeated. 3 Dichromate etching, (Aluminum and 6061, 2024 Aluminum Alloys). a b Degrease the part with a clean oil-free organic solvent such as C04-001, C04-003, or C04-035. Mix an etching solution as follows: 30 parts by weight, clean demineralized, oil-free water. 10 parts by weight C04-101. 1 part by weight C04-229. c d e f Immerse for 10 to 15 minutes at 1508-1608F (668-718C) in the C04101/C04-229 etch solution. Rinse 5 minutes in cold tap water. Rinse with demineralized or distilled water. Check for water breaks and if necessary repeat etch and rinse operations. Dry in a 1408-1508F (608-668C) air circulating oven for 20 to 30 minutes. NOTE: Part must be either protected by primer coat of adhesive or in bond cycle within 4 hours after completion of surface preparation. Surface shall not be contaminated by oil, foreign material, or touched by bare hands. Primer should be applied within 8 hours after surface preparation or surface preparation shall be repeated. 4 Hand sanding, (Non-Metallics). a Degrease with a clean oil-free non-halogenated organic solvent such as C04-001, C04-003, or C04-035.
EFFECTIVITY: ALL
70-43-13
STANDARD PRACTICES MANUAL AS907-1-1A b Hand sand the surface to be adhesive bonded with sandpaper C10-105. No unsanded areas shall be allowed. SOLVENTS ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPOR AND CONTACT WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME.
WARNING:
Clean with cheesecloth wetted with C04-001, C04-003, or C04-035. NOTE: Parts should be packaged and sealed in polyethylene bags, if storage is necessary. Packaged parts can be stored indefinitely.
d (d)
Parts should be cleaned just before the application of primer with C04-001, C04-003, C04-035, or equivalent.
Application of C03-017 Primer. Touch up bare spots or completely recoat as follows: 1 2 Mix per manufacturer instructions. Add 0.5 to 1.5 parts (by volume) of C03-011 thinner to 2 parts (by volume) of catalyzed primer and mix thoroughly. This is for ease of application. Allow mixture to stand for 60 minutes minimum before application. Pot life should be 24 hours maximum. Spray primer to 0.0005 to 0.0015 inch (0.013-0.038 mm) dry thickness. Cure at 758F 108F (248C 68C) for 35 5 minutes. Primed parts may be coated with polyurethane within an indefinite time after completion of the cure cycle.
3 4 5 6
(e) Consumable C03-027
Preparation of Urethane Elastomer Coating Formulation. Name Polymer, Elastomer Polyurethane Abrasion Resistant Catalyst Coloring Pigment, Lamp Black Solvent, General 1 2 PPH by Weight 100 1
C03-028 C03-029 C04-102
31.1 1 61 50 1
Mix C03-029/C04-102 to give a good homogeneous mixture. Add C03-029/C04-102 mixture to C03-028 catalyst. This mixture may be stored a minimum of 60 days at room temperature. The pigment will
EFFECTIVITY: ALL
70-43-13
STANDARD PRACTICES MANUAL AS907-1-1A settle slowly and should be remixed prior to use after standing four hours. 3 Add C03-029/C04-102/C03-028 mixture to C03-027 and mix thoroughly. This formulation will have a 30 to 40 minute sprayable pot life when used with standard hand cup guns or pressure feed tank equipment.
CAUTION: POLYURETHANE ELASTOMER C03-027 SHOULD NOT BE APPLIED WHEN THE RELATIVE HUMIDITY EXCEEDS 45 PERCENT. POLYURETHANE ELASTOMER SHOULD BE PROCESSED WHEN THE TEMPERATURE IN THE PROCESSING AREA IS 758F (248C). (f) Application of Urethane Elastomer Formulation. 1 Spray on primed metal or plastic substrate. Apply a maximum thickness without creating sag, runs or orange peel condition. Cross coating technique is desirable if practical. Allow solvent to flash a minimum of 20 minutes at room temperature. Spray a second coat of urethane. Allow solvent to flash a minimum of 20 minutes at room temperature. Cure 2 hours 5 minutes, at 2408 - 2608F (1168 -1278C) in circulating air oven. Remove from oven and cool to room temperature.
2 3 4 5 6
SUBTASK 70-43-13-380-103 D. Quality Check. (1) Check the coating visually for voids, blisters or missing coating. If necessary, touch up as directed in TASK 70-43-14-380-011, Urethane Elastomer Touch-Up.
EFFECTIVITY: ALL
70-43-13
EFFECTIVITY: ALL
70-43-13
URETHANE ELASTOMER TOUCH-UP - URETHANE ELASTOMER TOUCH-UP TASK 70-43-14-380-011 1. Urethane Elastomer Touch-Up SUBTASK 70-43-14-99G-011 A. General. (1) This procedure describes the materials and process for touching up the erosionresistant urethane coating to parts specified in the applicable manual.
SUBTASK 70-43-14-380-111 B. Description Sandpaper Solvent, General Solvent, General Solvent, General Abrasive Pad Elastomer, Polyurethane, Abrasion Resistant Catalyst Coloring Pigment, Lamp Black Solvent, General SUBTASK 70-43-14-380-112 C. Procedure. (1) Areas to be touched up must have old coating removed and must be clean and dry. Prepare areas for coating by manual removal of old coating, to minimize plugging of panel holes. (a) Manual Removal. Remove old coating manually as follows: 1 Peel off as much of the old urethane coating as required, using fingers and plastic scraper. Materials. Consumable Code C10-105 C04-001 C04-003 C04-035 C10-010 C03-027 C03-028 C03-029 C04-102
CAUTION: USE CARE TO AVOID EXPOSING OR CUTTING INTO GLASS FIBERS OF THE SUPPORT SURFACE. 2 Hand-sand the exposed support surface lightly to roughen the surface, using 180-240 Grit Abrasive C10-105 paper. Feather-edge urethane coating surrounding the repair area.
EFFECTIVITY: ALL
70-43-14
URETHANE ELASTOMER TOUCH-UP Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: SOLVENTS ARE TOXIC AND EXTREMELY FLAMMABLE. USE IN A WELL VENTILATED AREA AND TAKE PRECAUTIONS AGAINST FIRE. 3 Clean the surface, using Abrasive Pad C10-010 or equivalent. Follow up with a clean, lint-free cloth saturated with C04-001, C04-003, or C04-035. Let dry completely. WEAR CLEAN NYLON OR POLYETHYLENE GLOVES WHEN HANDLING THE PART TO BE COATED, AND WHILE MIXING AND APPLYING THE RESIN. USE ADEQUATE VENTILATION, MAINTAIN THOROUGH CLEANLINESS, WEAR GOGGLES OR FACE SHIELD, AND TAKE PRECAUTIONS AGAINST FIRE.
WARNING:
CAUTION: USE CARE TO AVOID FILLING OR CLOSING HOLES IN THE SURFACE OF SOUND-SUPPRESSION PANELS. HOLES MUST NOT BE REDUCED BELOW 0.057 INCH (1.45 MM) BY THE NEW COATING. (b) Ingredients C03-027 Elastomer, Polyurethane, Abrasion Resistant C03-028 Catalyst C03-029 Coloring Pigment, Lamp Black C04-102 Solvent, General 1 2 Preparation of Urethane Elastomer Coating Formulation. PPH by Weight 100 1 31.1 1 61 50 1 Mix C03-029/C04-102 to give a good homogeneous mixture. Add C03-029/C04-102 mixture to C03-028 catalyst. This mixture may be stored a minimum of 60 days at room temperature. The pigment will settle slowly and should be remixed prior to use after standing four hours. Add C03-029/C04-102/C03-028 mixture to C03-027 and mix thoroughly. This formulation will have a 30 to 40 minute sprayable pot life when used with standard hand cup guns or pressure feed tank equipment.
CAUTION: POLYURETHANE ELASTOMER C03-027 SHOULD NOT BE APPLIED WHEN THE RELATIVE HUMIDITY EXCEEDS 45 PERCENT. POLYURETHANE ELASTOMER SHOULD BE PROCESSED WHEN THE TEMPERATURE IN THE PROCESSING AREA IS 758F (248C). (c) Application. Apply the mixed urethane coating material with brush or spray (DeVilbiss Gun JGA-502, Nozzle No. 30, Tip No. AU-15-E, Needle A401E, or
EFFECTIVITY: ALL
70-43-14
STANDARD PRACTICES MANUAL AS907-1-1A equivalent). If a spray gun is used, mask all unprepared areas with masking tape before application. NOTE: The coating mixture contains solvents, which will evaporate before the resin sets up. A coating of 0.002-0.006 inch (0.05-0.15 mm) thickness should be applied so that the final coating thickness will dry to 0.001-0.005 inch (0.03-0.13 mm). (d) Curing. Allow solvent to flash for a minimum of 20 minutes at room temperature. Cure for 2 hours, plus or minus 5 minutes, at 2408-2608F (11681278C) in a circulating air oven. Remove from oven and cool to room temperature.
SUBTASK 70-43-14-380-113 D. Quality Check. (1) No voids, blisters, sags, runs or orange peels are acceptable. If necessary, touch up as indicated above.
EFFECTIVITY: ALL
70-43-14
EFFECTIVITY: ALL
70-43-14
SOLID-FILM LUBRICANT - ABRADABLE PLASTIC SEAL COMPOUND (RSP-3) TASK 70-43-15-360-001 1. Abradable Plastic Seal Compound (RSP-3) SUBTASK 70-43-15-99G-001 A. General. (1) This procedure describes the materials and processing requirements for the preparation and application of an epoxy resin-diethylenetriamine-microballoon compound used for abradable seals. The process is designated as RSP-3.
SUBTASK 70-43-15-360-011 B. Description Solvent, General Solvent, General TASK 70-00-99-801-172, Solution S1172 SUBTASK 70-43-15-360-012 C. Procedure. (1) Prepare surface to be repaired, and apply compound as follows: WARNING: ACETONE AND METHYL-ETHYL-KETONE ARE TOXIC AND HIGHLY FLAMMABLE. USE IN A WELL VENTILATED AREA, AND TAKE PRECAUTIONS AGAINST FIRE. Materials. Consumable Code C04-001 C04-003 Solution S1172
(a)
If part size permits, vapor degrease per TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, unless prohibited by applicable repair procedure. Follow vapor degreasing by wiping surface to be coated with a clean lint-free cloth moistened in general solvent C04-001 or C04-003. Let surface air-dry.
CAUTION: APPLY SEALING COMPOUND TO ROUGHENED SURFACE WITHIN 4 HOURS OF THE ROUGHENING OPERATION. DO NOT TOUCH PREPARED SURFACE WITH BARE HANDS. WEAR CLEAN NYLON OR POLYETHYLENE GLOVES WHEN HANDLING PART TO BE REPAIRED, AND WHEN MIXING AND APPLYING SEAL COMPOUND. (b) Just before applying seal compound, roughen the repair area with No. 2-grit abrasive paper or a rotary file, or by grit-blasting with 200-mesh aluminum oxide grit. Mask areas that are not to be grit-blasted, and remove residual
EFFECTIVITY: ALL
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ABRADABLE PLASTIC SEAL COMPOUND (RSP-3) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A grit with a blast of clean, dry, shop air, or vacuum with a clean, oil-free vacuum brush. NOTE: If repair is localized in a small area, the abradable compound kit from TASK 70-00-99-801-172, Solution S1172 (Type 2) will be used. (c) Apply the seal compound to the prepared surface as follows: WARNING: THE SEAL COMPOUND CONTAINS DIETHYLENETRIAMINE, WHICH IS TOXIC. CONTACT WITH THE SKIN CAN CAUSE SEVERE DERMATITIS AND PERMANENT TISSUE DAMAGE. VAPOR IS IRRITATING TO THE EYES AND MUCOUS MEMBRANES. USE ADEQUATE VENTILATION, EYE AND SKIN PROTECTION. KEEP AREA THOROUGHLY CLEAN AT ALL TIMES. IF DIETHYLENETRIAMINE CONTACTS THE SKIN, WASH THOROUGHLY WITH SOAP AND WATER AT ONCE.
CAUTION: USE SEAL COMPOUND IMMEDIATELY AFTER MIXING. THE EFFECTIVE WORKING OF POT LIFE OF A 140-GRAM BATCH OF COMPOUND IS 30-45 MINUTES AT ROOM TEMPERATURE. WHEN MIXED, THIS MATERIAL INCREASES IN TEMPERATURE THROUGH EXOTHERMIC REACTION. POT-LIFE DECREASES WITH INCREASING QUANTITY AND TEMPERATURE; THE PERIOD CAN BE EXTENDED BY SPREADING THE COMPOUND IN A THIN LAYER ON A COOL, CLEAN SURFACE. 1 Spread a thin layer of seal compound ( TASK 70-00-99-801-172, Solution S1172 (Type 1)) on the prepared surface with a metal spatula or wooden blade such as a tongue depressor. Be sure that all surfaces are covered. Fill in remaining void flush with the contour of the part, being careful to avoid entrapping air bubbles. NOTE: You can get a better bond if you apply a thin layer of catalyzed adhesive without microballoons C01-017 before you apply the seal compound. Scrub the adhesive onto the surface with a stiff brush to get a thin coating and to assure wetting. 2 After the compound has become tacky, scrape the excess compound from around the edge of the repair area. Smooth the edge by covering with a sheet of plastic or polyethylene and rubbing it lightly. Leave the plastic or polyethylene in place until the compound has hardened.
(d)
After application, cure the compound for at least 8 hours at room temperature 758F (248C). The time may be reduced by curing at room temperature for 2 hours, followed by curing the compound to one of the following options: 1 2 3 1 hour at 1508-2008F (668-938C). 2 hours at 1308-1508F (548-668C). 3 hours at 1008-1308F (388-548C).
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (e) Use a contact pyrometer to measure surface temperature of the metal adjacent to the repair area. GRINDING DUST IS HARMFUL TO THE LUNGS. WEAR A RESPIRATOR, AND POSITION A FAN TO BLOW DUST AWAY FROM THE WORK AREA.
WARNING:
(f)
Blend the repair area flush with the surface contour of the part, using medium-grade abrasive paper.
EFFECTIVITY: ALL
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EFFECTIVITY: ALL
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SOLID-FILM LUBRICANT - SOLID-FILM LUBRICANT - C02-049 TASK 70-43-16-640-004 1. Solid-Film Lubricant - C02-049 SUBTASK 70-43-16-99G-004 A. General. (1) The solid-film lubricant coating described here consists of dry lubricants dispersed in a mixture of high-temperature resin binders and dissolved in toluene or other volatile organic solvents. The lubricant forms a high-temperature lubricating surface on plated or unplated parts to prevent galling or seizing. It can be applied by dipping, brushing or spraying.
SUBTASK 70-43-16-640-041 B. Description Solid Film Lubricant Solvent, General SUBTASK 70-43-16-640-042 C. Procedure. (1) Prepare the surface to be coated, and apply the coating in accordance with the following steps. (a) Clean the surface to be cleaned per applicable Engine/Shop Manual section for this part. The surface must be free from rust, scale, oil, grease or other foreign material, so as to ensure a tight bond between the surface and the coating. When the coating is to be applied to corrosion-resistant steel, the surface should be slightly vapor-blasted before application. Prepare the coating material for application as follows: 1 For spray or brush application, dilute one part of C02-049 with 3-4 parts general solvent C04-036. Stir the C02-049 thoroughly before mixing with solvent, and agitate container during use to keep the solids in suspension. Air pressure of 25-40 psi (172.4-275.8 kPa) is recommended for spraying. Material. Consumable Code C02-049 C04-036
(b)
EFFECTIVITY: ALL
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SOLID-FILM LUBRICANT - C02-049 Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: GENERAL SOLVENTS CAN BE TOXIC AND HIGHLY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPORS AND CONTACT WITH THE SKIN. TAKE PRECAUTIONS AGAINST FIRE.
For dip-coating, dilute one part of C02-049 with 4-5 parts general solvent C04-036. Agitate contents of container before and during use to keep solids in suspension.
(c)
Apply material and cure coating as directed in the following steps: 1 2 Spray, dip, or brush coating on part. Let coated surfaces air-dry for 15 minutes minimum until wet appearance disappears, or until coating is dull in appearance. Heat to 1758F (798C) max may be used to accelerate drying. Apply second coat. Air-dry for 15-20 minutes. Bake for one hour at 5008F (2908C). Air-cool.
3 4
SUBTASK 70-43-16-640-043 D. Quality Standard. (1) The coating shall be free of mars, blisters and foreign matter, and shall be a continuous, homogeneous coating of uniform thickness, which shall not exceed 0.0005 inch (0.013 mm).
(a)
If the initial coat exhibits evidence of poor or lacking bond, sags, runs, or separation of ingredients, reclean the part by grit-blasting, and recoat. The coating shall not peel or flake when a strip of cellophane or paper masking tape is applied, pressed down firmly, then abruptly peeled off. The finished coating shall be removable only by grit-blasting.
(b)
EFFECTIVITY: ALL
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EPOXY REPAIR - EPOXY REPAIR OF MATING SURFACES AND INSERTS TASK 70-43-17-360-002 1. Epoxy Repair of Mating Surfaces and Inserts SUBTASK 70-43-17-99G-002 A. General. (1) The 2-part adhesive-filler compound described here may be used for the repair of gearboxes, when authorized by the applicable Engine Manual, or for securing threaded inserts, studs and bolts. Refer to TASK 70-48-09-350-012, Repair of Blind Threaded Holes in Aluminum Castings, for repair procedure. This procedure is used to fill in nicks, dents or scratches on sealing surfaces, where such voids could affect the sealing capability or on machined mating surfaces to restore loss of contact area.
SUBTASK 70-43-17-360-021 B. Description Epoxy Adhesive SUBTASK 70-43-17-360-022 C. Procedure. WARNING: IF RESIN CONTACTS THE SKIN, REMOVE WITH ISOPROPYL ALCOHOL AND SCRUB AREA IMMEDIATELY WITH SOAP AND WARM WATER. THE RESIN SHOULD BE MIXED AND APPLIED IN A WELL-VENTILATED AREA. AVOID INHALATION OF VAPORS. Materials. Consumable Code C01-011
(1)
Before applying the epoxy adhesive filler material, clean parts thoroughly, as follows: (a) Clean parts so that no oil, grease or other contaminants remain on the surface. Clean out each void by hand using a sharp pointed tool to scrape the surface until bright metal is exposed. Alternative procedure available. Vapor degrease per TASK 70-21-02-110002, Cleaning Method No. 2 - Vapor Degreasing. Alternative procedure. Vapor degrease by applying liquid degreasing agent locally.
(b) (c)
EFFECTIVITY: ALL
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EPOXY REPAIR OF MATING SURFACES AND INSERTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: IF CATALYST IS AMBER COLORED, OR IF THERE IS A NOTICEABLE CHANGE IN THE WORKING CHARACTERISTICS OF THE RESIN AT ROOM TEMPERATURE, DISCARD EPOXY COMPONENTS. (2) Mix the components thoroughly in a clean container, so that catalyst is uniformly dispersed in resin. The ratio of mixing will be (by weight) 100 parts -Part A and 33 parts -Part B. Apply resin as soon after mixing as possible. The "pot life" of a 450-gram mass of epoxy resin at 778F (258C) is approximately 40 minutes. Fill voids with the epoxy mixture to slightly above adjacent surfaces. Remove excess immediately. If threaded inserts or other threaded parts are to be installed, secure in place by applying the epoxy resin mixture to the male threads only. Install the insert and remove excess adhesive filler immediately. Allow the epoxy to cure at room temperature, 758F (248C) for 24 hours minimum. Sand the epoxy flush with the adjacent surface. Sanding must be done in a circular direction.
(3) (4) (5)
(6) (7)
EFFECTIVITY: ALL
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EPOXY REPAIR OF MATING SURFACES AND INSERTS Page 2 Dec 01/03
CHEMICAL TOUCH-UP OF ALUMINUM - CHEMICAL TOUCH-UP OF ALUMINUM PROTECTIVE COATING (CHROMATE CONVERSION COATING) - C03-008 TASK 70-43-18-380-012 1. CHEMICAL TOUCH-UP OF ALUMINUM PROTECTIVE COATING (CHROMATE CONVERSION COATING) - C03-008 SUBTASK 70-43-18-99G-012 A. General. WARNING: THE SOLUTION USED IN THIS PROCESS IS HIGHLY CORROSIVE. USE RESPIRATORS, GOGGLES AND FACE-SHIELD, AND RUBBER OR NEOPRENE GLOVES, BOOTS AND APRONS WHEN HANDLING OR APPLYING THE SOLUTION. WASH OFF IMMEDIATELY IF SOLUTION CONTACTS THE SKIN. IF SOLUTION CONTACTS THE EYES, FLUSH THEM WITH CLEAR WATER, IRRIGATE WITH BORIC ACID SOLUTION, AND SEEK IMMEDIATE MEDICAL ASSISTANCE.
(1)
This process is used to produce a protective coating on external aluminum and aluminum alloy surfaces when the characteristic appearance of aluminum must be retained. The material may be brushed, sprayed or sponged onto the cleaned surface, and should be used only when directed by the applicable Shop Manual.
SUBTASK 70-43-18-380-121 B. Materials. CAUTION: YOU CANNOT MIX ONE COATING MATERIAL WITH ANOTHER. IF YOU MIX TWO DIFFERENT COATING MATERIALS TOGETHER, THE RESULT COULD GIVE UNSATISFACTORY PROTECTION. CAUTION: DO NOT USE LEAD, GLASS, IRON, TIN OR GALVANIZED CONTAINERS. (1) Interchangeability. You can use the materials listed in QPL-81706 as alternatives to the materials in the table that follows if: (a) (b) (c) - they are from the same class, and - they use the same method of application. The materials in QPL-81706 and the materials in the table that follows will give equivalent protection if they are from the same class and method of application. Consumable Code C03-008 C04-001 C04-003
CHEMICAL TOUCH-UP OF ALUMINUM PROTECTIVE COATING (CHROMATE CONVERSION COATING) - C03-008 Page 1 Dec 01/03
Description Conversion Coating, Chromated Solvent, General Solvent, General

EFFECTIVITY: ALL
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Description Solvent, General SUBTASK 70-43-18-380-122 C. Procedure. (1)
Consumable Code C04-035
Refinish exposed areas as directed in the following steps: WARNING: DEGREASING SOLVENTS ARE TOXIC AND SHOULD BE USED IN A WELL VENTILATED AREA. AVOID PROLONGED BREATHING OF VAPORS OR REPEATED OR PROLONGED CONTACT WITH THE SKIN.
CAUTION: DO NOT PERMIT SURFACE COATING SOLUTION TO CONTACT ORGANIC SOLVENTS. IT CAN IGNITE THEM. (a) (b) Clean surface with liquid solvent degreaser, such as C04-001, C04-003, or C04-035 using a clean brush or lint-free cloth. Sand area lightly, using 180-grit or finer abrasive paper, until all scratches, pits or roughness are removed.
CAUTION: DO NOT PERMIT SWABS, CLOTHS, PAPER, ETC., USED FOR APPLYING OR REMOVING THE SURFACE COATING SOLUTION TO DRY OUT. THESE MATERIALS ARE COMBUSTIBLE WHEN DRY, AND CONSTITUTE A FIRE HAZARD. IMMEDIATELY AFTER USE, SOAK THE ITEMS THOROUGHLY IN WATER BEFORE DISCARDING. CAUTION: IF YOU USE AN INTERCHANGEABLE MATERIAL, OBEY THE MANUFACTURERS INSTRUCTIONS TO MIX AND APPLY THE MATERIAL. IF YOU DO NOT USE THE MANUFACTURERS INSTRUCTIONS, THE RESULT COULD BE DAMAGE TO THE PART OR UNSATISFACTORY PROTECTION. (c) Material C03-008 and Water at 65-758F (18-248C) (d) Mix the surface treatment solution as follows. Mixing Ratio (US) 4-6 ounces compound to 1 gallon water Mixing Ratio (SI) 31-47 cc compound to 1 liter water
Rinse with clear water, and immediately apply the touch-up solution to the area to be coated. Use Nylon brush, cellulose sponge or spray equipment. Use as many applications as necessary to obtain the coating desired, allowing approximately one minute reaction time between applications at room temperature or above.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (e) Normally, one to 5 minutes are required for complete formation of the coating. NOTE: Ordinary spray equipment is satisfactory for short or infrequent use in applying the touch-up solution, but it will be slowly attacked by the corrosive chemicals in the solution. This corrosion may be minimized by thoroughly flushing the equipment with clear water immediately after each use. For continuous use, plastic or stainless steel cups and nozzles should be used. (f) Rinse the work thoroughly with clean water, followed by air-drying, blowing dry with clean shop air, warm or hot air-drying, or wiping gently with clean cloths. Make sure that all joints, cavities or crevices are blown or wiped dry.
EFFECTIVITY: ALL
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EFFECTIVITY: ALL
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SOLID-FILM LUBRICANT - SOLID-FILM LUBRICANT - C02-027 TASK 70-43-19-640-005 1. Solid-Film Lubricant - C02-027 SUBTASK 70-43-19-99G-005 A. General. (1) The solid-film coating described here consists of dry molybdenum disulfide lubricant dispersed in a high-temperature synthetic resin binder C02-027. The coating forms a heat-resistant lubricating surface on mating parts to prevent galling or seizing. The material is applied by brushing or spraying.
SUBTASK 70-43-19-640-054 B. Description Solid Film Lubricant Solvent, General Solvent, General SUBTASK 70-43-19-640-051 C. Procedure. (1) Prepare the surface, and apply the solid-film lubricant as follows: WARNING: CLEANING SOLVENTS ARE TOXIC AND HIGHLY FLAMMABLE. USE IN A WELL VENTILATED AREA, AND TAKE PRECAUTIONS AGAINST FIRE. Material. Consumable Code C02-027 C04-003 C04-001
CAUTION: DO NOT TOUCH CLEANED AREA WITH BARE HANDS OR EXPOSE IT TO ANY SOURCE OF CONTAMINATION. IF THE COATING IS NOT APPLIED WITHIN 15 MINUTES OF CLEANING, THE PARTS MUST BE RECLEANED. (a) Clean the surface to be coated by wiping with clean cheese-cloth moistened with general solvent C04-001 or C04-003. Repeat, if necessary, until the surface of the cloth remains clean. Let the cleaned surface air-dry, or wipe it dry with clean, dry cheesecloth. Apply the coating as follows:
(b)
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: DO NOT DILUTE THE LUBRICANT. 1 Open the container of solid-film lubricant and stir contents until thoroughly mixed. Pour out a quantity sufficient for about one hours use, into a clean container. Reseal the original container.
CAUTION: THE COATING WILL BE UNACCEPTABLE UNLESS THE LUBRICANT IS THOROUGHLY MIXED BEFORE AND DURING USE. CAUTION: FAILURE TO THOROUGHLY MIX THE LUBRICANT OR ALLOWING IT TO SETTLE OUT WILL EACH RESULT IN AN UNACCEPTABLE COATING. 2 Apply the solid-film lubricant to the cleaned surfaces with a camels hair brush, or by spraying with a Binks Model 26 gun that has a D-76S air cap and a 76-SS fluid nozzle and needle, or equivalent. The coating must be uniform, thin, and free from lumps, streaks and foreign material. Stir the lubricant as often as possible, using a wide paddle. Optimum condition is obtained by continuous stirring. NOTE: Containers of lubricant that do not have close-fitting lids to exclude air must be discarded. The lubricant withdrawn into the working container must not be put back into the original container. 3 Let coated surfaces air-dry for 15 minutes minimum until wet appearance disappears, or until coating is dull in appearance. Heat below 1758F (798C) max may be used to accelerate drying. Check thickness and continuity of coating. No metal shall be visible through the coating. If necessary to complete coverage or to increase thickness, re-coat and air-dry as described in step 3, avoiding overlapping previously coated areas. Refer to Step D.(c) in SUBTASK 70-43-19-640-052, Quality Provisions. Bake the air-dried coated parts in a preheated oven at 3758-4008F (19182048C) for 60 to 90 minutes (part temperature).
CAUTION: DO NOT LET WATER, OIL, SOLVENTS, OR ANY OTHER CONTAMINANTS COME IN CONTACT WITH THE COATED SURFACE BEFORE BAKING. 6 Let parts air-cool.
SUBTASK 70-43-19-640-052 D. Quality Provisions. (1) Material must be used before its shelf-life period is exceeded. The coating, after oven-curing, shall have the following characteristics. (a) The coating shall be free of sags, blisters, bubbles, flakes and foreign material.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (b) (c) Brush strokes in the coating must not be visible at arms length under normal lighting. The coating shall not peel or flake when a strip of cellophane or paper masking tape is applied, pressed down firmly, then abruptly pulled off. GENERAL SOLVENTS ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPOR AND CONTACT WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME.
WARNING:
(d)
Rubbing the oven-cured coating for one minute with a solvent-wet cloth C04001 or C04-003 combination shall not remove the coating. A slight black residue on the cloth is permissible. Scratching the coating with the fingernail shall not remove the coating. The coating must appear dull. Shiny or glossy appearance is not acceptable.
(e) (f)
SUBTASK 70-43-19-640-053 E. Handling. (1) Coated parts shall be handled in such a way that no chipping, scratching or other damage can occur.
EFFECTIVITY: ALL
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EFFECTIVITY: ALL
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HONEYCOMB BONDMENT ADHESIVE - HONEYCOMB BONDMENT ADHESIVE TASK 70-43-20-360-003 1. Honeycomb Bondment Adhesive SUBTASK 70-43-20-99G-003 A. General. (1) This procedure describes the materials and processing requirements for the application of epoxy adhesive resin in the repair of honeycomb bondment which has become delaminated. Distressed areas which are located and removed per specific applicable Engine/Shop Manual repairs, may have replacement honeycomb rebonded per this procedure.
SUBTASK 70-43-20-360-032 B. Description Supported Film Adhesive Unsupported Film Adhesive Primer, Adhesive Solvent, General Solvent, General Acid Acid Acid Chemical Compound, Surface Treatment Chemical Filler, Fumed Silica Viscosity Control Agent SUBTASK 70-43-20-360-033 C. Procedure. (1) Prepare the surfaces, apply adhesive, and bond the honeycomb as follows: (a) Cleaning Aluminum: Aluminum alloys and wrought aluminum faying surfaces are to be cleaned and prepared as follows: Materials. Consumable Code C01-136 C01-139 C01-166 C04-001 C04-003 C04-011 C04-093 C04-101 C04-150 C04-229 C10-022
EFFECTIVITY: ALL
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HONEYCOMB BONDMENT ADHESIVE Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: CLEANING SOLVENTS ARE TOXIC AND HIGHLY FLAMMABLE. USE IN A WELL VENTILATED AREA, AND TAKE PRECAUTIONS AGAINST FIRE.
Degrease the surfaces per TASK 70-21-01-110-001, Cleaning Method No. 1 - Solvent Degreasing, or TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, or wipe the surfaces with general solvent C04-001 or C04-003. Mix acid/dichromate solution as follows: a b c 30 parts by weight, clean demineralized oil-free water 10 parts by weight, acid chemical C04-101 1 part by weight, chemical C04-229
3 4
Immerse the parts in an acid solution of C04-101/C04-229 for 10 minutes at 1508 to 1608F (65.68 to 71.18C). Rinse the parts in demineralized water at a temperature no higher than 1508F (65.68C) and with a pH no greater than 7.5. Check immediately for water breaks on the surfaces. The water has broken if it does not cascade from the parts in a smooth, continuous sheet. If water breaks occur, repeat Step C.(1)(a) 3. Dry the rinsed parts for 30 minutes, or until thoroughly dry, at a temperature no greater than 1508F (65.68C) and repeat the waterbreak test, as in Step C.(1)(a) 4.
(b)
Cleaning Stainless Steel: Stainless steel faying surfaces are to be cleaned and prepared as follows: WARNING: CLEANING SOLVENTS ARE TOXIC AND HIGHLY FLAMMABLE. USE IN WELL VENTILATED AREA AND TAKE PRECAUTIONS AGAINST FIRE.
Degrease the surfaces per TASK 70-21-01-110-001, Cleaning Method No. 1 - Solvent Degreasing, or TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, or wipe the surfaces with general solvent C04-001 or C04-003. THIS SOLUTION IS TOXIC AND REACTS VIGOROUSLY. WEAR PROTECTIVE CLOTHING, GLOVES AND FACE PROTECTION WHILE HANDLING AND USING. WASH IMMEDIATELY WITH CLEAR WATER IF SOLUTION CONTACTS THE SKIN OR EYES.
WARNING:
CAUTION: DO NOT DIP ALUMINUM OR ALUMINUM ALLOY PARTS IN THIS SOLUTION. 2 Mix acid/dichromate solution as follows: a 96.9 percent by volume of general solvent C04-101
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A b 3 4 (c) 3.4 percent by volume saturated water solution of C04-229
Immerse the parts in a strong acid solution of C04-101/C04-229 for 15 minutes at 1508 to 1608F (65.68 to 71.18C). Rinse and dry the parts as in Steps C.(1)(a) 4 and C.(1)(a) 5.
Cleaning Aluminum (Alternate Method): Before exposed skin areas are patched with honeycomb replacement core, clean and non-tank anodize the exposed areas with a surface treatment compound C04-150 as follows: WARNING: CLEANING SOLVENTS ARE TOXIC AND HIGHLY FLAMMABLE. USE IN A WELL-VENTILATED AREA, AND TAKE PRECAUTIONS AGAINST FIRE.
Solvent-wipe the skin area with C04-003, C04-001, or equivalent. Drywipe the bondment area with clean cotton gauze or equivalent until the area is thoroughly dry and no residue (gray in color) is present on the gauze. NOTE: If the bondment area has been previously cleaned with a strong alkaline, a hydrofluoric acid (HF) etch will be required to remove the gray residue.
Manufacture a dam around the core replacement area with C01-136 supported film adhesive: a b c Use a heat gun to tack a 2 inch wide strip of the C01-136 adhesive into the existing adhesive fillet at the retained core-to-skin joints. Cover the core sidewalls with the C01-136 adhesive strip and wrap the strip around the top of the core. Cover the core that remains exposed around the area to be patched with plastic sheet and tape the sheet in position. TWO PERCENT HYDROFLUORIC ACID IS CORROSIVE TO HUMAN TISSUE. WEAR RUBBER GLOVES FOR PROTECTION. IF SKIN CONTACT IS MADE, IMMEDIATELY FLUSH WITH WATER AND REPORT TO A MEDICAL STATION.
WARNING:
If the bondment area has been previously cleaned with a strong alkaline, moisten, but do not saturate, a clean gauze pad with a 2% hydrofluoric acid (HF) solution made from water and acid C04-011. Wipe the abraded area with the pad. After the acid has worked for 15 to 30 seconds, dampen a clean gauze pad with clean water and wipe the acid-treated area.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A 4 Apply a uniform layer, approximately 1/8 inch thick, of surface treatment compound C04-150 or equivalent to the area that you will anodize. NOTE: A phosphoric acid gel or surface treatment can be made by thickening a 10 1% aqueous solution of phosphoric acid with silica filler C10-022. The solution is prepared by mixing 1.89 liters of C10-022 with 250 milliliters of acid C04-093. 5 6 7 Apply two layers of cheesecloth or cotton gauze over the surface treatment compound C04-150 or phosphoric acid gel. Apply an additional layer of phosphoric acid gel over the cheesecloth or cotton gauze. Place a piece of pre-contoured stainless steel wire screen over the area that you will anodize. The phosphoric acid gel must touch the screen, but the screen must not touch the surface to be anodized. Connect the screen as cathode (-) and the aluminum substrate as anode (+). Allow one cathode and one anode connection for each square foot of surface to be anodized. Clean the aluminum skin to bare metal and tape the anode connection on the opposite skin surface. Make pig tails on the screen with stainless steel wire for the cathode connections. Apply a potential of 4-7 volts for 10-12 minutes. NOTE: Bubbles will be generated during the anodizing process. If you do not see the bubbles in an area, or if the amperage indicates a short circuit, check the screen and make sure that it is not touching the surface that you are anodizing. 10 Remove the screen and gauze from the surface rapidly, and wash the surface with clean water immediately. Wipe the surface lightly with a clean, wet cloth while you rinse it, but do not scrub the surface. Dry the bondment area completely at room temperature, or at an elevated temperature that does not exceed 1508F (65.68C). Check for the presence of an anodic coating on the aluminum surface that you treated: a Test equipment required: A white frosted mercury-vapor lamp, or a white daylight fluorescent lamp. An optical polarizing filter (available from laboratory supply houses or Polaroid, Inc., Cambridge, MA). b Procedure.
11 12
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Illuminate the treated aluminum surface with a white frosted mercury-vapor lamp or a white daylight fluorescent lamp. The angle of incidence between the light beam from this lamp and the plane of the treated surface must not exceed 5 degrees. Place an optical polarizing filter between your eyes and the reflected illuminator image on the treated surface. Look at the treated surface through the filter. Check for interference colors that may appear. NOTE: Because of differences in alloy composition or metallurgical condition, different pieces of aluminum that are anodized under the same conditions may show different interference colors. Purple, yellow, and green hues are seen most frequently. While you look at the treated surface through the polarizing filter, rotate the filter 90 degrees to check for a change in the interference color. An anodic coating is present on the treated surface if you see the color change to its complementary color (from a purple to a yellow green, for example). NOTE: Rotation of the polarizing filter is required. Some pale shades of yellow or green are so close to white that they might be considered no color if the filter is not rotated to check for a color change. CAUTION: THE WORK AREA, WHERE DETAILS ARE PRIMED, MUST BE RELATIVELY DUST FREE. AN AREA SIMILAR TO THAT REQUIRED FOR ADHESIVE APPLICATION IS SATISFACTORY. REFER TO PARAGRAPH C.(1)(E). (d) Adhesive Primer: Coat the detail surfaces and unprimed honeycomb core surfaces (previously sanded) with adhesive primer C01-166 as follows. 1 Do not spray the honeycomb core, but spray a smooth, even film of adhesive primer C01-166 on the other detail surfaces to a dry-film thickness of 0.0001-0.0003 inch (0.003-0.008 mm). Agitate the spray device to keep the primer solids from collecting at the bottom. Air-dry primed details for a minimum of 60 minutes at room temperature, then oven-bake them at 2358-2508F (112.8-121.18C) for 30 minutes. Prime the honeycomb core details (replacement core only) with either of the following procedures: a Spray-prime all surfaces of honeycomb core with adhesive primer C01-166 to give a nominal dry-film thickness of 0.00010.0003 inch (0.003-0.008 mm). Spray one side of the core first,
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A holding the spray gun at the appropriate angles to ensure adequate coverage of all cell walls. Then turn the core over and repeat the spray procedure. b Dip-coat or pour-coat the honeycomb core details with primer. Make sure that the coverage is complete and uniform. Allow excess material to drain from the core. Rap the core lightly to remove excess primer. Blot off residual primer with Kimwipe or cheesecloth.
Cure the primer coat with either of the following procedures: a To minimize core stabilization effects, air-dry the honeycomb core details only for a minimum of ten hours in the environmentcontrolled area. Cure the primer coat with Step C.(1)(d) 2. NOTE: Process Time Limitation - Adhesive primer shall be applied to details within 16 hours of completing the surface preparation. Details that have been primed and oven-cured may be stored in the environment-controlled area for a maximum of 30 days prior to application of the film adhesive. Air-dried core details shall not be stored in the environment-controlled area for more than 10 days prior to application of the film adhesive.
(e)
Adhesive: Apply C01-136 orC01-139 film adhesive. The adhesive must be applied in a controlled area. The environmental conditions (temperature, humidity, dust count, and cleanliness) must be as follows: NOTE: During its use in the Bond Shop, each roll of film adhesive shall be suspended horizontally through its axis, free from contact with other rolls or objects. Handle the film adhesive with clean, white cotton gloves. The film adhesive must be applied to repair details in the environment-controlled area, and the process control panels must also be located within that area. Adhesive-coated and/or cleaned details shall not be removed from the environment- controlled area until assembled into the bondment. 1 Film adhesive shall be applied to assemblies at a temperature between 658-908F (18.38-32.28C), and the relative humidity shall not exceed 70% in a relatively dust-free room. This would be a room containing not more than 5000 particles larger than 5 microns per cubic foot, using the Rayco Model 220 Aerosol Particle Monitor per Federal Standard 209 with a flow rate of 0.1 cubic foot per minute. Alternately, when measured per ASTM F25-68 the contamination level should not exceed 2500 particles larger than 5 microns per cubic foot. This method is based on microscopical examination of particles impinged upon a membrane filter with the aid of a vacuum. The number of sampling points is proportional to the floor area of the enclosure to be checked. The apparatus and facilities required are typical of a laboratory for the study of micro-particle contamination. The operator must have adequate basic training in microscopy and the techniques of particle
EFFECTIVITY: ALL
70-43-20
STANDARD PRACTICES MANUAL AS907-1-1A sizing and counting. Specifically, these contamination levels are typical of clean rooms and dust-controlled areas designed for electronic work. 2 The ideal combination of temperature and humidity for application of film adhesive to assemblies is 708F (21.18C) and 50% relative humidity. The application should be discontinued if at any time the temperature is below 658F (18.38C) or exceeds 908F (32.28C), or if the relative humidity exceeds 70%. If the temperature falls below 658F (18.38C), or if the relative humidity exceeds 70%, the following shall apply: a b 4 Unprimed details shall be oven-dried for 20 minutes at 1508F (65.68C) before they are primed. Primed details shall be redried in the oven 20 minutes at 1508F (65.68C) before adhesive film is applied.
If the relative humidity in the dust-free room stays less than 70%, yet the temperature exceeds 908F (32.28C), details shall not require any special reprocessing, regardless of their processing stage. Under any conditions other than those described above, strip the details per TASK 70-23-14-110-029, Stripping Epoxy Resin from Aluminum, and reprocess them. To keep contamination within acceptable levels, a positive pressure shall be maintained in the bond rooms at all times. The pressure system shall be capable of maintaining this pressure during normal flow of traffic in and out of these areas. The floors of the bond and lay-up rooms should be thoroughly cleaned after each use. If protective papers are used on the workbenches, they should be changed daily, or more frequently if they become contaminated. The floors of the bond and lay-up rooms having tile or linoleum floor coverings do not require additional sealing. Bare concrete or wood floors should be coated with clear lacquer sealer or equivalent as often as required to ensure complete sealing of the floor. To assure proper adhesive quality, the following conditions must be met: a Supported and unsupported film adhesives are to be stored in accordance with the manufacturers instructions. Before use, the adhesive must have been stored unwrapped for a minimum of 48 hours at 25% maximum relative humidity, and an ambient temperature between 458 and 758F (7.28 and 23.98C). Unwrapped rolls of film adhesive shall not be exposed to the environmental-controlled atmosphere in excess of 168 hours. After 168 hours of exposure, such rolls shall be returned to the
7 8 9
10
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A 25% relative humidity environment (above) for a minimum of 48 hours, at which time the adhesive may be returned to the environment-controlled area. 11 Apply supported adhesive film C01-136 as follows: a Use one layer of supported film adhesive in all honeycomb-tononperforated skin areas, over a layer of unsupported film adhesive which has been beaded to the prepared honeycomb surface. Use one layer of supported film adhesive only, in all metal-to-metal areas. The use of additional layers of supported film adhesive is not recommended, but may be necessary to fit up adjacent detail parts. Separator sheets shall not be removed from the surface of the film adhesive until immediately before the detail is applied to that surface of the adhesive and/or the taped details are assembled. The film adhesive shall be pressed firmly and smoothly in place over its entire area. When necessary for bonding purposes, heattacking of the adhesive may be used, provided the adhesive is protected from contamination and the tacking temperature neither exceeds 1808F (82.28C) nor is not applied for more than 60 seconds. Trim the film adhesive to leave approximately 1/8 inch (3.18 mm) excess beyond the perimeter of faying surfaces whenever possible. When more than one piece of film adhesive is used per detail component, use overlap splices with overlaps that do not exceed 1.0 inch (25.4 mm). Tape areas around film adhesive joints to prevent leaking. Tack large or curved details toward the center only to allow the film adhesive to flow outwardly toward the edges during bonding and cure, and to prevent bulging during the application of pressure.
e f
12
Apply unsupported film adhesive C01-139 as follows: a Apply unsupported film adhesive in all bonds of honeycomb-toperforated skin. Before assembling the honeycomb core to the bondment area, bead the unsupported film adhesive to the honeycomb core by applying a heat gun to the adhesive [1808F (82.28C) max.]. Bead the unslotted side of the honeycomb core before inserting the core into the cavity. Local heating of the film adhesive to make the adhesive tacky is acceptable. Splice the pieces as you are directed by the applicable manual Repair. Prick a hole in each cell to aid reticulation (beading). You may accomplish this by perforating the adhesive on a bed of photograph needles, on 1/2 inch (12.5 mm) spacing. Back up the film adhesive with plywood that is covered with a sheet of rubber.
EFFECTIVITY: ALL
70-43-20
STANDARD PRACTICES MANUAL AS907-1-1A 13 Adhesive-coated details do not leave the environment-controlled area prior to assembly. They shall be assembled and bagged ready for an autoclave cure within 24 hours maximum. NOTE: Cover all adhesive-coated details to protect them from atmospheric dust. The covering materials shall not contact the adhesive surface. (f) Bonding: Assemble parts for bonding as follows: 1 Assemble all details to bondment in an environment-controlled area. Assemble the details per applicable manual instructions for the specific bondment. Attach thermocouples as directed by the applicable manual repair. Place thermocouples on the skin surface in a manner that will not cause mark-off, and include areas representing the hottest and coldest adhesive line temperature points of the unit. Thermocouples shall be attached to all process control panels. As bonding is done under autoclave pressure, vacuum/pressure probes are required as follows: a Locate at least one pressure (or vacuum) sensor beneath the diaphragm for each 10 square feet or 10 lineal feet of peripheral part length or fraction thereof, whichever is greater. Locate the sensors adjacent to the part and distribute them to give the best presentation of the pressure existing under the entire pressure diaphragm. Include gages in your installation that are readily accessible for recording the readings. Air evacuation (bleed) lines extending from beneath the pressure diaphragm (blanket) to the atmosphere may be used to determine atmosphere pressure under the diaphragm, provided the following conditions are met: Diameter of the smallest opening in each evacuation (bleed) line (valves, fittings, outlets, etc.), shall be a minimum of 1/4 inch (6.4 mm). The bleed line opening under the diaphragm must not be restricted in any manner to prevent the flow of air through the line to the atmosphere or a vacuum pump during the cure cycle. All bleed lines shall be vented (opened) to the atmosphere during the cure cycle. They shall remain vented to the atmosphere until the part has completed the cure period and has cooled to room temperature. Each line extending to the atmosphere shall have a pressure-measuring device (gage, recorder, manometer, etc.), which shall be placed in the bleed line at a point as close to the pressure diaphragm as is practical.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A c To assure adequate bond pressure, a minimum of one reading from the measuring devices shall be made each 10 minutes during the cure cycle.
(g)
Pressurization and Cure. Parts are autoclave cured as follows: 1 Assemblies repaired with this procedure shall be autoclave-cured at 3408-3608F (171.18-182.28C) for 60 to 90 minutes. Use full pressure and a vented bag prior to the temperature application. Autoclave pressure shall be 30 to 40 psi (206.8-275.8 kPa). Begin the cure when the coldest thermocouple reaches 3408F (171.18C). No thermocouple shall exceed the maximum temperature or time limitations. NOTE: The cure time of the process control specimens is the time above 3408F (171.18C), and must be within 5 percent of the cure time for the bondment. 3 When part temperatures reach 1508F (65.68C) on the leading thermocouple, pressurize the autoclave. Then when the autoclave pressure reaches the pressure exerted by the 8 to 10 inches Hg vacuum pressure on the assembly, the vacuum lines shall be vented to atmospheric pressure. The rate of heating from room temperature to the minimum cure temperature [3408F (171.18C)] shall be uniform and within the limits 5888F (38-58C) per minute. At the completion of the cure cycle, the bondment assembly shall be cooled, without inert cooling, from 3508 to 2008F (1788 to 93.38C) within a maximum of 30 minutes. Cool the bondment below 2008F (93.38C) at any convenient rate.
(h)
Quality Assurance: With each repair bondment, process control specimens shall be processed identically to the detail parts and cured concurrently with them. Refer to TASK 70-70-00-700-001, Testing and Quality Analysis. 1 Process control specimens are required as follows: a b c 2 Lap Shear (Refer to TASK 70-71-05-700-006, Adhesive Bond Strength Tensile Lap Shear Testing). Climbing Drum Peel (Refer to T , Adhesive Bond Strength Climbing Drum Peel). Flatwise Tensile (Refer to TASK 70-71-07-700-008, Adhesive Bond Strength Flatwise Tensile Testing).
Inspection for internal unbonded areas shall be accomplished by tapping the part lightly over the surface with a suitable metallic object, or by harmonic, ultrasonic or holographic techniques. Any area having a sound difference from the immediate surrounding area representing
EFFECTIVITY: ALL
70-43-20
STANDARD PRACTICES MANUAL AS907-1-1A the same type of bond shall be marked as a possible void. No voids are acceptable, unless otherwise directed by the applicable manual repair. (i) Repair voids as directed by the applicable manual repair.
EFFECTIVITY: ALL
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EFFECTIVITY: ALL
70-43-20
SURFACE PREPARATION - SURFACE PREPARATION OF ALUMINUM FOR REPAIR BONDMENTS (GELLED PHOSPHORIC ACID ANODIZE METHOD) TASK 70-43-21-380-013 1. Surface Preparation of Aluminum for Repair Bondments (Gelled Phosphoric Acid Anodize Method) SUBTASK 70-43-21-99G-013 A. General. WARNING: THE CHEMICAL USED IN THIS PROCESS IS HIGHLY CORROSIVE. USE RESPIRATORS, GOGGLES OR FACE SHIELD, RUBBER OR NEOPRENE BOOTS AND APRONS WHILE MIXING OR HANDLING. WASH OFF IMMEDIATELY IF CHEMICALS OR SOLUTION CONTACT THE SKIN. IF CHEMICALS OR SOLUTION CONTACT THE EYES, FLUSH THEM WITH CLEAR WATER, IRRIGATE THE BORIC ACID SOLUTION, AND SEEK IMMEDIATE MEDICAL AID.
(1)
This process describes a surface preparation method for aluminum and is especially effective for repair bonding applications. The process uses a gelled acid as the electrolyte, coupled with a stainless steel wire screen as the cathode, to anodize aluminum by applying a potential of 5 volts for 12 minutes. The environmentally stable oxide created from this anodize process results in improved bond reliability and durability when used in adhesive bond repairs. Adhesive strengths obtained using this process, approach those of tank processed parts.
SUBTASK 70-43-21-380-131 B. Description Solvent, General Solvent, General Solvent, General Compound, Surface Treatment Abrasive Pads Filler, Fumed Silica Viscosity Control Agent Materials. Consumable Code C04-001 C04-002 C04-035 C04-150 C10-010 C10-022
EFFECTIVITY: ALL
70-43-21
SURFACE PREPARATION OF ALUMINUM FOR REPAIR BONDMENTS (GELLED PHOSPHORIC ACID ANODIZE METHOD) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-43-21-380-132 C. Procedure. (1) Aluminum alloys and wrought aluminum faying surfaces are to be cleaned and prepared per the following procedure. NOTE: Poor preparation of the skin will result in poor adhesion of the replacement part. Replacement parts are to be cleaned and prepared as directed by the applicable Engine/Shop Manual repair or in the case of the honeycomb bondment repair may be prepared as follows: (a) Clean inner skin, outboard surface to remove all adhesive from the exposed areas to within 0.250 of the retained core material. No. 400 sandpaper mounted on electric drill rotor or air tool may be used. Care should be taken to assure that all adhesive is removed from the designated skin area. NOTE: Poor preparation of skin will result in poor adhesion of the replacement core. (b) Remove old adhesive from the retained honeycomb core edges using a similar procedure to that in paragraph 1. above. Sand edges of core until bare metal is obtained. Witness of adhesive fillet retained in the core cells is acceptable. After sanding, blow core and skin with clean dry shop air and vacuum carefully. Wipe or spray with trichloroethane. Retained honeycomb on the bondment will be cleaned as follows: WARNING: DEGREASING SOLVENTS ARE TOXIC AND SHOULD BE USED IN A WELL VENTILATED AREA. AVOID PROLONGED BREATHING OF VAPORS OR REPEATED OR PROLONGED CONTACT WITH THE SKIN.
(c)
1 2 3
Solvent spray core in stabilized general solvent C04-002, C04-035, or equivalent at room temperature. Vapor degrease is acceptable. Do not wipe but let solvent drain and air dry. During drying, bondment shall be positioned in such a way that the cell cavities are fully exposed to air circulation and that adequate drainage or entrapped fluids is assured.
(d)
Water break test the inner skin using demineralized water at room temperature and with a pH no greater than 7.5. Observe immediately for water breaks on the skin surface as evidenced by water not cascading from the skin in a continuous sheet. If water breaks occur, abrade the area using TASK 70-21-14-110-012, Cleaning Method No. 14 - Manually-Assisted Detergent Cleaning, and Scotch Brite pads C10-010, or equivalent. If necessary, clean the surface with C04-001, C04-035, or equivalent. Let the surface dry then do the water break test again. Repeat this procedure until the surface can pass the water break check. Dry the bondment for 30 minutes minimum at a temperature no greater than 1508F (668C) until thoroughly dry. Anodize exposed skin areas using C04-150 as follows:
(e)
EFFECTIVITY: ALL
70-43-21
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: DEGREASING SOLVENTS ARE TOXIC AND SHOULD BE USED IN A WELL VENTILATED AREA. AVOID PROLONGED BREATHING OF VAPORS OR REPEATED OR PROLONGED CONTACT WITH THE SKIN.
Solvent wipe the skin area with C04-001, C04-035, or equivalent. Thoroughly dry the bondment. Wipe skin area with clean dry paper wipe until the residue of cleaning (gray color) is not present on the wipe. Repeat solvent wash and wipe until paper wipe is clean. Manufacture a dam around the patch area to be cleaned. a b c Install press tight sealant around the patch periphery at the bond line, and on each bond line within the dammed area. Install wide masking tape to the side wall of the repaired core and set into press tight of the bond line. Cover exposed core around the patch with plastic sheet and tape in position.
Apply a uniform coating of about 0.100 inch (2.54 mm) thickness of surface treatment compound, C03-048, or equivalent. NOTE: Gelled phosphoric acid may be made from 10-12% solution or phosphoric acid combined with an inorganic bonder C10-022. The gel consistency should be such that it will stay in position on the curved portions of the bondment without running. Bondment may be positioned such as to minimize the affect of gravity on the gel.
4 5 6
Place one or two layers of clean gauze, or equivalent, over the coating. Apply an additional thin coat of surface treatment compound, C04-150 or gelled phosphoric acid over the gauze. Secure a piece of stainless steel wire screen over the coating. Screen may be contoured to patch area within 0.5 to 0.57 inch of patch size.
CAUTION: CHECK TO BE SURE THAT NO PART OF THE SCREEN IS IN CONTACT WITH THE ALUMINUM. 7 Connect screen as cathode (-) and the aluminum substrate as anode (+). a b Each input to the screen and substrate should encompass an area no greater than one square foot. Anode connection may be taped to the inside surface of the bondment from the center of each square foot area. Clean the skin to bare metal at attachment point.
EFFECTIVITY: ALL
70-43-21
STANDARD PRACTICES MANUAL AS907-1-1A c The cathode connection can be attached by attaching clips to the edge of the screen. NOTE: Best results, bend a corner of the screen about 908 to the nominal surface to be anodized to attach cathode (-). One connection for each square foot of surface. CAUTION: TAKE CARE NOT TO RUB THE ANODIZED SURFACE. 8 Apply potential of 4 to 6 volts for 10 to 14 minutes. At the end of anodizing time, open circuit, remove screen and gauze. Lightly wipe off gelled acid with wet gauze. Rinse the anodized area with deionized water or moistened gauze and lightly wipe clean. Dry at room temperature or in oven not exceeding 1508F (668C) for 30 minutes.
9 10
SUBTASK 70-43-21-380-133 D. Quality Check. (1) Verification of presence of anodic coating: (a) Test equipment required: 1 2 A white frosted mercury vapor lamp or white daylight fluorescent lamp. Optical polarizing filter (available from laboratory supply houses or Polaroid, Inc.) Refer to the List of Suppliers in Step D. of Subtask 70-8000-800-003.
(b)
Test Procedure 1 Illuminate processed aluminum part surfaces using a mercury vapor or fluorescent lamp, so that incidence angle of this light beam from the lamp to the plane of the part surface does not exceed 5 degrees. Place a polarizing filter between the observer and the reflected illuminator image on the detail surface. Observe the detail surfaces for the appearance of interference colors. NOTE: Different pieces of aluminum anodized under the same conditions may show different interference colors because of differences in alloy composition and metallurgical condition. The colors most frequently seen are purple, yellow, and green hues. 4 While viewing the surfaces, rotate the polarizing filter 90 degrees. The presence of anodic coating on a surface is verified by an observed
2 3
EFFECTIVITY: ALL
70-43-21
STANDARD PRACTICES MANUAL AS907-1-1A change to the complementary color (for example, from a purple to a yellow green). NOTE: Rotation of the polarizing filter is required. Some pale shades of yellow or green are so close to white that without a color change inspection they might be considered no color. (2) Inspect dry anodized surface for: (a) Detail parts displaying the color change, as above, on all surfaces to be bonded are acceptable. Abrupt differences in color of local areas (with exception of electrical contact points) from the background color, such as those caused by finger prints on abrasions subsequent to anodizing are not acceptable. Surface shall be free of burned areas and areas which are not anodized, except electrical contact areas which are not anodized are acceptable. Parts or areas which do not conform to requirements of this paragraph may be recycled to this Standard Practice as directed by the applicable manual repair. Retest in accordance with this paragraph.
(b) (c)
EFFECTIVITY: ALL
70-43-21
EFFECTIVITY: ALL
70-43-21
EPOXY POLYAMIDE COATING - PAINT - EPOXY COATING FOR ALUMINUM AND FERROUS ALLOYS TASK 70-43-22-380-014 1. PAINT - EPOXY POLYAMIDE COATING FOR ALUMINUM AND FERROUS ALLOYS SUBTASK 70-43-22-99G-014 A. General. (1) Epoxy is an erosion resistant, protective coating C03-010 and an effective coating for aluminum and ferrous materials, for use in areas subject to corrosion. To apply this coating to composites, refer to TASK 70-43-27-380-001, Paint - Epoxy and Polyamide Coating for Composites.
SUBTASK 70-43-22-380-141 B. Description Primer, Epoxy Paint, Epoxy Reducer, (MIL-T-81772) Type II Solvent, General Solvent, General Solvent, General SUBTASK 70-43-22-380-142 C. Procedure. (1) Strip old paint or other residues as prescribed by the applicable manual repair. WARNING: CLEANING SOLVENTS ARE TOXIC AND HIGHLY FLAMMABLE. USE IN A WELL-VENTILATED AREA, AND TAKE PRECAUTIONS AGAINST FIRE. Materials. Consumable Code C03-007 C03-010 C04-029 C04-001 C04-003 C04-035
(a)
If parts have been inspected/repaired after paint stripping, vapor degrease in accordance with, TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, or hand clean with a paper wipe moistened with general solvent C04-001, C04-003, C04-035, or equivalent. Allow part to dry completely. Mask all areas that are not to be painted, following detailed part instructions. Dry abrasive (grit) blast in accordance with TASK 70-21-04-120-001, Cleaning Method No. 4 - Dry Abrasive Blast Cleaning, using aluminum oxide grit in the
(b) (c)
EFFECTIVITY: ALL
70-43-22
PAINT - EPOXY COATING FOR ALUMINUM AND FERROUS ALLOYS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A 120-220 mesh range as an abrasive. Remove residual grit by blasting with clean, dry air. NOTE: Do not handle prepared parts with bare hands. Use clean, white, cotton gloves. If parts are not to be coated within 4 hours after cleaning, they should be stored in clean, sealed polyethylene bags. WARNING: PRIMER C03-007 IS TOXIC AND HIGHLY FLAMMABLE. KEEP AWAY FROM HEAT OR OPEN FLAME. USE IN A WELLVENTILATED AREA AND WEAR A SUITABLE RESPIRATOR. AVOID SKIN CONTACT OR PROLONGED BREATHING OF THE VAPOR. IF THE PRIMER CONTACTS THE SKIN, WASH THE CONTACTED AREA WITH SOAP AND WATER IMMEDIATELY. IF IT CONTACTS THE EYES, IRRIGATE AND SEEK MEDICAL AID AT ONCE.
(d)
Apply primer C03-007. NOTE: Primer C03-007 is stored in a freezer. 1 2 Remove primer from the freezer and allow to come to room temperature before opening the container. Mark the time and date that the primer was removed from the freezer on the outside of the container. NOTE: The shelf life of this material is seven days at room temperature. This material cannot be refrozen after the shelf life has expired. 3 4 5 6 7 8 Mix the primer in its own container. Check the spray gun for cleanliness and the air hose to be sure that there is no oil or water contamination. Pour the mixed primer into the spray gun cup using a funnel strainer. Adjust the air pressure for the best spraying results. Spray primer for 100% coverage of part. Primer thickness is to be approximately 0.0004 inch (0.010 mm) - a very light haze. Allow the part to air dry for 30 minutes minimum. Cure the primer C03-007 as follows: a b c Preheat an oven to 2508 108F (1218 68C). Place part in oven and cure for 60 - 90 minutes at 2508 108F (1218 68C). Allow part to cool to 1508F (65.58C) maximum.
EFFECTIVITY: ALL
70-43-22
STANDARD PRACTICES MANUAL AS907-1-1A (e) Apply epoxy coating C03-010. NOTE: Prior to painting, part must be clean and dry. WARNING: CLEANING SOLVENTS ARE TOXIC AND HIGHLY FLAMMABLE. USE IN A WELL-VENTILATED AREA, AND TAKE PRECAUTIONS AGAINST FIRE.
Surface to be painted may be cleaned with a paper wipe moistened with general solvent C04-001, C04-003, C04-035, or equivalent. Allow the part to dry completely. Mask all areas that are not to be painted, following detail part instructions. Mix each individual component in its original container. Mix the base and the curing solution as specified by the manufacturer. Stir thoroughly and allow this mixture to stand at room temperature for 30 minutes minimum (chemical reaction time). NOTE: This waiting period will apply after the addition of reducer (C04-029) if reducer is required. NOTE: Thinning the material up to a 90% paint/10% reducer mixture is the recommended range.
2 3
Spray the paint in repeated thin coats to produce a satisfactory surface finish of 0.003-0.005 inch (0.08-0.13 mm). MAKE SURE THE PAINT IS DRY BEFORE YOU PUT THE PARTS IN THE OVEN. WET PAINT CAN START A FIRE OR AN EXPLOSION.
WARNING:
5 6 7
Air dry painted parts for 30 minutes minimum. Oven cure at 1308 108F (548 68C) for 30 - 60 minutes. Remove all masking and clean as required.
EFFECTIVITY: ALL
70-43-22
EFFECTIVITY: ALL
70-43-22
CHEMICAL TOUCH-UP - CHEMICAL TOUCH-UP FOR BLACK OXIDE SURFACE COATINGS TASK 70-43-23-380-015 1. Chemical Touch-Up for Black Oxide Surface Coatings SUBTASK 70-43-23-99G-015 A. General. (1) Black oxide finish is applied to low carbon alloy steels as a surface treatment in conjunction with preservative oil to retard corrosion. Typical parts protected by black oxide are gears, shafts and bearing housings. Missing coating may be restored using a chemical touch-up solution. The solution may also be used to test for complete removal of any previous plating when performing plating repairs of those parts. Plating will not become black.
SUBTASK 70-43-23-380-151 B. Description Conversion Coating, Black Oxide Touch Up Solvent, General Solvent, General Solvent, General SUBTASK 70-43-23-380-152 C. Procedure. CLEANING SOLVENTS ARE HIGHLY FLAMMABLE, VOLATILE AND TOXIC. THEY SHOULD BE USED WITH ADEQUATE VENTILATION. AVOID PROLONGED BREATHING OF VAPORS OR PROLONGED CONTACT WITH SKIN. Materials. Consumable Code C03-049 C04-001 C04-003 C04-035
WARNING:
(1)
Vapor degrease entire part per TASK 70-32-02-230-001, Fluorescent-Penetrant Inspection, or wipe area to be touched up with general solvent C04-001, C04-003, C04-035, or equivalent, using a clean lint-free cloth or paper wipers. TOUCH-UP SOLUTION CONTAINS ACID. WEAR FACE SHIELD AND PROTECTIVE CLOTHING. IF SOLUTION CONTACTS EYES OR SKIN, FLUSH IMMEDIATELY WITH CLEAN WATER AND SEEK MEDICAL AID.
WARNING:
(2) (3)
Using cotton swab or small brush, apply black oxide touch-up solution C03-049 with slight rubbing motion until surface becomes black. Allow parts to sit in air until touch-up solution is dry.
EFFECTIVITY: ALL
70-43-23
CHEMICAL TOUCH-UP FOR BLACK OXIDE SURFACE COATINGS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (4) (5) Rinse in clean water or with wiper dampened with clean water. Dry immediately with shop air or clean wiper. Corrosion protect all surfaces of part per TASK 70-60-00-620-001, Preservation of Engine Parts.
EFFECTIVITY: ALL
70-43-23
CHEMICAL TOUCH-UP FOR BLACK OXIDE SURFACE COATINGS Page 2 Dec 01/03
MOLYBDENUM DISULFIDE - APPLICATION OF MOLYBDENUM DISULFIDE DISPERSED IN POLYIMIDE RESIN TASK 70-43-24-640-006 1. Application of Molybdenum Disulfide Dispersed in Polyimide Resin SUBTASK 70-43-24-99G-006 A. General. (1) Molybdenum disulfide dispersed in Polyamide resin is a dry film lubricant which is applied by spraying. It is very effective in preventing seizing and is also resistant to hydrocarbons.
SUBTASK 70-43-24-640-061 B. Equipment. (1) (2) (3) (4) Efficient ventilation system for extracting and neutralizing vapors. Oven capable of maintaining 4908F (2548C) for prebaking and baking parts. Sprayer able to deliver lubricant at 25-40 psi (175-275 kPa). Clean cloth for cleaning and removing excess lubricant.
SUBTASK 70-43-24-640-062 C. Material. NOTE: All materials are used at ambient temperature. Consumable Product A. Solvent (1) Acetone (2) Isopropyl Alcohol B. Dry Film Lubricant (1) D85 TER C. Tape, Paint Adhesion Testing (1) 3M No. 250 SUBTASK 70-43-24-640-063 D. Procedure. (1) To assure quality, process a test piece (strip of sheet metal) along with the part that is going to be dry lubricant coated.
APPLICATION OF MOLYBDENUM DISULFIDE DISPERSED IN POLYIMIDE RESIN Page 1 Dec 01/03
No. C04-003 C04-035 C02-068 C10-189
EFFECTIVITY: ALL
70-43-24
STANDARD PRACTICES MANUAL AS907-1-1A (2) If the process document specifies a thickness of applied lubricant, measure the thickness of the test piece before application of the lubricant. CLEANING SOLVENTS ARE FLAMMABLE, VOLATILE, AND TOXIC. THEY SHOULD BE USED WITH ADEQUATE VENTILATION. AVOID PROLONGED BREATHING OF VAPORS AND REPEATED OR PROLONGED CONTACT WITH THE SKIN, OR CLOTHING.
WARNING:
(3)
Unless otherwise specified in the process document, clean the part and test piece with a cloth saturated with either solvent listed in SUBTASK 70-43-24-640-062, Material.
CAUTION: DO NOT TOUCH PREPARED AREA OF THE PART WITH BARE HANDS OR EXPOSE THE PART TO OTHER CONTAMINATION. (4) (5) (6) Apply masking to the part as referenced in the process document, if specified. To get a more regular coating and to prevent flowout, you may preheat the parts in an oven preheated to 140-1768F (60-808C) for 15 minutes. If you preheated the part, apply the lubricant immediately by spraying. Apply the lubricant listed in SUBTASK 70-43-24-640-062, Material. (a) (b) (7) Apply a uniform coating that is free of sags or runs. Use an air pressure of 25-40 psi (170-275 kPa).
If more than one application is required to obtain the specified lubricant thickness called for in the process document, dry the part in 140-1768F (60-808C) oven for 15 minutes between applications. To calculate the lubricant thickness, measure the test piece thickness after each lubricant application and subtract the initial measurement taken in Step (2). CLEANING SOLVENTS ARE FLAMMABLE, VOLATILE, AND TOXIC. THEY SHOULD BE USED WITH ADEQUATE VENTILATION. AVOID PROLONGED BREATHING OF VAPORS AND REPEATED OR PROLONGED CONTACT WITH THE SKIN, OR CLOTHING.
(8)
WARNING:
(9)
Use a clean cloth dampened with either solvent to remove any overspray or excess lubricant.
(10) Remove masking if applied. WARNING: WEAR INSULATED GLOVES TO PREVENT INJURY WHEN HANDLING HOT PARTS.
(11) To cure the lubricant, bake the parts in an oven at the following temperatures and times (total of 3 hours): 200-2208F (95-1058C) for one hour, then 380-4008F (195-2058C) for one hour, then 470-4908F (245-2558C) for one hour.
EFFECTIVITY: ALL
70-43-24
STANDARD PRACTICES MANUAL AS907-1-1A (12) Remove part from oven and allow to air cool at room temperature. SUBTASK 70-43-24-640-064 E. Quality Assurance. (1) Perform the following test on the test piece that was processed with the part. (a) (b) (2) Apply and press on a strip of pressure sensitive tape to the test piece. Coating shall not peel when the tape is pulled off. Scratch the coating on the test piece using a fingernail. The scratching shall not remove the coating.
Examine the coating on the processed part. (a) (b) (c) The coating should be free of sags, blisters, flakes, or foreign material. The finish should be smooth and uniform. The coating should be dark.
(3)
If the coating fails any of these tests or examinations, remove the coating and process the part again.
EFFECTIVITY: ALL
70-43-24
EFFECTIVITY: ALL
70-43-24
GRAPHITE LUBRICANT - APPLICATION OF SOLID FILM GRAPHITE LUBRICANT DAG-143 TASK 70-43-25-640-007 1. Application of Solid Film Graphite Lubricant Dag-143 SUBTASK 70-43-25-99G-007 A. General. (1) This section provides instruction for the application of a heat cured, solid film lubricant film containing graphite in an aluminum phosphate binder. This film is designed for high temperature applications.
SUBTASK 70-43-25-640-071 B. Equipment. (1) (2) (3) Efficient ventilation system for extracting and neutralizing vapors. Oven capable of heating to 7008F (3718C). Sprayer able to deliver lubricant mixture to the surface to be coated in a fine, even spray pattern.
SUBTASK 70-43-25-640-072 C. Materials. No. C04-003 C04-035 C04-036, C04-102 C02-067
Consumable Product A. Solvent, Cleaner (1) Acetone (2) Isopropyl Alcohol (3) Toluene B. Solid Film Lubricant (1) DAG 143 SUBTASK 70-43-25-640-073 D. Procedure. (1)
Before preparation and use, ensure that the shelf lives of the products have not been exceeded.
EFFECTIVITY: ALL
70-43-25
APPLICATION OF SOLID FILM GRAPHITE LUBRICANT DAG-143 Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: CLEANING SOLVENTS ARE FLAMMABLE, VOLATILE, AND TOXIC. USE IN A WELL-VENTILATED AREA TAKING PRECAUTIONS AGAINST FIRE. AVOID PROLONGED BREATHING OF VAPORS AND REPEATED OR PROLONGED CONTACT WITH THE SKIN OR CLOTHING.
CAUTION: DO NOT TOUCH PREPARED AREAS WITH BARE HANDS OR EXPOSE THE AREAS TO ANY SOURCE OF CONTAMINATION. THE COATINGS SHOULD BE APPLIED WITHIN 60 MINUTES. (2) Clean the surface to be coated so that it is free of contaminates that may interfere with the ability of the coating to adhere to the substrate. (a) Use a clean cheesecloth moistened with acetone C04-003 or with a 50-50 mixture of isopropyl alcohol C04-035 and either industrial grade toluene C04036 or reagent grade toluene C04-102. If a low volatility solvent is used, ensure that the part is dry before applying the coating.
(b) (3)
Application of the Coating. (a) If required, mix the coating as follows: 1 Measure A and B components and deionized water in the following proportions by volume: three parts component B, three parts deionized water, and two parts component A. Pour the contents of the container marked component B into a large, clean mixing bowl. Add an equal volume of deionized water after using the water to first rinse the component B container. Slowly mix the contents of the bowl by hand or with a low speed mechanical stirrer. While continuing to mix, slowly add the contents of the container marked component A to the mixture. Continue to mix for three to five minutes and transfer the mixture to a suitable storage container. NOTE: This mixture may be used for up to 30 days from the time it is mixed. 7 (b) Mark the shelf life expiration date on the container.
2 3 4 5 6
Apply the coating as follows: 1 Mask the areas that are not to be coated. Reference the repair document to define the area(s) that are to be masked.
EFFECTIVITY: ALL
70-43-25
STANDARD PRACTICES MANUAL AS907-1-1A 2 3 4 Heat the part to 2758-3508F (1358-1778C). The part shall be maintained at this temperature throughout the coating application process. Slowly mix the mixture for three to five minutes by hand or with a low speed mechanical stirrer. Apply the undiluted mixture by spraying with a coating thickness from 0.0006 to 0.0012 inch (15-30 microns). NOTE: After the application and up to the final stage of curing, the coating shall be protected against humidity. 5 (4) Remove the masking.
The coating shall be cured according to one of the following cycles: NOTE: The temperatures that are specified are part temperatures and the times are the time at temperature. (a) Cycle A. 1 2 3 4 (b) Heat in an air furnace to 3758 258F (1918 148C) and hold for 45 to 60 minutes. Cool in air to room temperature. Reheat the part in an air furnace to 6808 258F (3608 148C) and hold at temperature for 45 to 75 minutes. Cool in air to room temperature.
Cycle B. 1 2 3 Heat in an air furnace to 3758 258F (1918 148C) and hold for 45 to 60 minutes. Increase temperature to 6808 258F (3608 148C) and hold at temperature for 45 to 75 minutes. Cool in air to room temperature.
SUBTASK 70-43-25-640-074 E. Quality Requirements. NOTE: Test coupons shall be approximately 6 inches (152 mm) long by 1 inch (25 mm) wide by 0.040 inch (1 mm) thick. The coupon material may be ANSI 312 SS. (1) Appearance. (a) (2) Check to ensure that the coating on the hardware has a uniform, dull black color and is free from defects such as pits, blisters, bubbles, or scaling.
Coating Thickness.
EFFECTIVITY: ALL
70-43-25
STANDARD PRACTICES MANUAL AS907-1-1A (a) (3) Unless otherwise specified in the repair document, check to ensure that the coating thickness is from 0.0006 to 0.0012 inch (15-30 microns).
Solubility Test. (a) (b) Use a test piece processed with the hardware to perform a solubility test. Wipe the cured coating on the test piece under water with gauze. The coating should still adhere. NOTE: Some evidence of graphite on the gauze is acceptable.
(4)
Adhesion. (a) Use a test piece bent 180 degrees on a 1.00 inch (25.4 mm) mandrel and ensure that there is no evidence of scaling, peeling, or lifting of the coating.
SUBTASK 70-43-25-640-075 F. Handling. (1) Handle all coated parts in such a way to prevent chipping, scratching, or other damage to the coating.
EFFECTIVITY: ALL
70-43-25
SILICONE ABRADABLE COATING - APPLICATION OF SILICONE ABRADABLE COATING CHARGED WITH GLASS BEADS TASK 70-43-26-380-001 1. Application of Silicone Abradable Coating Charged with Glass Beads SUBTASK 70-43-26-99G-001 A. General. (1) (2) (3) The sealing product consists of a mixture of organo-polysiloxane compound with insert fillers. To increase hardness and to provide for material abradability, the product is charged with glass beads which have the appearance of a fine white powder. This Standard Practice is applied to local repair, using equipment such as spatula, or for complete reconditioning, using injection equipment.
SUBTASK 70-43-26-380-051 B. Equipment. (1) The following equipment is required for the application of this process: (a) (b) (c) (d) A dry, dust-free, well ventilated room, temperature regulated at 688F (208C) used solely for applying assembly products or coatings. An applicator, a spatula or a syringe, for local application. Brush of good quality. Injection equipment, for complete reconditioning of abradable such as one of the following systems or equivalent: 1 Complete injection system, mixing the different abradable components under vacuum and capable to inject the compound with a minimum of operation: Description Mixer and injection system
Equipment Reference: DYNAFLOW 4010 This tool can be purchased from: O.M.T. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. 2
System of a mixer and using a pneumatic gun equipped with cartridge for injection:
APPLICATION OF SILICONE ABRADABLE COATING CHARGED WITH GLASS BEADS Page 1 Dec 01/03
Equipment Reference: SEMCO S1378 SEMCO 550-20 This tool can be purchased from: SEMCO Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. OR COMET Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. (e) (f) (g) (h) (i) (j) Vacuum degassing facility.
Description Mixer Pneumatic Gun
Mechanical device for adjoining parts. Infrared lamp capable of 3208 (1608C). A ventilated oven with temperature control capability from 32 - 3208F (0 1608C). A dynamometer having 220 lb (100 kg) capacity. A tensile system having a tension load rate of 0.3937 inch/minute (10 mm/ minute).
SUBTASK 70-43-26-380-052 C. Material Abrasive Cloth Primer - MB Primer SS-4155 Glass Beads for Abradable Filler RTV148 Compound RTV148A RTV147A Catalyst 147B (Black) RTV630 Compound RTV630 part A and B C01-142
Materials. Consumable Product No. C10-196 C01-170 C01-092 C10-197 C01-167 C01-168 C01-169
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-43-26-380-053 D. Procedure. (1) Prepare the following for quality assurance: (a) A test piece made of the same material as the part and having the following dimensions: Dimensions: 4 x 4 inch (100 x 100 mm) (b) Two metallic discs equipped with a pulling device (such as hook or threaded rod) and having the following dimensions: Diameter: 0.79 inch (20 mm) Thickness: 0.16 inch (4 mm) (2) (3) (4) (5) Process the test piece mentioned in paragraph D.(1)(a) along with the part to be coated. Ensure parts have been prepared as specified in the process document. Roughen the surface to be reconditioned using product listed in paragraph C. in SUBTASK 70-43-26-380-052, Materials. Apply primer if specified in the process document as follows: (a) Choice of primer. 1 2 (b) With RTV148 compound use product listed in paragraph C. in SUBTASK 70-43-26-380-052, Materials. With RTV630 compound use product listed in paragraph C. in SUBTASK 70-43-26-380-052, Materials.
Apply a coat of primer by brushing.
CAUTION: THE PRIMER C01-092 MUST BE DRIED IN AN AREA WITH A MINIMUM OF 40% RELATIVE HUMIDITY. FORMATION OF A CHALKY WHITE HAZE INDICATES ADEQUATE DRYING OF THE PRIMER C01-092. DO NOT REMOVE OR CONTAMINATE SUCH A FILM PRIOR TO APPLICATION OF THE RTV SILICONE RUBBER COMPOUND. (c) (6) (7) (8) Allow to dry at room temperature for 1 hour.
Allow temperature of products to stabilize at ambient working room temperature. Oven dry the product listed in paragraph C. at 3008F (1508C) for 1 hour, before use in the following operation. Refer to SUBTASK 70-43-26-380-052, Materials. Depending on the type of compound used (RTV 148 or RTV 630) prepare a mixture with the products listed below:
STANDARD PRACTICES MANUAL AS907-1-1A (a) For RTV148 Compound: NOTE: Make sure to use material as specified in the process document. One of the products listed in paragraph C.: 19.5 parts by weight The product listed in paragraph C.: 21 parts by weight The product listed in paragraph C.: 70 parts by weight The product listed in paragraph C.: 9 parts by weight. (b) For RTV630 Compound: One of the products listed in paragraph C.: 11 parts by weight Part A of the product listed in paragraph C.: 100 parts by weight Part B of the product listed in paragraph C.: 10 parts by weight. (9) Stir the above mixture manually or mechanically until a homogeneous material is obtained. NOTE: It is mandatory to apply the products within 2 hours after mixing. (10) Perform degassing under 3.38 x 10-3 in Hg (1.33 x 10-4 Kpa) vacuum at ambient temperature within 15 minutes. NOTE: Degassing is not necessary if you use the equipment specified in paragraph B.(1)(d) in SUBTASK 70-43-26-380-051, Equipment. (11) Apply coating using a spatula or syringe (local repair) or injection equipment (full repair), as specified in the process document. (12) Cure using infrared lamp for 1 hour at 2108F (1008C) or 30 minutes at 3008F (1508C). SUBTASK 70-43-26-380-054 E. Quality Requirements. (1) (2) (3) (4) The seal bead must be uniform in color and free of defects such as bubbles, blisters and cracks. The seal should be elastic and no longer be sticky when touched. Adhesion test. This test must be performed on the test piece coated with the part and in two points located at least 1.6 inch (40 mm) apart. (a) Bond the disc mentioned in paragraph D.(1)(b) as follows: (Refer to SUBTASK 70-43-26-380-053, Procedure.) 1 2 Roughen the coated test piece and the disc surface using product listed in paragraph C in SUBTASK 70-43-26-380-052, Materials. Apply primer on the disc per paragraph D.(5) in SUBTASK 70-43-26380-053, Procedure.
STANDARD PRACTICES MANUAL AS907-1-1A 3 4 (b) (c) Bond the disc on the coated test piece using compound mentioned in paragraph D.(8) in SUBTASK 70-43-26-380-053, Procedure. Polymerize per paragraph D.(12) in SUBTASK 70-43-26-380-053, Procedure.
Cut the abradable around the disc up to the support using a 0.83 inch (21 mm) diameter hollow punch. Pull the disc using the tensile system equipped with the dynamometer until the abradable is pulled out. Two cases are possible: 1 The fracture is located between the abradable and the test piece or in the abradable. The correct adhesion of coating is determined according to the following formula: F/S = equal to or greater than 174 psi (1.2 MPa) where: F = Applied load, lb (N) S = Surface of bonded joint, Sq. in. (Sq. mm) 2 The fracture is located in the compound used to bond the disc: The test must be performed again if F/S is less than or equal to 174 psi (1.2 MPa).
(5)
If the coating fails any of these tests or examinations, remove coating and reprocess the part.
EPOXY POLYAMIDE COATING - PAINT - EPOXY POLYAMIDE COATING TASK 70-43-27-380-001 1. PAINT - EPOXY POLYAMIDE COATING FOR COMPOSITES SUBTASK 70-43-27-99G-001 A. General. (1) Epoxy polyamide is an erosion resistant, protective coating (Color Code 27038 Black) for use in areas subject to corrosion. To apply this coating to aluminum and ferrous alloys refer to TASK 70-43-22-380-014, Paint - Epoxy Polyamide Coating for Aluminum and Ferrous Alloys.
SUBTASK 70-43-27-380-051 B. Materials. Consumable Code C03-010 C04-029 C10-141 C10-182
Product Identification Epoxy Polyamide Coating Reducer Abrasive Paper, 120-180 Grit, SiC, Wet/Dry Cleaning Cloths SUBTASK 70-43-27-380-052 C. Procedure. (1)
Prepare bare surface of composite material for painting as follows: CAUTION: DO NOT EXPOSE THE UNDERLYING FIBERS OR DAMAGE TO THE PART WILL OCCUR. (a) Using 120-180 grit abrasive paper C10-141, hand-sand the surface of the unfinished composite material. Sanding is to be performed dry. 1 2 On new composites sand sufficiently to break the resin surface glaze. On existing composites that do not have surface glaze, lightly sand to remove surface contamination.
EFFECTIVITY: ALL
70-43-27
PAINT - EPOXY POLYAMIDE COATING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: USE EYE PROTECTION WHEN YOU USE COMPRESSED AIR TO CLEAN, COOL, OR DRY PARTS OR TOOLS. PARTICLES CAN CAUSE AN INJURY TO YOUR EYES. DO NOT USE MORE THAN 30 PSIG (200 KPA). DO NOT POINT COMPRESSED AIR AT YOURSELF OR OTHER PERSONS.
(b) (c)
Clean the debris from the area to be repaired with clean, dry, oil-free compressed shop air. Mask areas around portion to be painted per Composite Masking Method No. 3 in TASK 70-46-01-350-030, Masking and Cleaning of Epoxy and Polyester Matrix Thermosetting Composite Materials. CLEANING SOLVENTS ARE TOXIC AND HIGHLY FLAMMABLE. USE IN A WELL-VENTILATED AREA, AND TAKE PRECAUTIONS AGAINST FIRE.
WARNING:
(d)
Clean surface to be painted. Refer to Composite Cleaning Method No. 4 or 5 in TASK 70-46-01-350-030, Masking and Cleaning of Epoxy and Polyester Matrix Thermosetting Composite Materials. Allow the part to dry completely. Mask clean surface to be painted per Composite Masking Method No. 4 in TASK 70-46-01-350-030, Masking and Cleaning of Epoxy and Polyester Matrix Thermosetting Composite Materials.
(e)
(2)
Apply epoxy polyamide coating C03-010 and reducer C04-029 as follows: (a) Mix each individual component in its original container prior to use. Mix the coating and the reducer as specified by the manufacturer. Stir thoroughly and allow this mixture to stand at room temperature for 30 minutes minimum (chemical reaction time). NOTE: This waiting period will apply after the addition of reducer - if reducer is required. NOTE: For spray application, the two components may be thinned by the addition of reducer C04-029 as specified by the manufacturer. (b) (c) (d) (e) Remove masking from area to be painted. Refer to Step C.(1)(e). Spray the paint in repeated thin coats to produce a satisfactory surface finish of 0.003-0.005 inch (0.08-0.13 mm). Air dry painted parts for 30 minutes minimum. Do an inspection of the painted area for grit, seeds, runs, craters, and blisters. Acceptance level to be as defined by repair procedure calling out this standard practice. Rework as required. 1 Apply reducer C04-029 to cleaning cloth C10-182 and wipe surface to remove imperfections.
(f)
EFFECTIVITY: ALL
70-43-27
STANDARD PRACTICES MANUAL AS907-1-1A 2 WARNING: Repeat Steps C.(2)(b) thorough C.(2)(f). MAKE SURE THE PAINT IS DRY BEFORE YOU PUT THE PARTS IN THE OVEN. WET PAINT CAN START A FIRE OR AN EXPLOSION.
(g) (h)
Oven cure at 1758 108F (798 68C) for 60-90 minutes. Remove all masking and clean as required.
EFFECTIVITY: ALL
70-43-27
EFFECTIVITY: ALL
70-43-27
THREAD LUBRICANT COATING - APPLICATION OF PETROLATUM GRAPHITE THREAD LUBRICANT COATING - C02-079 TASK 70-43-28-380-001 1. Application Of Petrolatum Graphite Thread Lubricant Coating C02-079 SUBTASK 70-43-28-99G-001 A. General. (1) Application of petrolatum graphite to threaded fasteners can be accomplished by direct application of the paste C02-058 by brush or by the use of the liquid version C02-079 by spray or dip method. This procedure covers the application of the liquid version. For threaded fasteners 0.250 inch (6.35 mm) diameter and greater, the liquid version C02-079 is considered equivalent to the paste C02-058 in torquetension testing.
SUBTASK 70-43-28-380-001 B. Description Lubricant, Liquid Thread SUBTASK 70-43-28-380-001 C. Procedure. WARNING: SOLVENTS CAN BE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPOR AND CONTACT WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME. Materials. Consumable Code C02-079
(1) (2) (3) (4)
If the part has areas where no coating is necessary, apply masking tape to these areas. Liquid shall be thoroughly mixed before application and shall show no evidence of solvent separation during application of liquid to parts. Liquid shall be applied by dipping or spraying to provide a visually uniform coating. Application method shall not introduce foreign materials to the coating. After application of the liquid, coating shall be dried in air for a minimum of 5 minutes. OBSERVE PRECAUTION AGAINST FIRE AND EXCESSIVE BREATHING OF SOLVENT VAPORS.
WARNING: (5)
Remove masking. Wipe off any superfluous coating, using a cloth moistened in a general solvent C04-001 or C04-003.
APPLICATION OF PETROLATUM GRAPHITE THREAD LUBRICANT COATING - C02079 Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (6) Examine coating before assembling part. The coating shall visually exhibit complete and uniform coverage in areas specified for coating. Areas of the part designated to be free from lubricant coverage shall be masked or otherwise handled to protect them from lubricant coverage.
APPLICATION OF PETROLATUM GRAPHITE THREAD LUBRICANT COATING - C02079 Page 2 Dec 01/03
MIXING INSTRUCTIONS - MIXING INSTRUCTIONS FOR CONSUMABLE MATERIALS TASK 70-43-99-800-001 1. Mixing Instructions for Consumable Materials SUBTASK 70-43-99-800-001 A. General. (1) The 70-43-99 section contained instructions for mixing consumable materials. The information in 70-43-99 been moved to separate tasks (70-43-xx). Since some repairs and other documents might still refer to the old numbers, the following information is provided as a cross-reference. Applicable TASK in 70-43-xx TASK 70-43-17-360-002, Epoxy Repair of Mating Surfaces and Inserts TASK 70-43-20-360-003, Honeycomb Bondment Adhesive Consumable C01-011
Old Code Number in 70-43-99 A-3
A-4
C01-136 C01-139 C01-166 C04-001 C04-003 C04-011 C04-093 C04-101 C04-150 C04-229 C10-022 C02-048 C03-043 C02-006
B-1 L-1
TASK 70-43-12-380-009, Black Oxide Finish TASK 70-43-09-640-001, Replacement of Dry-Film Lubricant TASK 70-43-16-640-004, SolidFilm Lubricant
L-2
C02-049 C04-036
EFFECTIVITY: ALL
70-43-99
MIXING INSTRUCTIONS FOR CONSUMABLE MATERIALS Page 1 Dec 01/03
Old Code Number in 70-43-99 P-1
Applicable TASK in 70-43-xx TASK 70-43-13-380-010, Elastomer Coating, Abrasion Resistant TASK 70-43-14-380-011, Urethane Elastomer Touch-Up
Consumable C03-011 C03-017 C03-027 C03-028 C03-029 C04-001 C04-003 C04-035 C04-101 C04-102 C04-112 C04-113 C04-114 C04-229 C10-010 C10-105 C04-001 C04-003 C04-001 C04-003 C03-030 C04-002 C04-003 C04-035
P-2-I
TASK 70-43-15-360-001, Abradable Plastic Seal Compound (RSP-3) TASK 70-43-15-360-001, Abradable Plastic Seal Compound (RSP-3) TASK 70-43-01-380-001, Touch-Up Silicone Aluminum Paint TASK 70-43-02-380-002, Silicone-Aluminum Paint OneCoat Process TASK 70-43-03-380-003, Silicone-Aluminum Paint TwoCoat Process TASK 70-43-01-380-001, Touch-Up Silicone Aluminum Paint TASK 70-43-04-380-004, Epoxy Painting
P-2-II
P-3
P-4
C03-030 C04-002 C04-003 C04-035 C03-034 C03-035 C03-080 C04-036 C03-034 C03-035 C03-080 C04-036 C03-038 C03-039 C03-055 C03-091
P-5
P-6
TASK 70-43-04-380-004, Epoxy Painting
P-7
TASK 70-43-05-380-005, Inorganic Aluminum Protective Coating
EFFECTIVITY: ALL
70-43-99
Old Code Number in 70-43-99 P-8
Applicable TASK in 70-43-xx TASK 70-43-05-380-005, Inorganic Aluminum Protective Coating TASK 70-43-06-380-006, Clear Epoxy Painting TASK 70-43-22-380-014, PaintEpoxy Coating for Aluminum and Ferrous Alloys
Consumable C03-038 C03-039 C03-055 C03-091 C03-035 C03-041 C03-007 C03-010 C04-001 C04-003 C04-029 C04-035 C02-048 C03-043 C03-081 C03-082 C03-084 C04-002 C04-003 C04-035 C03-006 C03-046 C03-083 C04-002 C04-003 C04-035 C04-072 C03-006 C03-046 C03-083 C04-002 C04-003 C04-035 C04-072 C03-008 C04-001 C04-003 C04-035 C04-001 C04-002 C04-035 C04-150 C10-010 C10-022
P-9 P-10
T-1 T-2-I
TASK 70-43-12-380-009, Black Oxide Finish TASK 70-43-07-380-007, Chemical Touch-Up Surface Refinishing Process for Aluminum
T-2-II
TASK 70-43-08-380-008, Chemical Film Coating for Aluminum
T-2-III
TASK 70-43-08-380-008, Chemical Film Coating for Aluminum
T-3
TASK 70-43-18-380-012, Chemical Touch-Up of Aluminum Protective Coating (Chromate Conversion Coating) - C03-008 TASK 70-43-21-380-013, Surface Preparation of Aluminum for Repair Bondments
T-4
EFFECTIVITY: ALL
70-43-99
Old Code Number in 70-43-99 T-5
Applicable TASK in 70-43-xx TASK 70-43-23-380-015, Chemical Touch-Up for Black Oxide Surface Coatings
Consumable C03-049 C04-001 C04-003 C04-035
EFFECTIVITY: ALL
70-43-99
EQUIPMENT AND SETUP - LOCALIZED HEAT TREATMENT EQUIPMENT AND SETUP TASK 70-44-01-370-002 1. Localized Heat Treatment Equipment and Setup SUBTASK 70-44-01-99G-002 A. General. (1) Localized heat treatment is a process used to stress relieve or age repair welds. The process is particularly suited to the heating of small localized areas on large parts that may be difficult or inconvenient to transport or process in a furnace. This section identifies the equipment and setup procedure, while TASK 70-44-02-370003, Localized Heat Treatment Procedures, lists various heat treat cycles that apply, using this method. The repair procedure for a particular part, contained in the applicable Engine/Shop Manual, specifies the required cycle by referring to the applicable cycle code number and TASK 70-44-02-370-003, Localized Heat Treatment Procedures. NOTE: Localized heat treatment is to be used only when specifically directed by repair instructions for a particular part. SUBTASK 70-44-01-370-021 B. Equipment. (1) Heaters. Tungsten-quartz heating elements with reflectors shall be used for heating. Each quartz lamp assembly shall be equipped with a separate ammeter and power control. The reflector and case body is normally water cooled. The lamp chamber, enclosed behind a quartz window, should contain provisions for air cooling the heating elements and seals. The reflector should be capable of withstanding a cooling air pressure of 10-30 psi (68.9-206.8 kPa). The following listed equipment, or equivalent, satisfactorily meets these requirements. Table 1. Equipment Research, Incorporated Refer to the List of Suppliers in Step D. of SUBTASK 70-80-00-800-003. Reflector Type and Model No: Flat, Model 5208-5 Overall length 9.50 inch (241.3 mm) Flat, Model 5208-10 Overall length 12.625 inches (326.1 mm) Patch Heater, Model 5066-5 (Patch heater is supplied with required service leads and heating lamps, Q500T4/2CL.) General Electric Co. Refer to the List of Suppliers in Step D. of SUBTASK 70-80-00-800-003. Infrared Lamp Model No. 1200 T3/CL 2000 T3/CL
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LOCALIZED HEAT TREATMENT EQUIPMENT AND SETUP Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (2) Service Leads. With the exception of the patch heater, Model 5066-5, service leads for power, air and water cooling are required for the recommended reflector assemblies. (3) Thermocouples. Thermocouples with associated compatible potentiometers and readout equipment shall be used for determining the temperature of the repair part during heat treatment. The temperature-sensing range shall be from room temperature to 25008F (13718C). Chromel-alumel 20 gage wire with refrasil covering is recommended for application of thermocouples. (4) Setup. Set up the equipment in the following manner. (a) Heat reflectors. 1 Position reflectors so that they are centered with respect to the repair area and are parallel to the repair area to the extend that surface condition and strut interference permit. When using more than one reflector on one side of the repair surface, keep the reflectors close together so that there is a minimum of separation between them. Heat may be applied to both sides of a repair, if accessible, or to one side only. Configuration of part and heating equipment usually determines which way the heat is applied. If heat is applied from one side only, an asbestos or fiber glass blanket or batt should be used on the side opposite the heater. Surfaces surrounding the repaired area should be protected from infrared heating by covering or shielding them with insulation blankets or batts. Only those surfaces requiring heat treatment are to be exposed to infrared heating. The heating elements shall extend at least 2.00 inches (50.8 mm) beyond all parts of the repair, and shall be positioned approximately 0.50 inch (12.7 mm) from the surface of the part.
3 4
(b)
Thermocouples. 1 Generally, thermocouples should be attached to the back or reverse side of the repair area from the heating element. Enough thermocouples shall be used to ensure that the repair area reaches, and is held at, the specified temperature. Enough thermocouples shall be located at a distance from the repair area to inform the operator of what area, and to what extent, the part is subjected to temperatures in excess of the specified aging temperature. This information is needed to ascertain that all areas subjected to solution temperature levels are reached.
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STANDARD PRACTICES MANUAL AS907-1-1A 2 Temperatures should be monitored constantly, and thermocouple readings should be logged at regular (30 minute) intervals. Each thermocouple should be numbered, and a map of thermocouple positions, preferably drawn to scale, attached to the log sheet.
EFFECTIVITY: ALL
70-44-01
EFFECTIVITY: ALL
70-44-01
HEAT TREAMENT PROCEDURES - LOCALIZED HEAT TREATMENT PROCEDURES TASK 70-44-02-370-003 1. Localized Heat Treatment Procedures SUBTASK 70-44-02-99G-003 A. General. (1) Localized heat treatment processes are to be used only when directed by repair instructions for a particular part.
SUBTASK 70-44-02-370-031 B. Equipment. (1) For equipment requirements and setup procedure, refer to TASK 70-44-01-370-002, Localized Heat Treatment Equipment and Setup.
SUBTASK 70-44-02-370-032 C. Localized Heat Treatment Cycles. NOTE: Each heat treatment cycle is identified by a letter-number code, and consists of the following temperatures, rates, and times. Heat-up and cool-down rates are general guidelines and are recommended to minimize distortion. Cycle LH-1 Procedure Short age cycle for Inconel 718 fabrications, and some A286 fabrications. (1) Apply power to heating elements, and heat to 6008F (3168C) at the rate of 158-258F (88-148C) per minute. (2) Continue heating to 14008F (7608C) at the rate of 38-48F (1.582.258C) per minute. (3) Hold at 14008 258F (7608 148C) for 2 hours. (4) Reduce temperature to 11508F (6218C) at the rate of 1008F (568C) per hour [48-68F (2.258-3.48C) every 3 minutes]. (5) Hold at 11508 258F (6218 148C) for 4 hours. (6) Reduce temperature to 8008F (4278C) at the rate of 38-48F (1.508-2.258C) per minute. (7) Turn off power, remove insulation, and let part cool to room temperature. LH-2 Full age for Rene 41 and Rene 77 castings. (1) Apply power to heating elements, and heat to 14008F (7608C) at the rate of 38-48F (1.508-2.258C) per minute.
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LOCALIZED HEAT TREATMENT PROCEDURES Page 1 Dec 01/03
Cycle
Procedure (2) Hold at 14008 258F (7608 148C) for 16 hours. (3) Reduce temperature to 8008F (4278C) at the rate of 38-48F (1.508-2.258C) per minute. (4) Turn off power, remove insulation, and let part cool to room temperature.
LH-3
Age/stress relief for 17-4 PH fabrications. (1) Apply power to heating elements, and heat to 11508F (6218C) at the rate of 108-208F (5.58-11.28C) per minute. (2) Hold at 11508 258F (6218 148C) for 2 hours. (3) Reduce temperature to 6008F (315.58C) at the rate of 108-208F (5.58-11.28C) per minute. (4) Turn off power, remove insulation, and let part cool to room temperature.
LH-4
Stress relief for aluminum weld repair. (1) Apply power to heating elements, and heat to 3258F (1638C). (2) Hold at 3258 258F (1638 148C) for 6 hours. (3) Turn off power, remove insulation, and let part cool to room temperature.
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70-44-02
LOCALIZED HEAT TREATMENT PROCEDURES Page 2 Dec 01/03
FURNACE HEAT TREATMENT - FURNACE HEAT TREATMENT TASK 70-44-03-370-004 1. Furnace Heat Treatment SUBTASK 70-44-03-99G-004 A. General. (1) The heat treatment cycles described in this section are identified in groups related to the type of furnace atmosphere required. Cycle code numbers with the prefix letters V, I, A, and H show atmosphere requirements for vacuum, inert gas, air, and hydrogen, respectively. Where inert gas is specified, argon (99.995 percent purity) or nitrogen (99.98 percent purity) may be used in the following conditions: (a) (b) (c) (2) A dew point of -608F (-518C) or colder is measured at the inlet. As an alternative, a dew point of -308 (-348C) or colder is measured at the exhaust. Nitrogen may not be put into the furnace above 20008F (10938C). Nitrogen may not be used with titanium alloys above 6508F (3438C).
To get the best physical properties, some materials require close control of heating and cooling rates through specific temperature ranges. The heat treatment cycles in this section identify these heating and cooling rates. The optimum temperature and time for each cycle is given with a tolerance permitted for variation, but it is best to hold the parameters that are specified. The repair procedure for a part will specify the required heat treat cycle (as well as optional cycles if they are applicable) by referring to the cycle code numbers contained in this section. If a part requires a heat treat cycle other than one of those contained in this section, the heat treat cycle will be included in that repair procedure. Inconel 718 aging treatments are designated as full age, alternate full age, and short age cycles. The short age cycles (V-16, I-10, and A-7) were initially developed to age dabber TIG seal tooth weldments in seal repairs. These aging treatments are to be used on repairs where no solution treatment is used. This type of aging treatment restores almost all physical properties in the weldment area and does not overage the parent metal. The alternate full age cycle was developed for use as an alternative for the full age 16 hour cycle (V-2, I-2, A-2), to increase production cycle efficiency. The full age and alternate full age cycles are to be used only after a solution treatment. They must not be used as stand-alone aging treatments in a repair, as overaging will occur. The short age cycle must not be used as a replacement for the full age or alternate full age cycle after a solution treatment. Air Cool Rate. (a) If the procedure is done in a vacuum or inert gas furnace and the cycle states to air-cool the parts, they shall be cooled to less than 10008F (5388C) by
(3)
(4)
(5)
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FURNACE HEAT TREATMENT Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A backfilling with argon or nitrogen. When inert gas cooling is used, the cooling rate shall be at least 20-408F (11-228C) per minute to less than 10008F (5388C). Cooling from 10008F (5388C) to the ambient shop temperature may be at any rate. CAUTION: DO NOT IMMERSE PARTS IN LIQUID TO COOL THEM. (b) When the heat treatment cycle is done in an atmosphere furnace and the cooling rate specified is air-cool or faster, the parts shall be withdrawn from the furnace and cooled in the air with a minimum cooling rate of 20-408F (11228C) per minute to less than 10008F (5388C). Fans may be used to aid and achieve the cooling rates. Cooling from 10008F (5388C) to the ambient shop temperature may be at any rate.
(6)
Heat Treatment Equipment (a) Heat treatment equipment calibration is defined per TASK 70-44-04-370-001, Heat Treat Equipment Calibration.
(7)
Back-to-Back Heat Treatment Cycles. (a) For heat treatment of alloys where both a solution and an age heat treatment is performed, and the age temperature is greater than 10008F (5408C), it is not necessary to cool the part to room temperature between the heat treatment cycles. 1 2 (b) (c) (d) (e) As specified in 70-44-03, each cycle is planned as an independent heat treatment cycle. This applies to alloys such as Inco 718, R41, Waspalloy, etc.
After the solution heat treatment cycle, the thickest part of the section must be cooled to below 10008F (5408C). Re-evacuate the furnace for vacuum heat treatment. Reheat the furnace to 10008F (5408C) and stabilize for 10 minutes. Start the age heat treatment.
SUBTASK 70-44-03-370-051 B. Cycle V-1 Vacuum Furnace Cycles. Procedure General solution treatment for Inconel 718. (1) Evacuate chamber to 0.5 micron. (2) Heat to 10008 258F (5388 148C) and stabilize. (3) Within 60 minutes, heat to 17508 258F (9548 148C). Hold for 1 hour.
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Cycle
Procedure (4) Introduce inert gas, and cool to 10008F (5388C) at rate of not less than 308F (178C) per minute. (5) Air-cool, or cool at the equivalent rate, to room temperature.
V-2
Alternative procedure available. Full age cycle for Inconel 718 fabrications. NOTE: See paragraph A.(4) (1) Evacuate chamber to 0.5 micron. (2) Heat to 13258 258F (7198 148C). Hold for 8 hours. (3) Cool to 11508 258F (621 148C). Hold for 8 hours. (4) Air-cool, or cool at the equivalent rate, to room temperature.
V-2
Alternative procedure. Full age cycle for Inconel 718. NOTE: See paragraph A.(4) (1) Evacuate chamber to 0.5 micron. (2) Heat to 14008 258F (7608 148C) repairs. Hold for 5 hours. (3) Cool to 12008 258F (6498 148C). Hold for 1 hour. (4) Air-cool, or cool at the equivalent rate to room temperature.
V-3
High temperature solution treatment for Inconel 718 fabrications. Also, the regular solution treatment for Inconel 718 forgings. (1) Evacuate chamber to 0.5 micron. (2) Heat to 10008 + 258F (5388 148C) and stabilize. (3) Heat to 17758 258F (9688 148C) within 60 minutes. Hold 10-20 minutes. (4) Introduce inert gas, and cool to 10008F (5388C) at a rate of not less than 308F (178C) per minute. (5) Air-cool, or cool at the equivalent rate, to room temperature.
V-4
Solution treatment for Rene 80. (1) Evacuate chamber to 0.5 micron. (2) Heat to 22008 258F (12048 148C). Hold for 2 hours. (3) Introduce inert gas, and cool to 10008F (5388C) at a rate not less than 308F (178C) per minute. (4) Air-cool, or cool at the equivalent rate, to room temperature.
V-5
Second solution cycle for Rene 80. (1) Evacuate chamber to 0.5 micron. (2) Heat to 20008 258F (10938 148C). Hold for 4 hours. (3) Introduce inert gas, and cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. (4) Air-cool, or cool at the equivalent rate, to room temperature.
EFFECTIVITY: ALL
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Cycle V-6
Procedure Simulated diffusion cycle for Rene 80. (1) Evacuate chamber to 0.5 micron. (2) Heat to 19258 258F (10528 148C). Hold for 4 hours. (3) Introduce inert gas, and cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. (4) Air-cool, or cool at the equivalent rate, to room temperature.
V-7
Stress relief for 300 series stainless steel and Hastelloy X. Solution treatment for Rene 41 and Rene 80. (1) Evacuate chamber to 0.5 micron. (2) Heat to 19258 258F (10528 148C). Hold for 30 minutes. (3) Introduce inert gas, and cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. (4) Air-cool, or cool at the equivalent rate, to room temperature.
V-8
Solution treatment for Rene 41 and Hastelloy X. (1) Evacuate chamber to 0.5 micron. (2) Heat to 19508 258F (10668 148C). Hold for 30 minutes. (3) Introduce inert gas, and cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. (4) Air-cool, or cool at the equivalent rate, to room temperature.
V-9
Solution treatment for Rene 41 and Rene 77. (1) Evacuate chamber to 0.5 micron. (2) Heat to 19758 258F (10798 148C). Hold for 30 minutes. (3) Introduce inert gas, and cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. (4) Air-cool, or cool at the equivalent rate, to room temperature.
V-10
Final age cycle for Rene 77 and Rene 80. (1) Evacuate chamber to 0.5 micron. (2) Heat to 15508 258F (8438 148C). Hold for 16 hours. (3) Introduce inert gas, and cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. (4) Air-cool, or cool at the equivalent rate, to room temperature.
V-11
Solution treatment for certain (special) Inconel 718. X-40 stress relief. (1) Evacuate chamber to 0.5 micron. (2) Heat to 18008 258F (9828 148C). Hold for 30 minutes. (3) Introduce inert gas, and cool to no more than 10008F (5388C). (4) Air-cool, or cool at the equivalent rate, to room temperature.
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Cycle
Procedure NOTE: For A286 solution/age, see V-18 and V-19.
V-12
Full age cycle for certain (special) Rene 41. (1) Evacuate chamber to 0.5 micron. (2) Heat to 16508 258F (8998 148C). Hold for 4 hours. (3) Introduce inert gas, and cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. (4) Air-cool, or cool at the equivalent rate, to room temperature.
V-13
Full age cycle for Rene 41, Rene 77, Rene 95, and Rene 120. (1) Evacuate chamber to 0.5 micron. (2) Heat to 14008 258F (7608 148C). Hold for 16 hours. (3) Introduce inert gas, and cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. (4) Air-cool, or cool at the equivalent rate, to room temperature.
V-14
Stress relief for certain titanium alloys. (1) Evacuate chamber to 0.5 micron. (2) Heat to 13008 258F (7048 148C). Hold for 1 hour. (3) Introduce inert gas, and cool to 10008F (5388C) at a rate of 308F (178C) per minute. Cooling rate is not critical. (4) Air-cool, or cool at the equivalent rate, to room temperature.
V-15
Stress relief for certain titanium alloys. (1) Evacuate chamber to 0.5 micron. (2) Heat to 12008 258F (6498 148C). Hold for 1 hour. (3) Introduce inert gas and cool to 10008F (5388C) at a rate of 308F (178C) per minute. Cooling rate is not critical. (4) Air-cool, or cool at the equivalent rate, to room temperature.
V-16
Short age cycle for Inconel 718. NOTE: See paragraph A.(4) (1) Evacuate chamber to 0.5 micron. (2) Heat to 14008 258F (7608 148C). Hold for 2 0.25 hours. (3) Introduce inert gas, and cool to 11508 258F (6218 148C). (4) Hold at 1150 258F (6218 148C) for 4 0.25 hours. (5) Air-cool to room temperature.
V-17
Solution treatment for Hastelloy X and HS188. (1) Evacuate chamber to 0.5 micron. (2) Heat to 20758 258F (11358 148C). Hold for 30 minutes minimum.
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Cycle
Procedure (3) Introduce inert gas, and cool from 20758F (11358C) to 12008F (6498C) in 20 minutes. (4) Air-cool, or cool at the equivalent rate, to room temperature.
V-18
Solution cycle for A286. (1) Evacuate chamber to 0.5 micron. (2) Heat to 18008 258F (9828 148C) for 1 hour 5 minutes. (3) Introduce inert gas and cool to 10008F (5388C) in 10 minutes or less. (4) Cool part to 2008F (938C) in 1 hour 10 minutes. (5) Air-cool to room temperature.
V-19
Age cycle for A286. (1) Evacuate furnace to 0.5 micron. (2) Heat to 13258 258F (7188 148C) for 16 hours 30 minutes. (3) Cool to room temperature at a rate equivalent to air-cool. SUBTASK 70-44-03-370-052 C. Inert Gas Furnace Cycles. Procedure Solution cycle for Inconel 718. See V-1. (1) (2) (3) Displace all air in chamber with inert gas. Heat to 10008 258F (5388 148C). Stabilize. Within 60 minutes, heat to 17508 258F (9548 148C). Hold for 1 hour. Cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. Air-cool, or cool at the equivalent rate, to room temperature.
Cycle I-1
(4)
(5)
I-2
Alternative procedure available. Full age cycle for Inconel 718. See V-2. NOTE: NOTE: See paragraph 1.D.
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Cycle (1) (2) (3) (4)
Procedure Displace all air in chamber with inert gas. Heat to 13258 258F (7188 148C). Hold for 8 hours. Cool to 11508 258F (6218 148C). Hold for 8 hours. Air-cool, or cool at the equivalent rate, to room temperature. Displace all air in chamber with inert gas. Heat to 14008 258F (7608 148C). Hold for 5 hours. Cool to 12008 258F (6498 148C). Hold for 1 hour. Air-cool, or cool at equivalent rate, to room temperature.
I-2
Alternative procedure. Full age cycle for Inconel 718. (1) (2) (3) (4)
I-3
Stress relief for 300 series stainless steel. Solution treatment for Rene 41 and Rene 80. (1) (2) (3) Displace all air in chamber with inert gas. Heat to 19258 258F (10528 148C). Hold for 30 minutes. Cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. Air-cool, or cool at the equivalent rate, to room temperature. Displace all air in chamber with inert gas. Heat to 15508 258F (8438 148C). Hold for 16 hours. Cool to 10008F (5388C) at a rate of no less than 308F (178C) per minute. Air-cool, or cool at the equivalent rate, to room temperature.
(4)
I-4
Full age cycle for Rene 77 and Rene 80. See V-10. (1) (2) (3)
(4)
I-5
Solution cycle for certain Inconel 718, X-40 stress relief.
EFFECTIVITY: ALL
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Cycle (1) (2) (3)
Procedure Displace all air in chamber with inert gas. Heat to 18008 258F (9828 148C). Hold for 30 minutes. Cool to room temperature.
NOTE: NOTE: For A286 solution/age, see I-12 and I-13. I-6 Solution treatment for Rene 41 and Rene 77. (1) (2) (3) Displace all air in chamber with inert gas. Heat to 19758 258F (10798 148C). Hold for 30 minutes. Cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. Air-cool, or cool at the equivalent rate, to room temperature. Displace all air in chamber with inert gas. Heat to 19508 258F (10668 148C). Hold for 30 minutes. Cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. Air-cool, or cool at the equivalent rate, to room temperature. Displace all air in chamber with inert gas. Heat to 16508 258F (8998 148C). Hold for 4 hours. Cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. Air-cool, or cool at the equivalent rate, to room temperature.
(4)
I-7
Solution treatment for Rene 41 and Hastelloy X. See V-8. (1) (2) (3)
(4)
I-8
Full age cycle for certain Rene 41. See V-12. (1) (2) (3)
(4)
I-9
Age cycle for Rene 77, Rene 41, Rene 95, and Rene 120. See V13.
EFFECTIVITY: ALL
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Cycle (1) (2) (3)
Procedure Displace all air in chamber with inert gas. Heat to 14008 258F (7608 148C). Hold for 16 hours. Cool to 10008F (5388C) at a rate no less than 308F (178C) per minute. Air-cool, or cool at the equivalent rate, to room temperature.
(4)
I-10
Short age cycle for Inconel 718. NOTE: NOTE: See paragraph 1.D. (1) (2) (3) (4) (5) Displace all air from the chamber with inert gas. Heat to 14008 258F (7608 148C). Hold for 2 0.25 hours. Cool to 11508 258F (6218 148C). Hold at 11508 258F (6218 148C) for 4 0.25 hours. Air-cool to room temperature. Displace all air in chamber with inert gas. Heat to 13008 258F (7048 148C). Hold for 1 hour. Cool to 10008F (5388C) at a rate of 308F (178C) per minute. Cooling rate is not critical. Air-cool, or cool at the equivalent rate, to room temperature. Displace all air in chamber with inert gas. Heat to 18008 258F (9828 148C) for 1 hour 5 minutes. Cool to 10008F (5388) in 10 minutes or less.
I-11
Stress relief for certain titanium alloys. (1) (2) (3)
(4)
I-12
Solution cycle for A286. (1) (2) (3)
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Cycle (4)
Procedure Cool part to 2008 258F (938 148C) in 1 hour 10 minutes Air-cool to room temperature. Displace all air in chamber with inert gas. Heat to 13258 258F (7188 148C) for 16 hours 30 minutes. Cool to room temperature at a rate equivalent to air cool.
(5) I-13 Age cycle for A286. (1) (2)
(3)
SUBTASK 70-44-03-370-053 D. Cycle A-1 (1) Air Furnace Cycles. Procedure Solution cycle for Inconel 718. See V-1. Insert part in furnace heated to 008 258F (3168 148C) and stabilize. Heat at furnace rate to 10008 258F (5388 148C) and stabilize. Within 60 minutes, heat to 17508 258F (9548 148C). Hold for 1 hour. Cool to below 11008F (5938C) in 17 to 23 minutes.
(2)
(3)
(4) A-2
Alternative procedure available. Full age cycle for Inconel 718. See V-2. NOTE: NOTE: See paragraph A.(4). (1) Insert part in furnace at 6008 258F (3168 148C) and stabilize. Heat at furnace rate to 13258 258F (7188 148C) and stabilize. Hold for 8 hours. Cool to 11508 258F (6218 148C). Hold for 8 hours.
(2)
(3)
EFFECTIVITY: ALL
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Cycle (4) A-2 (1)
Procedure Air-cool to room temperature. Insert part in furnace heated to 6008 258F (3168 148C) and stabilize. Heat to 14008 258F (7608 148C). Hold for 5 hours. Cool to 12008 258F (6498 148C). Hold for 1 hour. Air-cool, or cool at the equivalent rate, to room temperature. Insert part in furnace heated to 16508 258F (8998 148C) and stabilize. Hold for 4 hours. Remove part from furnace and air-cool. Insert part in furnace heated to 14008 258F (7608 148C) and stabilize. Hold for 16 hours. Remove part from furnace and air-cool. Alternative procedure. Full age cycle for Inconel 718.
(2) (3) (4)
A-3
Full age for certain Rene 41. See V-12. (1)
(2) A-4
Full age for Rene 41, Rene 77, Rene 95 and Rene 120. See V-13. (1)
(2) A-5
Stress relief/ age for 17-4 PH and temper for 403 and 410 stainless steel. (1) Insert part in furnace heated to 11508 258F (6218 148C) and stabilize. Hold for 4 hours. Remove part from furnace and air-cool. Insert part in furnace heated to 3258 258F (1638 148C) and stabilize. Hold for 6 hours. Remove part from furnace and air-cool.
(2) A-6
Stress relief of aluminum. See LH-4. (1)
(2) A-7
Short age cycle for Inconel 718. See LH-1. NOTE: NOTE: See paragraph A.(4).
EFFECTIVITY: ALL
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Cycle (1) (2)
Procedure Insert part in furnace heated to 6008 258F (3168 148C). Heat to 14008 258F (7608 148C) and stabilize. Hold for 2 0.25 hours. Cool to 11508 258F (6218 148C). Hold at 11508 258F (6218 148C) for 4 0.25 hours. Air-cool to room temperature.
(3) (4) (5) SUBTASK 70-44-03-370-054 E. Hydrogen Furnace Cycles. WARNING: (1)
HYDROGEN GAS MIXED WITH AIR MAY EXPLODE AT TEMPERATURES BELOW 14008F (7608C).
Displace all air in the furnace with an inert gas, following both approved safety procedures and all recommended equipment manufacturers instructions. Procedure Primary. (1) (2) Displace all air from the chamber/retort with inert gas. Heat to 14008F (7608C) with inert gas flowing, then introduce hydrogen gas [having a dewpoint range of 708F to -1208F (-578C to -848C) measured at the furnace exhaust.] With hydrogen flowing, heat to 20758 258F (11358 148C) and hold for 30 minutes minimum. Rapid-cool with hydrogen gas to 16008F (8718C). Change flow to inert gas and continue rapid-cool to 12008F (6498C). Temperature must be reached within 20 minutes.
Cycle H-1
(3)
(4)
EFFECTIVITY: ALL
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Cycle (5)
Procedure Continue to cool with inert gas flowing for another 30 minutes, then air-cool to room temperature.
H-1
Alternative. NOTE: NOTE: This cycle is to be used when an inert atmosphere will interfere with the process CAUTION: CAUTION: MAKE SURE THAT POSITIVE PRESSURE OF THE HYDROGEN IS MAINTAINED THROUGHOUT THE CYCLE. IF HYDROGEN PRESSURE IS LOST, IMMEDIATELY PURGE WITH INERT GAS. DO NOT INITIATE FLOW OF HYDROGEN INTO THE CHAMBER IF IT IS ABOVE ROOM TEMPERATURE. (1) Displace all air from chamber with hydrogen gas [having a dewpoint range of -708F to 1208F (-578C to -848C) measured at the furnace exhaust]. Heat to 20758 258F (11358 148C) and hold for a minimum of 30 minutes. Rapid-gas-cool from 20758F (11358C) to 12008F (6498C) in 20 minutes. NOTE: NOTE: Initiate inert atmosphere purge at 16008F (8718C); shut off hydrogen flow after inert atmosphere flow has started. (4) Continue to cool with inert atmosphere flowing for a minimum of 30 minutes. Remove parts from chamber and cool to room temperature.
(2)
(3)
(5)
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EQUIPMENT CALIBRATION - HEAT TREAT EQUIPMENT CALIBRATION TASK 70-44-04-370-001 1. HEAT TREAT EQUIPMENT CALIBRATION SUBTASK 70-44-04-99G-001 A. General. (1) This standard practice deals with the set-up and qualification requirements of thermocouples, and furnace temperature uniformity/atmosphere performance. It will cover furnaces used to perform vacuum, inert gas, air, and hydrogen heat treatments.
SUBTASK 70-44-04-370-001 B. Applicable Documents. (1) Aerospace Material Specifications: (a) (2) AMS 2750, Pyrometry
American Society for Testing and Material: (a) (b) ASTM E 230, EMF Tables for Standardized Thermocouples ASTM E 220, Manufacturing and Calibration of Thermocouples
SUBTASK 70-44-04-370-002 C. Definitions. (1) (2) Air Cool in Vacuum Furnace - When the rate specified is air cool or equal, the cooling rate shall be 308F (178C) per minute or greater to at least 10008F (5388C). Air, Oil, Water Cool/Quench - Describes the equivalent cooling rate range required, rather than the specific cooling medium which must be used. For example: Circulated argon in a vacuum furnace might be equivalent to air cool, while different polymer-water solution concentrations might be equivalent to oil or water quench. Control or Furnace Thermocouple - A thermocouple installed within the furnace volume which is used to control the heat input to the working zone. Gas Dew Point - Colder or better dew point means lower impurity content. Required levels will usually be specified by the drawing or material specification, and unless otherwise stated are maximum levels. Heat Sink - A mass of material equivalent to the heat transfer characteristics of the thickest section of the part being heat treated. A thermocouple surrounded by the heat sink is expected to represent the metal temperature.
(3) (4)
(5)
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HEAT TREAT EQUIPMENT CALIBRATION Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (6) (7) Heat Treatment - A heating and cooling process that modifies or changes the inherent physical or metallurgical properties of a solid metal or alloy. Leak-Up Rate - A test in which the furnace chamber is evacuated, isolated from the evacuation source, and the leakage determined within the system by observing the pressure rise per unit of time. Note that the leak-up rate is expressed in microns/ hour (1 micron = 10-3 torr). Metal Temperature - The temperature specified on the drawing or material specification represents metal temperature, which is the actual temperature of the material including temperature variation from sources such as furnace tolerance, etc. Overtemperature Control - A furnace system which reduces or halts heat input by the furnace in response to a detected overtemperature condition.
(8)
(9)
(10) Overtemperature Thermocouple - An independent thermocouple installed in the furnace volume which is used to monitor any overtemperature occurrences and generate an alarm and/or cut back or shut down heat input. (11) Vacuum Level - Higher or better vacuum means lower pressure. Required levels will usually be specified by the drawing or material specification, and unless otherwise stated are maximum pressure levels. For conversion: 1 torr = 1 mm Hg = 133 pascals. (12) Working Zone - The volume of the heated region of a furnace which meets the requirements of the furnace survey. Note that all parts must be contained in this working zone. (13) Workload Thermocouple - Any thermocouple which is attached to the part or heat sink which is being heat treated. SUBTASK 70-44-04-370-003 D. Requirements/Test Methodology. (1) Temperature Uniformity. (a) (b) (c) The maximum temperature variation of test thermocouples from the control temperatures must not exceed 258F (148C) at thermal equilibrium. Test thermocouples must not indicate temperatures in excess of the maximum control temperature prior to reaching thermal equilibrium. Test Method. NOTE: Furnace surveys performed with full loads of representative hardware will better define the temperature variations in the furnaces working zone. The effects of shielding and the load mass will be taken in account during the furnace survey. 1 Prepare furnace with representative load of parts, fixtures, and suitable atmosphere.
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STANDARD PRACTICES MANUAL AS907-1-1A 2 Distribute test thermocouples symmetrically within the furnace working zone as follows: a b Use a minimum of 2 thermocouples in a furnace or 10 cu ft (0.28 cu m) of working zone volume or less. Use a minimum of 8 thermocouples or one per 25 cu ft (0.78 cu m) of working zone, whichever is greater, in furnaces with working zone volumes of more than 10 cu ft (0.28 cu m).
Initially, test furnace at lowest and highest operating temperature, and at intermediate temperature(s) such that the difference between the next higher or lower test temperature is less than 6008F (3338C). Example: If the lowest operating temperature is 8008F (4278C) and the highest operating temperature is 24008F (13168C): Select 13508F (7328C) and 19008F (10388C) as possible intermediate tests.
Read and record temperature indications of all test and furnace control thermocouples at 5-minute intervals starting immediately after application of heating power. Continue recording temperature measurements for a minimum of onehalf hour following indication of thermal equilibrium by furnace control thermocouples. See AMS 2750 Appendix A for further clarification.
6 (2)
Recording Instrumentation and Thermocouples. (a) Thermal Controls. 1 Ensure that all temperature measuring instruments have an indicated temperature measuring accuracy of 0.5 percent of the maximum temperature measured over the entire furnace operating range. Thermocouples must be in accordance with ASTM E 220 and ASTM E 230. Furnace must have overtemperature protection, and overtemperature sensors which notify the operator in response to an overtemperature condition. Test Method - Temperature sensors and recording devices will be calibrated per the procedure of AMS 2750 sections 3.1 (Temperature Sensors) and 3.2 (Instrumentation) unless specified otherwise herein.
2 3
(b)
Vacuum Controls. 1 For cold cathode vacuum instrument use, the vacuum sensing element shall be cleaned on a regular basis.
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STANDARD PRACTICES MANUAL AS907-1-1A 2 Thermoconductivity type gages (thermocouple, Pirani, thermister, etc.) which may or may not be calibratable shall be used to measure pressure of 1 x 10-3 torr (one micron) (0.13 Pa) or higher. Ionization gages (hot ion or cold cathode) or any other demonstrated calibratable vacuum gage shall be used to measure pressures less than 1 x 10-3 torr (one micron) (0.13 Pa). The chamber vacuum sensors shall be located on the furnace chamber wall or between the furnace chamber and the diffusion pump and as close to the furnace chamber as practicable. Test Method. a Vacuum indicating instrument calibration shall be in accordance with manufacturers recommendations. Calibration shall include the vacuum sensor, control panel, and when present the vacuum recorder. The vacuum sensor which utilizes a mechanical or thermal conductivity principle for pressure measurement shall not come under calibration control. Vacuum sensors which utilize an ionization principle for pressure measurement shall be under calibration control.
c (c)
Dew Point Measurement. 1 Calibration of dew point measurement equipment shall be over the range of use. The equipment performance shall be within the limits supplied by the equipment manufacturer. Test Method - Displace all air in furnace with flowing gas. Measure dewpoint or equivalent oxygen content.
2 (3)
Furnace Atmosphere. (a) Vacuum. 1 The furnace must be able to maintain a pressure of 1 x 10-3 torr (0.13 Pa) or lower at temperature. Leak-up rate shall be less than 30 microns per hour. Test Method - Measure press in furnace using ion gages or equivalent for pressures of 1 x 10-3 torr (0.13 Pa) using thermocouple gages or equivalent. All pressure measuring equipment must be checked in accordance with manufacturers recommendations.
(b)
Inert Gas Atmosphere and Quenching. 1 The gas supply shall be argon or nitrogen of 99.98 percent by volume purity and a dew point of -608F (-518C) at the exhaust of the furnace. This shall be monitored at the point as close as possible to where the gas enters the furnace, or at the farthest point from the source of gas when multiple furnaces are used.
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STANDARD PRACTICES MANUAL AS907-1-1A 2 3 Dew point measurements shall be taken whenever the gas supply is replenished. Test Method - A pressurized leak check of the quenching system at its maximum operating pressure using a suitable chemical leak detector may also be used to qualify the system. HYDROGEN GAS MIXED WITH AIR MAY EXPLODE AT TEMPERATURES BELOW 14008F (7608C).
WARNING: (c)
Hydrogen Gas. 1 2 The gas supply shall be hydrogen gas of 99.95 percent by volume purity and a dew point of -608F (-518C) or colder at the exhaust of the furnace. Test Method - See test method for inert gas.
(d)
Air (oxidizing atmosphere). 1 Furnace atmosphere is air.
(4)
The furnace interior and all holding fixtures used in furnace must be kept clean and free of contaminants which could be detrimental to parts being heat treated. Furnace bake out shall be performed every seven days.
SUBTASK 70-44-04-370-004 E. Quality Control. (1) (2) Calibration of equipment shall be accomplished using equipment which is traceable to an internationally recognized standards organization. Frequency of calibration and verification of equipment capability on a regular basis will be established in the maintenance and quality plan/system for the facility in question. This frequency will be established to insure that the equipment can reliably and consistently produce the needed tolerances required to process materials. Record the detailed results of the approved tests in a log document. Record, at least, the following: (a) (b) (c) (d) (e) (f) (g) Furnace identification. Instrumentation procedures including thermocouple type and placement. Vacuum or gas purity records. Temperature records. Mass of furnace loads. Schematic of furnace survey load. All calibration records.
(3)
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(h)
Traceability for thermocouples wire material.
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VOLUME II STANDARD PRACTICES MANUAL
PART NUMBER 3030001-4
MODEL NUMBER AS907-1-1A
STANDARD PRACTICES MANUAL
This document and all information and expression contained herein are the property of Honeywell International Inc., are provided in confidence, and may be used by persons required by Federal Aviation Regulation Part 21.50 to comply with any of the terms of these instructions. Except as set forth above, no person may, in whole or in part, use, duplicate or disclose this information for any purpose without the prior written permission of Honeywell International Inc.
This publication was prepared by Honeywell International Inc. Engines, Systems & Services Cage Code (99193) Technical Publications
FAA APPROVED
72-05-14
Copyright 2003 Honeywell International Inc. All rights reserved.
Page T-1 Dec 01/03
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Page T-2 Dec 01/03
CHROME PLATING - CHROME PLATING PROCEDURE TASK 70-45-01-330-002 1. Chrome Plating Procedure SUBTASK 70-45-01-99G-002 A. General. (1) Chrome plating should be done in accordance with this document and AMS 2406 with the exception that the embrittlement test defined in AMS 2406 is not required. In cases of conflict between AMS 2406 and this document, this document shall apply. After grinding, the thickness of the chrome plate should not be less than 0.0005 inch (0.013 mm) [0.001 inch (0.03 mm) on diameter] nor more than 0.006 inch (0.15 mm) [0.012 inch (0.31 mm) on diameter] on rotating parts, no more than 0.015 inch (0.38 mm) [0.030 inch (0.76 mm) on diameter] on static parts. These thickness limits apply unless otherwise specified for a specific part. It is important to have good plating and control practices for effective plating. To successfully plate parts, attention must be paid to the proper preparation of the part in the masking and electrical hook-up of the part. It is important to have good post plating de-masking and part cleaning procedures. All masking residues (wax, lacquer, tape, and tape adhesive residue) must be completely and thoroughly cleaned off prior to the bake process to remove hydrogen from the part. It is recommended as good shop practice that a procedure be developed and documented for each part. This procedure will ensure that all parts will be masked, plated, and cleaned to the same procedure by the different operators in the shop.
(2)
(3)
(4)
SUBTASK 70-45-01-330-021 B. Equipment. (1) (2) The plating equipment must be in good working shape and free from corrosion and corrosion products. The electrical cables used to connect the power supply to the anodes and to the cathode (part to be plated) need to be free of corrosion and big enough to handle the electrical power without overheating. The solution heaters and the temperature measuring device must be in good condition. It is important to calibrate the temperature control system so that the plating tank temperature is constant and repeatable. The tank bus bars must be free of corrosion to provide good electrical contact with the electrical cabling that goes to the anodes and cathode(s). The power supply must be in good condition. It is important that the power supply and the power meters are calibrated so that power settings are repeatable.
(3)
(4) (5)
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CHROME PLATING PROCEDURE Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (6) The plating and activation solutions should be monitored so that these solutions are in control when they are used. It is important that the consumable materials used (brushes, Scotch-brite, abrasive materials) are fresh and free of contamination. The rinse tank waters should be sufficiently clean. The rinse waters shall be either potable or deionized water. If potable water is used, attention must be paid to the hardness and chloride content of the water if improper plate performance is suspected. If potable water is used to make up solution levels in the plating tanks, the tanks should be analyzed for excessive chloride. Constant replenishment with potable water can raise the chloride level in the tanks. Part lifting fixtures should be electrically isolated from the part. It is recommended that the lifting device not be used to supply the electrical power to the part. Movement of the part using an electrically live lifting fixture could create arcing in areas where there is poor contact with the part.
(7)
(8)
(9)
(10) Electrical plating contact points shall have positive force contact. Spring load Alligator clips are not recommended for positive contact to the part. The contact electrode(s) shall be of sufficient size to pass the electrical power required. The contact electrode(s) surfaces shall be smooth and free of corrosion or oxides products so as to maintain good electrical contact with the part surface. The contact electrodes shall also have a shape to make sure the electrode is in direct contact with the part with no lift off areas. (11) The crane or lifting device hook used to position the part in the plating bath must be electrically isolated from the crane bridge. There is not to be a continuous electrical path from the part to ground through the lifting device. SUBTASK 70-45-01-330-022 C. Procedure. (1) Grind diameter to a clean, 32 (0.8 micrometer) or less, surface. Part dimensions must be within the stated limits per the applicable Engine/Shop Manual to permit plating within the limits as stated in paragraph 1.A. Remove high metal, burrs, and sharp corners. NOTE: On surfaces that were previously plated, all chrome plate must be removed. (2) After grinding, the part should be inspected by the fluorescent-penetrant or magnetic-particle method, as designated in the applicable Engine/Shop Manual for the particular part to be sure that no surface cracks have been caused by grinding. Parts requiring FPI shall be acid etched per the instructions in the applicable Engine/Shop Manual prior to FPI. Parts requiring fluorescent MPI will require demagnetization (and de-magnetization verification) prior to plating. The surfaces to be plated must be chemically cleaned. Ensure that all existing chrome plate has been removed before new plating is deposited. Mask all areas of the part that are not to be plated or that are used for electrical contact.
(3) (4)
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STANDARD PRACTICES MANUAL AS907-1-1A (a) Exceptions to complete masking are allowed when the part size is too big. In these cases (eg., the fan mid shaft), the part masking will be put on up to a level on the part above the bath so that the plating solution or fumes from the heated bath do not contact the part being plated. Masking materials used such as tape, wax lacquer, or various combinations of these materials shall be used to mask the part surfaces. Proper adhesion is required to make sure that plating solutions do not leak into the masking and touch the part surface. When plating external surfaces, internal cavities such as shaft inside diameters shall be completely masked or the end shall be capped and sealed so that solutions cannot enter the shaft cavity. Make electrical connections to the part and then mask the contact areas with the rest of the part.
(b)
(c)
(d) (5)
After masking, position the part in the tank for plating. (a) Where possible, avoid live entry into solution(s) where there is a possibility on the part bumping into the bus bars, anodes, or tank walls due to part size/ geometry. Remove or reposition bus bars if it is difficult to get part into tank so that the part is easy to get into tank. Replace or reposition bus bars to plating configuration after part is in the plating position. If the part is bumped into bus bars or tank walls, make sure the bumping action did not break the masking at the bumping contact point. If the masking is broken, remove part from plating process; clean and remask the area where the maskant is damaged.
(b)
(c)
(6) (7)
Plate part as required to achieve the necessary thickness for the repair. When the plating operation is complete, shut off power supply, remove electrical connections, and demask the part. It is important to thoroughly clean off all masking materials and plating solution residues prior to thermal treatment. Allowed times between plating and baking operations are listed in paragraph 3.J. (a) (b) Remove all tape and overlaying wax and remove electrode connections. Clean off all wax and lacquer residue with hot water soak, solvent soak ( TASK 70-21-01-110-001, Cleaning Method No. 1 - Solvent Degreasing), or degreasing operation ( TASK 70-21-02-110-002, Cleaning Method No. 2 Vapor Degreasing). Clean part in alkaline bath per TASK 70-21-06-110-004, Cleaning Method No. 6 - Heavy-Duty Alkaline Cleaner (Without Inhibited Phosphoric Acid), or equivalent or in light duty cleaning bath TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning.
(c)
(8)
Inspect part for any corrosion as a result of leaking maskant. Special attention required at electrical contact areas. Review electrical contact areas with a minimum of 10X magnification for any signs of electrical arcing or burning and any
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STANDARD PRACTICES MANUAL AS907-1-1A possible surface attack such as intergranular attack or pitting. Intergranular attack is indicated by a noticeable and irregular network of surface attack where raised areas are surrounded by groove-like depressions. (9) Unless, otherwise specified, the hydrogen bake-out cycle shall be obtained using the time-temperature parameters (see Figure 1, Page 5) for the as-applied (not asground) thickness of the chromium deposit. (a) (b) Aluminum alloys shall be baked at a temperature no greater than 3008F (1488C). Unless otherwise specified by the applicable Engine/Shop Manual, carbon steel, maraging steel (i.e., Marage 200, Marage 250), austenitic stainless steel (i.e., A286), martensitic precipitation hardened stainless steel (i.e., 174PH) and low alloy steel parts (i.e., B5F5, AISI4340, AISI 9310) shall be baked at 3758F (1918C). Unless otherwise specified by the applicable Engine/Shop Manual, nickel base alloys (i.e., Inconel 718) may be baked at any temperature-time combination as indicated in Figure 1, Page 5.
(c)
(10) A time limit exists between the time the plating operation ends and the bake cycle begins. This time limit is important to follow for safe post-plate processing of the parts. Hydrogen embrittlement cracking can occur if the time limits are not followed: (a) Unless otherwise specified in the applicable Engine/Shop Manual for nickel base alloys (example: Inconel 718) and Maraging Steel, the maximum time allowed between the end of plating and the beginning of baking is eight hours. Unless otherwise specified in the applicable Engine/Shop Manual, for all other alloys, the maximum time allowed between the end of plating and the beginning of baking is two hours.
(b)
(11) Finish grind to required dimension. (12) Remove excess plating and sharp edges with a soft stone. (13) Vapor degrease in accordance with TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing, or clean per TASK 70-21-22-110-042, Cleaning Method No. 22 Light Duty Aqueous Cleaning. (14) Inspect chrome plate for cracks, which indicate chipping, flaking or separation, using 10X magnification. No cracks are permissible. NOTE: Hard chrome plated surfaces often show a network or mesh of hairline cracks. These indications are typical of chrome plating, and are not cause for rejection. Faulty bonding of the plating to the base surface, indicated by chipping, flaking, or any separation, is cause for rejection.
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Embrittlement Recovery Times and Temperature for Different Thicknesses of Electrodeposited Chromium Figure 1
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ELECTROLESS NICKEL PLATING - ELECTROLESS NICKEL PLATING TASK 70-45-02-330-003 1. Electroless Nickel Plating SUBTASK 70-45-02-99G-003 A. General. (1) Electroless nickel plating should be done in accordance with AMS 2404. This procedure should be used only where specified in the instructions on specific parts.
SUBTASK 70-45-02-330-031 B. Preparation for Plating. (1) If the part has been nickel plated previously, the old plating must be stripped before proceeding with the plating process. Strip the old plating in accordance with SUBTASK 70-45-02-330-033, Stripping Procedure. Clean the parts as follows: (a) (b) Rinse part in running tap water. Clean part using a heavy-duty alkaline cleaner ( TASK 70-21-06-110-004, Cleaning Method No. 6 - Heavy-Duty Alkaline Cleaner (Without Inhibited Phosphoric Acid)), at 1808-2008F (828-938C) for 2-3 minutes. Dip rinse in tap water, then pressure spray with an air-water gun to remove residual grit or chemical residue. Dry part complete with clean shop air.
(2)
(c) (3)
Mask all areas of the part that are not to be plated in accordance with detail part instructions.
SUBTASK 70-45-02-330-032 C. Plating Procedure. (1) Electroless nickel plate in accordance with AMS 2404 (Kanigen Process or equivalent). (a) (b) (c) Build up a thickness to the applicable Engine/Shop Manual requirements on all unmasked surfaces. Remove masking. Bake and age the part in accordance with detail part instructions.
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ELECTROLESS NICKEL PLATING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-45-02-330-033 D. Stripping Procedure. (1) When necessary, strip existing nickel plate as follows: (a) Vapor degrease in accordance with TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing. ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING OF VAPORS. OPERATOR SHOULD WEAR FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
WARNING:
WARNING: (b)
Soak part in alkaline solution used in TASK 70-21-06-110-004, Cleaning Method No. 6 - Heavy-Duty Alkaline Cleaner (Without Inhibited Phosphoric Acid), for 1-5 minutes. Rinse parts thoroughly in tap water. THIS PROCESS SOLUTION CONTAINS CYANIDE. USE ONLY IN A WELL VENTILATED AREA. WEAR FACE SHIELD, RUBBER GLOVES AND APRON, AND WASH HAND, FACE, AND OTHER EXPOSED SKIN AREAS THOROUGHLY AFTER REMOVING PROTECTIVE WEAR.
(c)
WARNING:
(d)
Strip the plating according to TASK 70-23-04-110-021, Stripping Nickel and Silver Plate (Chemical Solutions). NOTE: Black areas remaining on part after stripping indicate incomplete removal of old plating. NOTE: Nitric acid base strippers work faster and better on many Ni-Cr alloys. Such parts can be stripped in 50 percent volume 428 Be nitric acid - 50 per-cent volume water. Refer to TASK 70-23-12-110-027, Stripping of Thermal Spray Aluminum Oxide, Non-Ferrous, and Bond Coatings. Do not use on low alloy steels.
(e)
Rinse part thoroughly in water, and blow dry with clean shop air.
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ELECTROLESS NICKEL PLATING Page 2 Dec 01/03
SELECTIVE CONTACT PLATING - SELECTIVE CONTACT PLATING TASK 70-45-03-330-004 1. Selective Contact Plating SUBTASK 70-45-03-99G-004 A. General. (1) The selective contact plating process is similar to brush plating. A carbon electrode or stylus is wrapped with an absorbent pad, which is then saturated with the desired stripping, activating, deoxidizing, or plating fluid, and connected as the anode to a direct-current power source. The work to be plated is connected to the power source as the cathode. Contact plating solutions, for the most part, consist of suspensions of organo-metallic chelates in water, adjusted to an appropriate pH value. Most contact plating fluids are relatively nontoxic. A wide variety of metals is available for contact plating. These include cadmium, copper, nickel, chromium, cobalt, tin, zinc, silver and gold. These may be mixed or used in sequence to form "sandwich" layers to obtain multipurpose coatings for buildup of worn or undertolerance areas, corrosion/erosion or wear resistance, or to provide anti-fretting and gasketing surfaces. Contact plating should be performed only as directed by the applicable Engine/Shop Manual, and the work should be done only by qualified, experienced operators.
(2)
SUBTASK 70-45-03-330-041 B. Advantages. (1) Contact plating has several advantages over conventional immersion bath plating in shop applications. Selected areas can often be plated with minimal masking; assembled parts that are difficult or impractical to disassemble or immerse can be selectively plated; building up worn or out-of-tolerance areas can be done to close limits. In addition, deposits are characterized by low stress, very fine grain, negligible hydrogen embrittlement and porosity, and excellent adhesion. The rate of deposition is high and can be accurately controlled.
SUBTASK 70-45-03-330-042 C. Equipment. (1) The following equipment and supplies are required for contact plating: (a) (b) (c) Power pack having a controllable, metered (voltage and amperage) DC output. Special electrodes or styli applicable to the plating being performed. Appropriate fixtures, turntables, lathes, drip-feed mechanisms and mechanical agitators, as required.
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STANDARD PRACTICES MANUAL AS907-1-1A (d) (e) (f) (g) Rinse tank for overflowing demineralized water. (Optional). Covered dip tank for methyl or ethyl alcohol, if used to facilitate drying. A number of evaporating dishes, swabs, absorbent cotton batting, masking material, gauze, and nylon thread or string. Equipment may be obtained from the sources listed below:
SUBTASK 70-45-03-330-043 D. Materials. No. C03-050 C03-051
Consumable Product Dalic Plating Equipment and Solutions LDC Plating Equipment and Solutions SUBTASK 70-45-03-330-044 E. Procedure. (1)
Prepare parts for contact plating by grinding down damaged surfaces to a maximum depth of 0.0025 inch (0.0635 mm), then proceed as follows: NOTE: Many nickel base alloys require an anodic etch in the appropriate solution before starting the plating operation. Refer to applicable Engine/Shop Manual for specific repair being performed. (a) (b) (c) Parts to be cleaned and masked as required per the applicable Engine/Shop Manual section. Connect part to negative (-) pole of DC power supply, and attach plating electrode to positive (+) pole. Adjust operating voltage as specified by manufacturer. OPERATOR SHOULD WEAR PROTECTIVE RUBBER GLOVES DURING THE DEOXIDIZING AND PLATING OPERATIONS.
WARNING: (d)
Saturate stylus (electrode-swab) with deoxidizing solution and rub it gently on the part to be plated until the part shows no water break when rinsed in clean tap water. The deoxidizing solution is indicated in SUBTASK 70-45-03330-043, Materials. Adjust the operating voltage for plating as specified by the manufacturer of the plating solution to be used. Saturate a clean electrode-swab in the plating solution and rub it gently on the part to be plated. The plating solution is indicated in SUBTASK 70-45-03330-043, Materials. Refer to the manufacturers instructions on the container of plating solution for proper plating current, type of stylus, rate of movement,
(e) (f)
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STANDARD PRACTICES MANUAL AS907-1-1A coverage, and thickness of deposit per minute of operation, and to the applicable Engine/Shop Manual for any special instructions. (g) Agitate the part in the rinse tank of overflowing demineralized water until all plating solution is removed. Withdraw and drain part, then return to rinse tank for 10-20 seconds. Agitate during second rinse. Drain. METHYL AND ETHYL ALCOHOL ARE FLAMMABLE AND TOXIC. USE IN A APPROVED TANK KEPT IN A WELL VENTILATED AREA. TAKE PRECAUTIONS AGAINST FIRE.
WARNING:
(h)
Air dry, or dip in reagent-grade methyl or ethyl alcohol for 10-20 seconds to facilitate drying. Properly preserve and protect parts after drying.
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SILVER PLATING - SILVER PLATING TASK 70-45-04-330-005 1. Silver Plating SUBTASK 70-45-04-99G-005 A. General. (1) A number of engine parts are silver plated to form an anti-seize coating or to protect parts against certain kinds of corrosion. Because of differences in use, the silver plating operation may be preceded by a flash-coating of nickel plate and it is always followed by a bake cycle of specific temperature and duration. The low temperature portion of the bake cycle is to remove hydrogen absorbed during the plating process and acts as an embrittlement relief. This portion must be accomplished in 4 hours or less as specified by the applicable Engine/Shop Manual. A subsequent high temperature cycle is used to demonstrate the quality of the applied plating. There is no specific time interval requirement provided that a low temperature bake has been performed within 4 hours of plating. All existing silver plate must be stripped from parts before they are replated. Parts to be plated, thickness and area of the plating, and the type of plating practice to be employed is specified in the applicable Engine/Shop Manual.
(2)
SUBTASK 70-45-04-330-051 B. Procedures. (1) The following procedures incorporate the steps required to strip and replate parts specified in the applicable Engine/Shop Manual. Either procedure may be used unless otherwise specified. (a) Procedure No. 1. 1 Strip existing silver plate as directed in TASK 70-23-03-110-020, Stripping Silver Plate (Electrolytic Method), or TASK 70-23-06-110-022, Stripping Silver Thermal Spray from Stationary Air- and Oil-Seals. Silver plate to the thickness and area specified in the applicable Engine/Shop Manual in accordance with AMS 2411. Within 4 hours after plating, bake parts at 3258-3758F (1638-1918C) for 4 hours and cool in still air. Adhesion and quality of silver plate shall be determined on representative parts or test panels processed with the parts according to the requirements of AMS 2411 after a one hour thermal treatment at 9008F (4828C) in an inert atmosphere.
2 3 4
(b)
Procedure No. 2.
EFFECTIVITY: ALL
70-45-04
SILVER PLATING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A 1 Strip existing silver plate as directed in TASK 70-23-03-110-020, Stripping Silver Plate (Electrolytic Method), or TASK 70-23-06-110-022, Stripping Silver Thermal Spray from Stationary Air- and Oil-Seals. Silver plate to the thickness and area specified in the applicable Engine/Shop Manual in accordance with AMS 2411. Within 4 hours after plating, bake parts at 7258-7758F (3858-4138C) for 2 hours and cool in still air. Adhesion and quality of silver plate shall be determined on representative parts or test panels processed with the parts according to the requirements of AMS 2411 without performing any additional thermal treatments.
2 3 4
EFFECTIVITY: ALL
70-45-04
SILVER PLATING Page 2 Dec 01/03
MASKING AND CLEANING - MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS TASK 70-46-01-350-030 1. Masking and Cleaning of Epoxy and Polyester Matrix Thermosetting Composite Materials SUBTASK 70-46-01-99G-030 A. General. (1) Scope. (a) Procedure describes methods of masking and cleaning of commercial aircraft epoxy and polyester matrix composite parts prior to their entry into the composites shop, masking and cleaning of on-wing repair areas in preparation for carrying out repairs and wipe cleaning during repair and prior to bonding. This procedure also describes how to do a water break check. NOTE: If this document is used for the masking or cleaning of materials other than epoxy and polyester matrix thermosetting composite materials, the fitness for this purpose must be determined by the user. (b) The methods of masking and cleaning described in this document have specific limited application and are not interchangeable. The methods shall only be used when specified in a Honeywell approved manual, a Honeywell approved repair procedure or with the agreement of the regulatory authority.
(2)
Purpose. (a) The purpose of this Standard Practice is to provide a set of standard methods for masking and cleaning of thermosetting composite materials that may be referenced in repair documents. The methods in this document are the same as those in ARP 4916 in order to achieve industry wide standardization of composite repair techniques. It is intended that ARP 4916 be one of a number of ARPs that will cover other aspects of the techniques required to perform composite repairs. This will provide a suite of available repair techniques that are acceptable for use throughout the commercial aircraft industry. These ARPs will be put into the Standard Practices Manual as they become available and are approved. The only changes will be the addition of consumable numbers to the materials described in generic form in the ARPs. Because all the sections of the ARP have been incorporated into this Standard Practice some sections
(b)
(c)
MASKING AND CLEANING OF EPOXY AND POLYESTER MATRIX THERMOSETTING COMPOSITE MATERIALS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A are similar to Standard Practice Manual sections already in existence. These section are referenced. NOTE: When ARP 4916 is approved and published as a SAE Aerospace Recommended Practice, this Standard Practice will be revised to delete all the data found in SAE Specifications which is not normally included in Standard Practices. Only the Procedures will remain in the Standard Practices. (d) (3) This Standard Practice shall be used for composite materials only.
Applicable Documents. The following publications form a part of this Standard Practice to the extent specified herein. The latest issue of all SAE Technical Reports shall apply. (a) SAE Publications. Available from SAE. Refer to the List of Suppliers in Step D. of Subtask 70-8000-800-003.
AMS 1526 AMS 1528 AMS 1530 AMS 1532 AMS 3819 AIR 4844 (b) ASTM Publications.
Aircraft Exterior Surfaces, Water Miscible Pressure Spraying Aircraft Exterior Surfaces, Emulsion, Pressure Spraying Aircraft Exterior Surfaces, Wipe on, Wipe off, Water Miscible Aircraft Exterior Surfaces, Wipe on, Wipe off, Emulsion Type Cloths, Cleaning, For Aircraft Primary and Secondary Structural Surfaces. Composites and Metal Bonding Glossary.
Available from ASTM. Refer to the List of Suppliers in Step D. of Subtask 7080-00-800-003. ASTM D 56 ASTM D 329 ASTM D 740 ASTM D 1153 Standard Test Method for Flash Point by Tag Closed Tester. Standard Specification for Acetone. Standard Specification for Methyl Ethyl Ketone. Standard Specification for Methyl Isobutyl Ketone. (c) Military Publications. Available from DODSSP. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003.
O-A-51 O-T-62 TT-I-735A (d) PA-TR-4883 Other Publications.
Federal Specification, Acetone, Technical. Federal Specification, 1,1,1-Trichloroethane, Technical, Inhibited (Methyl Chloroform). Federal Specification, Isopropyl Alcohol.
Processing Handbook on Surface Preparation for Adhesive Bonding. Arthur H. Landrock, 1975. Feltman Research Laboratory, Materials Engineering Division. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800003. (e) Standard Practices Manual References. Water Types. S1025 Alkaline Cleaning Solutions S1142 Light Duty Alkaline Cleaner Turco 5948R S1143 Light Duty Alkaline Cleaner - Blue Gold Industrial Cleaner S1145 Light Duty Alkaline Cleaner Daraclean 282 Cleaning Method No.2 - Vapor Degreasing Cleaning Method No.3 - Steam Cleaning Cleaning Method No.14 - Manually Assisted Detergent Cleaning. Cleaning Method No.22 - Light Duty Aqueous Cleaning. Cleaning Urethane Coated Acoustic Panels.
TASK 70-00-05-800-006, Water Types TASK 70-00-99-801-025, Solution S1025 TASK 70-00-99-801-142, Solution S1142 TASK 70-00-99-801-143, Solution S1143 TASK 70-00-99-801-145, Solution S1145 TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning TASK 70-21-14-110-012, Cleaning Method No. 14 - Manually- Assisted Detergent Cleaning TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning TASK 70-22-04-110-016, Special Cleaning Procedure No. 4 - Cleaning Urethane-Coated Acoustic Panels SUBTASK 70-46-01-350-301 B.
Tools, Equipment, and Consumable Materials. (1) (2) General Environmental and Health Aspects of Cleaning. General guidelines are given regarding the relative hazards to the user and to the environment of the materials and equipment listed. However the user shall obtain the Material Safety Data Sheet (MSDS) from the supplier prior to using any of the materials. The relevant environmental health and safety organizations shall be
STANDARD PRACTICES MANUAL AS907-1-1A consulted regarding safe use, transportation and disposal of the cleaners and the waste solutions. (3) The intention of the descriptions in this section is to describe materials and equipment generically in sufficient detail to allow a suitable commercial product to be purchased. It is not intended that the information provided be biased to any particular manufacturer and no commercial product is recommended in preference to any other. Equipment (a) Personnal Protective Equipment (PPE). 1 Specific personal protective equipment required to handle a specific material safely should be outlined in the suppliers material and safety data sheet (MSDS). Material suppliers are also a good source of information in the safe use of their materials. Safe handling and use can also be determined by a qualified health and safety professional. The exposure routes most frequently encountered when working with cleaning materials are the skin, eyes and respiratory tract. Guidance is given below on the kinds of equipment that may be required and typical uses. Before using any type of safety equipment, training shall be given to ensure that the equipment is used safely and correctly. It should be noted also that PPE such as gloves, as well as protecting the person performing the repair, protects the repair from contamination. Contamination of the repair area can cause a poor quality repair which if not detected may be a hazard to the aircraft and its passengers and crew.
(4)
3 4
(b)
Exhaust system, local. 1 Local exhaust systems shall be capable of providing a good flow of fresh air to personnel using solvents in confined spaces. The system shall be air operated or use flameproof motors if it is to be used in areas where fuel or other flammable vapors may be present. A local exhaust system may be used as a method of providing a safe environment with solvent fume concentrations below the allowable limits in confined spaces where solvent vapors may accumulate.
(c)
Extraction/ventilation system for extracting and neutralizing vapors from steam cleaning. 1 Extraction systems for use with steam cleaners shall be capable of extracting vapors from the cleaner such that the levels of vapor are kept below the allowable limits for the cleaning vapor as defined on the material safety data sheet. If alkaline cleaners are used the condensate may require neutralizing prior to disposal. The exact disposal requirements shall be obtained from the cleaner supplier and the relevant regulatory authorities.
STANDARD PRACTICES MANUAL AS907-1-1A 2 Extraction systems shall be used for fixed steam cleaning facilities and any steam clean operation where allowable concentrations may be exceeded.
(d)
Eye wash. 1 The eye wash facility shall conform to the local standards and shall be capable of hands free operation to allow the user to hold the eyelids open while operating the eye wash. Eye wash facilities shall be used if eyes are exposed to cleaning materials or solvents.
2 (e)
Emergency showers. 1 2 The showers shall conform to the local standards and shall be capable of hands free operation. Emergency showers shall be used if skin is exposed to aggressive concentrated cleaning materials or in the event of burns or scalds from steam or hot water cleaning equipment.
(f)
Processing plant for neutralizing waste and used steam and water wash solutions and/or recycling cleaning solutions: 1 Processing plant for neutralizing waste from steam and water wash cleaners shall be capable of recycling or neutralizing waste solutions prior to disposal. The exact disposal and recycling requirements shall be obtained from the cleaner supplier and the relevant regulatory authorities. Systems shall be used for all steam cleaning and water washing facilities unless the cleaning material is approved for direct disposal by the appropriate regulatory authorities.
(g)
Protective clothing. 1 2 Protective clothing, gloves, shoes and face masks shall be capable of protecting against alkaline detergent, steam and water splashing. Protective clothing shall be worn whenever steam or water wash equipment is being used.
(h)
Face shield, safety. 1 2 The face shield shall fit on the head comfortably and still allow the wearing of other related safety equipment. A safety face shield shall be used when operating steam or hot water wash cleaning equipment and shall be used in addition to safety goggles.
(i)
Gloves, lint free cotton.
STANDARD PRACTICES MANUAL AS907-1-1A 1 2 The gloves shall allow full hand dexterity and shall not be coated with any material that may contaminate cleaned parts. Clean lint free cotton gloves shall be used whenever cleaned parts are being handled in order to prevent recontamination from oils or perspiration from the hands.
(j)
Gloves, disposable, neoprene or rubber. 1 2 These gloves are disposable and shall not have any lubrication materials or coating that may contaminate the parts being cleaned. The gloves shall be used to protect hands from cleaning materials including solvents during hand wiping operations and to protect the parts from re-contamination from oils or perspiration from the hands.
(k)
Goggles, chemical safety. 1 The safety goggles shall conform to the local standards for chemical splash and impact resistant goggles and shall have sides that fit snugly around the face. Safety goggles shall be used when handling solvents or concentrated cleaning materials and whenever called for by the material safety data sheet for the material being handled.
(l)
Respirator, chemical cartridge (with organic vapor cartridge). 1 These respirators can be disposable with the mask covering nose and mouth or of the permanent full face type. This type of respirator is not for use in atmospheres that are immediately dangerous to life and health. When it is not practical to provide a safe breathable air environment, the respirators may be used as a method of providing a safe environment for a limited time, when using solvents in confined spaces or when the allowable vapor concentrations may be temporarily exceeded. If large concentrations or exposure times are anticipated a supplied air respirator shall be used.
(m)
Respirator, supplied air, with a full face mask. 1 This type of respirator is of the pressure demand type and is capable of being used in atmospheres that are immediately dangerous to life and health. This type of respirators may be used as a method of providing a safe environment when using solvents in confined spaces or at any time when the allowable vapor concentrations may be exceeded. If anticipated allowable concentration exceedence is not large a chemical cartridge type respirator is more appropriate. The material safety data sheet and advice from the supplier will give guidance in the appropriate choice of respirator.
STANDARD PRACTICES MANUAL AS907-1-1A (n) Steam Cleaning Equipment. The steam cleaning equipment specified here includes special requirements and settings for steam cleaning of composite parts. Equipment for steam cleaning other parts is described in TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning. In most cases the same equipment may be adjusted so that it may be used on both types of part. All types of steam cleaning equipment shall be set up and used such that the temperature of the part being washed does not exceed 1228F (508C). 1 Steam cleaning equipment. a Safety equipment shall consist of eye wash, emergency showers and protective clothing, gloves, shoes, face masks and safety glasses to protect against alkaline detergent, steam and hot water splashing. Processing plant for neutralizing waste and used solutions. Efficient extraction/ventilation system for extracting and neutralizing vapors.
b c 2
Portable Steam Cleaning Equipment. a Portable steam cleaning equipment contains all the necessary steam cleaning equipment on a cart or trolley that can be wheeled to convenient locations. Some types require an external electric power supply others use power from an LP gas cylinder mounted on the trolley. The potential use of the equipment should be determined to decide the type and capacity of the equipment. All types should, however, have tanks for water and detergent solutions. They should contain a heat source to generate steam and controls for temperature and flow mixing, to supply steam at up to 90-100 psi (600-700 kPa) at a flow rate of 20-40 cu ft/hr (6001200 1/hr.). The operation of the equipment requires a source of power to generate the steam from the water contained within the equipment. Separate tanks of detergent solution are mixed with the steam by metering valve controls. The detergent solution is premixed in the tank to the desired concentration. The equipment produces either pure steam or a steam and solution mixture.
Fixed Steam Cleaning Equipment. a Fixed equipment makes use of existing plumbed in services and requires an external supply of water at 20 psi (140 kPa) minimum, and of steam at 40-150 psi (270-1040 kPa). Concentrated liquid detergent containers will be required. The equipment contains controls to mix the water, steam, and detergent in desired concentrations to regulate water temperature and cleaning action. The operation of fixed equipment mixes steam, cold water and detergent and delivers hot detergent solution combined with
STANDARD PRACTICES MANUAL AS907-1-1A vapor, under pressure through a spray gun, to the surface to be cleaned. Impingement is directly related to steam pressure. The concentrated detergent is mixed with incoming water by means of an injector and the concentration is controlled by orifice taps. The detergent supply line can be closed for hot water rinse without stopping flow of water and steam. (o) Hot water wash equipment. CAUTION: SOME TYPES OF HOT WATER WASH EQUIPMENT ARE "PRESSURE WASHERS" WITH PRESSURES FROM 250 -1000 PSI (17 - 70 BARS). THESE HIGH PRESSURE WASHERS SHALL NOT BE USED ON COMPOSITE COMPONENTS BECAUSE OF THE RISK OF DAMAGE TO THE COMPONENTS. CAUTION: HOT WATER WASHING EQUIPMENT COMES IN SEVERAL TYPES AND DEGREES OF SOPHISTICATION. EACH TYPE WILL BE DESCRIBED SEPARATELY. 1 Steam cleaning equipment used for hot water washing. a Many types of steam cleaning equipment both portable and fixed are also capable of hot water washing. All the same descriptions apply.
Hot water wash equipment. a This equipment may be portable like the portable steam cleaners or may be fixed and attached to the building domestic hot water supply. Pressures of 30 psi (2 bars) and maximum temperatures of 1608F (718C) are typical. Cleaning solution is drawn from a separate container through a mixing head. All types of hot water wash equipment shall be set up and used such that the temperature of the part being washed does not exceed 1228F (508C).
Manual hot water equipment. When components cannot be brought to a convenient washing area hot water washing can be performed manually with simple buckets of cleaning solution and rinse water however care should be taken to use the correct cleaning cloths C10-182.
(p)
Cold water wash equipment. 1 For cleaning solutions that do not require hot water, ambient temperature water can be used with all the types of wash equipment described for hot water washing above. High pressure washers shall not be used.
(q)
Vapor Degreasing Equipment. 1 Currently vapor degreasing is carried out with 1-1-1 Trichloroethane. As this chemical is an ozone depleter and due to be banned in most
STANDARD PRACTICES MANUAL AS907-1-1A countries by 1995, alternative cleaning methods and materials are being studied. The only application for vapor degreasing in composite repairs is the cleaning of repair plugs of aluminum honeycomb. The requirements of the equipment needed for this application are outlined below. However, it should be considered as a way of reviewing the suitability of existing equipment until alternative methods can be found, not as the initiation of a new procurement. 2 In order to vapor degrease honeycomb satisfactorily the cell walls should be as near vertical as possible to allow the condensate to run off the part. A maximum angle of 308 from the vertical is recommended. The basket shall be capable of supporting the honeycomb to prevent distortion during the cleaning cycle the degreaser should be of the type that condenses and recycles and should be fitted with covers to cover the tank at all times except during loading and unloading. Processing plant is required for recycling used solvents and an efficient ventilation system for extracting and condensing vapors. The safety equipment and devices required are an eye bath, emergency showers and protective clothing against hot solvents.
3 4 (5) Materials. (a)
Masking and Surface Protection Materials. Masking materials come in two basic types, film and pressure sensitive adhesive tape. Generally both are used in all the types of masking that is required to keep repair areas clean and to prevent moisture entering. Apart from the masking that is required as a temporary repair to hardware that is going to continue to fly, the most common and the most practical masking materials are those consumable materials designed for use when doing composite cures. Therefore films designed as bagging or release films are very suitable and will withstand the heat applied during the repairs cure cycle. When using release film, however, care should be taken to choose the non perforated versions for masking. 1 Films. The most common films available are polyethylene, polyester C10-142, Fluorinated Ethylene Propylene (FEP), C10-133 and nylon C10-137. All films used in masking shall be new and clean and have been stored such that no condensation can form on the film. a Polyethylene film. Care should be taken if polyethylene film is to be used as a masking material as it will soften or melt if the part is subjected to heat during curing or steam cleaning. Rolls of polyethylene film used in a shop environment for protection from dust and paint do not always have the same level of cleanliness as films used for composite curing. Clean polyethylene bags are readily available in a range of sizes and are useful for storing cleaned parts until they are needed in the repair.
STANDARD PRACTICES MANUAL AS907-1-1A b Polyvinyl chloride (PVC) film (vinyl film). The same cautionary notes apply to this film as to polyethylene film above with the additional concern that plasticisers used to improve the films flexibility can migrate and cause contamination of bond lines, particularly if the film becomes warm. It is therefore not recommended for masking. c Polyester film C10-142. Polyester is the stiffest of the commonly available films and this should be taken into consideration when using this as a masking material. It has suitable temperature resistance for all types of epoxy cures. d Nylon film C10-137. Nylon films are commonly used for making vacuum bags and so are highly suitable for masking though again may be quite stiff. Like PVC film these may also be subject to plasticiser migration if they are not used in a controlled environment. e Fluorinated Perfluorethylene Propylene (FEP) film, C10-133. FEP films are used as release films for all types of epoxy cure and are light weight and easily conformable for masking. As both polyester and FEP films are commonly available in perforated form, care should be taken to select the non perforated type. 2 Tapes. Tapes are used in all types of masking situations. Below is a description of different types of tape and the uses to which they are commonly put. All tapes used in masking shall be new and clean and have been stored such that no condensation can form on the tape. a Pressure sensitive adhesive tape. Pressure sensitive adhesive tape, commonly known as flashbreaker tape, is used to hold down the edges of the film used for masking and can be obtained in heavier weights to provide a neat edge where resin may flow over the edge requiring the tape to break a thin layer of adhesive. The base of the tape may be polyester C10-136, nylon or polytetrafluorethylene (PTFE) C10040 and the adhesive may be a rubber base or a fully cured silicone. These types of tape can be used for any type of masking with the exception of the temporary flight repair. They are all capable of withstanding epoxy cure temperatures. Tapes with silicones that are not fully cured shall not be used due to the risk of contamination from unreacted silicones. If there is any doubt about a silicone adhesive a test should be performed to check for residual contamination and effect on bond strength if these tapes are to be used directly on the bond surface. The test should consist of two sets of applicable bond test pieces processed identically with the exception that one has previously had the tape adhered to it for the envisioned time and temperature and then removed prior to bonding.
STANDARD PRACTICES MANUAL AS907-1-1A b Metal foil tape. This family of tapes usually consists of aluminum or stainless steel foil tape and is often referred to as speed tape. It consists of a ductile metal foil with a pressure sensitive adhesive that is strong enough to resist the peel forces of the airflow when it is used as a temporary flight repair. This type of tape shall be used to mask damages to parts that are to continue in flight service to prevent moisture from entering the damage area prior to a repair being implemented. They may also be used if the part is to stand outside for a significant period of time prior to being brought into controlled conditions for repair. 3 Masking materials that should not be used. There are a large number of materials that may appear suitable for masking. However most can, under some circumstances, cause problems. Some of the more common ones are listed below. a Used materials. Although it may seem to be a cost saving to re-use masking materials the risk of contamination is such that they should be avoided if at all possible. An expensive repair may have to be repeated because of a small cost "saved". b Paper based materials. Although in the past unwaxed Kraft paper and paper masking tape have been used in masking composite repairs they are not recommended due to their flammability when used in an oven or autoclave or with any form of hot cure. Also their absorbency can lead to moisture and oils being absorbed unnoticed. c Domestic or office supplies. Tapes and films used in homes and offices often will not withstand the temperature of a hot cure and many of the adhesives used on the tapes can cause contamination and a poor bond when they are used as a maskant on a composite repair. Also some products are dissolved by the solvents commonly used for cleaning. WARNING: IN ALL COUNTRIES THE LOCAL REGULATIONS SHALL BE CHECKED BEFORE USING ANY CHEMICAL. YOUR COMPANY REGULATIONS AND HEALTH AND SAFETY EXPERTS SHALL ALSO BE CONSULTED.
(b)
Cleaning Agents. In the following table typical examples are given of the allowable concentrations of the solvents described in the following sections, as stipulated by the Occupational Safety and Health Administration (OSHA) of the U.S.A. and by Dutch Government requirements. This information is correct at the time of writing and is for guidance only to the relative hazard of the materials.
Table 1. Allowable Solvent Concentrations Solvent M.E.K. M.I.B.K. Acetone 1-1-1 Trichloroethane Isopropyl Alcohol OSHA Time Weighted Average (ppm) 200 50 750 750 400 Dutch Government Time Weighted Average (ppm) 200 25 750 200 400
NOTE: The OSHA values are permissible exposure levels (PEL) based on an 8 hour time weighted average. In most cases higher levels are permissible for durations up to 15 minutes. The MSDS sheet will give guidance. NOTE: All the flash points quoted are closed cup to ASTM D 56.
Methyl Ethyl Ketone (M.E.K.), C04-001. Methyl Ethyl Ketone is a commonly used wipe solvent today. It is also used as a diluent in some sprayable epoxy adhesives and primers. Efforts are being made to replace it as a cleaner due to its rating of "serious flammability," with a flash point of 208F (-78C) and some evidence of toxicity in animals. For typical allowable concentration in air, see Table 1, Page 12. Methyl Ethyl Ketone may be procured to ASTM D 740.
Methyl Isobutyl Ketone (M.I.B.K.), C04-170. Methyl Isobutyl Ketone is a less commonly used solvent similar to M.E.K. but with a higher flash point of 648F (188C) and a lower evaporation rate. For typical allowable concentration in air, see Table 1, Page 12. Methyl Isobutyl Ketone may be procured to ASTM D 1153.
Acetone, C04-003. Acetone is a commonly used wipe solvent today. Efforts are being made to replace it as a cleaner due to its rating of serious flammability, with a flash point of -48F (-208C) and its very high evaporation rate. For typical allowable concentration in air, see Table 1, Page 12. Acetone may be procured to O-A-51H or ASTM D 329.
1-1-1 Trichloroethane, C04-030. 1-1-1 Trichloroethane also known as methyl chloroform is a commonly used wipe and vapor degreasing solvent today. It is also used as a diluent in some sprayable adhesives. As it is an ozone depleter this chemical will be prohibited in most countries by 1995. Over exposure can cause liver and kidney damage. For typical allowable
STANDARD PRACTICES MANUAL AS907-1-1A concentration in air, see Table 1, Page 12. 1-1-1 Trichloroethane may be procured to O-T-620C. 5 Isopropyl Alcohol (IPA), C04-035. Isopropyl Alcohol or Isopropanol is a wipe solvent used as a less hazardous replacement for MEK, Acetone or 1-1-1 Trichloroethane. It is rated as flammable with a flash point of 538F (11.78C) and is toxic by inhalation and ingestion. For typical allowable concentration in air, see Table 1, Page 12. Its slow evaporation rate can increase the time required to clean with it. Isopropyl Alcohol may be procured to TT-I735A 6 Citrus based cleaners. a This is a group of cleaners that are based on the chemical dlimonene. Typically they do not contain any hazardous ingredients as defined by OSHA and are considered non toxic. They have flash points in the range 1308 - 1408F (548 - 608C) so are considered combustible liquids and unused liquid is considered ignitable for disposal although some may be diluted in water to raise the flash point prior to disposal. Initial evaluation has shown this group to be very effective cleaners with the solvent dissolving organic contaminants and the water dissolving salts. Some cleaners may leave a residue particularly if used in concentrated form and not given a subsequent water rinse. They are not easily recyclable but provide easy disposal provided the contaminant that is removed is not hazardous. Although some evaluation work has been carried out, these cleaners are not currently recommended for cleaning immediately prior to adhesive bonding.
Emulsion type cleaners. a This is a group of cleaners that contain a combination of emulsifiers and surfactants. The surfactants lift the oil off the surface to form a weak emulsion. Many contain some chemicals, usually glycol ethers or propylene glycol, which may have special waste disposal requirements. Initial evaluation has shown this group to be effective on light oil types of contamination. Some may leave surfactant residues. This group can be recycled by separation and ultra filtration to remove oil type contaminants. Although some evaluation work has been carried out these cleaners are not currently recommended for cleaning immediately prior to adhesive bonding. Cleaners conforming to AMS 1528 should be specified when using emulsion cleaners with pressure spray equipment
STANDARD PRACTICES MANUAL AS907-1-1A d Cleaners conforming to AMS 1532 should be specified when using emulsion cleaners for hot or cold water, hand wipe cleaning.
Alkaline detergent cleaners. a This group of cleaners contains an aqueous solution of alkaline salts that form a stable emulsion with oil type contaminants. It is not easy to separate the contaminants for recycling and they are generally used until saturated and then disposed of as hazardous waste.Particular care should be taken in the use of this type of cleaner on parts with aluminum core or fittings, as residues of alkaline cleaners will cause corrosion of the aluminum. Although some evaluation work has been carried out, these cleaners are not currently recommended for cleaning immediately prior to adhesive bonding. Cleaners conforming to AMS 1526 C04-152 or C04-168 should be specified when using water miscible detergent cleaners with pressure spray equipment Cleaners conforming to AMS 1530 C04-152 or C04-164 should be specified when using water miscible detergent cleaners for hot or cold water hand wipe cleaning.
(c)
Wipe Cleaning Cloths. The choice of cloths used in wipe cleaning, especially that prior to bonding, is very important to the strength of the resulting repair. Cloths should be chosen with care and contaminated cloths shall be disposed of in an approved manner. Cloths soaked in solvent may be considered hazardous waste. 1 AMS 3819 cleaning cloths, C10-182. a Cloths conforming to AMS 3819 are designed for wipe cleaning prior to bonding and are designed to be lint free and resistant to solvents. Cloth to this specification is highly recommended. Type 1 or type 2 cloths may be used. Grade A is good for all uses including final wipe cleaning operations before bonding or drying cleaned parts after water break test. Grade B may be used for most cleaning operations however grade A is recommended for final wiping prior to bonding.
Other cleaning cloths. a b If cloths to AMS 3819 are not available clean, white, lint-free cotton cloths should be used for wipe cleaning operations. As the repair area will be cleaned again prior to carrying out the repair, cloths used to assist in steam or water wash operations may be of a lesser quality. Care should be taken, however, to avoid any cloth that may contain abrasive materials which may
STANDARD PRACTICES MANUAL AS907-1-1A scratch surrounding painted surfaces. For this reason cotton waste or torn up clothing items should be avoided. 3 Cotton swabs. a For cleaning small inaccessible places, cotton swabs are useful. Take care to use a type that is not impregnated with oils or creams such as lanolin as this will contaminate the part. The stick that holds the cotton shall be made of a material that is not dissolved or softened by the solvent being used. Wood sticks are resistant to the solvents specified. Other types shall be checked by immersing the whole swab in the solvent for at least 24 hours and checking for signs of softening when compared with a swab that has not been immersed. An AMS 3819 cleaning cloth may be wrapped over the rounded end of a clean bare wooden stick as a substitute for the use of cotton swabs.
Cleaning brushes a Brushes used for removing dirt from parts that are being steam or water wash cleaned may be natural bristle C10-108 or have bristles made from nylon or polypropylene fibers. Brushes with any kind of metal bristles (wire brushes) shall not be used.
(d)
Water Types. For more information on water types see TASK 70-00-05-800-006, Water Types. 1 Water used in cleaning operations. a For cleaning operations covered in this Standard Practice, the normal water supply is perfectly suitable. If locally captured rain or well water is to be used or if the quality of the water supply is doubtful the water shall be filtered to remove any particles that might contaminate the cleaning solution.
Water for water break testing. a When carrying out water break tests, use de-ionized or distilled water in order to ensure a controlled surface tension and to prevent contamination of the bonding surface.
(e) Code No. C04-001 C04-003 C04-030
Consumable Materials. Description Solvent, Methyl-Ethyl Ketone (MEK) Solvent, Acetone Trichloroethane, 1,1,1 Use Cleaning Cleaning Cleaning
Code No. C04-035 C04-152 C04-164 C04-168 C04-170 C10-040 C10-108 C10-133 C10-136 C10-137 C10-108 C10-133 C10-136 C10-137 C10-139 C10-142 C10-182 Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase SUBTASK 70-46-01-350-302 C.
Description Isopropyl alcohol Turco 5948R Blue Gold Daraclean 282 Methyl Isobutyl Ketone (MIBK) Tape, Teflon 3M Scotch Brand 5490 Disposable Brush A4000 FEP Film, unperforated Airtech international. Tape, Flashbreaker No.855 0.002 inch thk. - 3M Bagging Film, Wrightlon 6400 Disposable Brush A4000 FEP Film, unperforated Airtech international Tape, Flashbreaker No.855 0.002 inch thk. - 3M Bagging Film, Wrightlon 6400 Gloves, White Cotton, Disposable Polyester (Mylar) film 0.0020.004 inch thick Cleaning Cloth Gloves, lint free cotton Gloves, disposable, neoprene or rubber Goggles, chemical safety Respirator, chemical cartridge (with organic vapor cartridge) Respirator, supplied air, with a full face mask Cotton swabs Cleaning brushes
Use Cleaning Steam clean Cleaning Cleaning Cleaning Holding film to part Cleaning Masking and Protection of clean surfaces Masking Vacuum bag film Cleaning Masking and Protection of clean surfaces Masking Vacuum bag film Handling part during installation Masking and protection of clean surfaces Cleaning
Composite Masking Methods. (1) Masking General.

STANDARD PRACTICES MANUAL AS907-1-1A (a) The following sections describe methods of masking parts at various stages of the repair process. The methods are prefaced with the words Composite Masking Method No.1, etc., so that they can be more easily referred to and will not be effected by renumbering of the sections of the document at future revisions. Method numbers will be controlled and if deleted will not be reassigned. The methods are not interchangeable and shall only be used when specified in an approved repair procedure or with the agreement of the Original Equipment Manufacturer (OEM) or regulatory authority. For complete descriptions of the materials and equipment referenced, refer to SUBTASK 70-46-01-350-301, Tools, Equipment, and Consumable Materials.
(b)
(c)
NOTE: Composite masking method No. 1 moisture prevention during continued service. (2) Composite Masking Method No. 1 The procedure that follows is not interchangeable with the other methods. It is used to prevent dirt and moisture entering the damage during temporary continued service. NOTE: This Method would not normally be incorporated into the Standards Practice Manual. As soon as SAE Aerospace Recommended Practice ARP 4916 is fully approved and published this Method will be deleted from the Standard Practices Manual. (a) General. 1 This masking is a method of temporarily covering the damage to prevent moisture from entering the repair area and for restoring the aerodynamic smoothness prior to the part being scheduled for permanent repair. The fitness for continued service must be determined based on the OEM allowable damage size or the approval of the appropriate regulatory authority. The tape does not impart any significant strength or stiffness to the part and damages covered in this way shall be permanently repaired as soon as possible. The strong adhesion of this type of tape makes it difficult to remove, compared to the kind of masking that is carried out for non flight applications and care must be taken to prevent further damage when it is removed. Of all methods of temporary covering or repair this restores the least strength to the part. Despite the comments above this tape is easier to remove and does less secondary damage than any other method of temporary repair. Metal foil tape shall not be used on the radome area or any other structure area that requires Radio Frequency (RF) microwave transparency. Compatibility of metal foil tape should be checked on areas that require electrical insulation for other reasons.
3 4
STANDARD PRACTICES MANUAL AS907-1-1A 5 If the tape is covering an open hole such that there is air trapped behind it, for example in sealing off a sandwich panel that has had a skin puncture, the differential pressure at altitude can cause the tape patch to rupture. For this reason it is recommended that in these instances only, a small pinhole is put through the foil tape to equalize the pressure. The hole should be positioned with care and be small to minimize the entry of water or dirt.
(b)
Composite Masking Method No.1 - Moisture Prevention during temporary Service procedure. CAUTION: THIS MASKING OPERATION DOES NOT RESTORE THE STRENGTH OR STIFFNESS OF THE PART. IT MAY RESTORE AERODYNAMIC SMOOTHNESS. MAKE SURE THAT IT IS ALLOWED TO FLY WITH THIS MASKED DAMAGE. 1 2 3 4 Use a dry cloth C10-182. Remove all the water you can see and as much dirt as you can from around the repair area. Use Composite Cleaning Method 4 or 5 of this Standard Practice to clean where the tape will be put. Get a roll of aluminum or stainless steel foil tape. Cut a piece of tape that will make an overlap of the damage area of 1 inch (25 mm) minimum. Cut the corners to a 0.25 inch (6 mm) radius. See Figure 1, Page 23. Apply the tape across the repair area. If the area is too large to be covered by one piece of tape. a b c 7 Apply pieces of tape in equal lengths starting at one side of the repair. Make an overlap of 0.5 inch (12 mm) with each piece of tape. Put one piece of tape across each end of the overlapped pieces. See Figure 1, Page 23.
5 6
Rub the surface of the tape firmly with your fingers or a soft plastic spatula. Push any air bubbles to the edge of the tape. Make sure all the edges are firmly pushed down. If you have covered a hole with air inside it, for example if you covered a hole in the skin of a honeycomb sandwich laminate, put a small hole in the tape 0.020 - 0.040 inches (0.5 - 1.0 mm) diameter.
(c)
Tape Removal. 1 To remove the tape before you do a permanent repair.
STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: TAKE CARE NOT TO MAKE THE DAMAGE BIGGER BY REMOVING PLIES FROM THE LAMINATE WHEN YOU PULL THE TAPE BACK. a b c 2 (3) Lift one corner and pull back on the tape, Figure 2, Page 24. Pull back all the edges around the outside. Pull towards the center of the damage area.
To remove any remaining adhesive use Composite cleaning method 4 or 5 of this Standard Practice.
Composite Masking Method No. 2. The procedure that follows is not interchangeable with the other methods. It is used to prevent dirt and moisture entering the damage during storage, washing, or cleaning of the part. NOTE: If Masking Method 1 has been carried out, that masking may remain on the part instead of being replaced by masking to this method. Check that the existing masking is not damaged and seal any small holes with tape. (a) General. 1 When masking prior to steam or hot water wash cleaning, the thicker grades of nylon or polyester film provide the best protection against accidental hose spray. This type of masking is also useful to prevent dirt and rain entering the damage area while the part is being transported between buildings. If the part is to spend a significant period of time outdoors or is to travel in bad weather, Masking Method 1 should be considered.
(b)
Composite Masking Method No.2 - Moisture Prevention During Storage, Washing, or Cleaning procedure. 1 2 3 4 5 6 Use a dry cloth C10-182. Remove all the water you can see and as much dirt as you can from around the repair area. Measure the size and shape of the damage area. Cut a piece of film C10-133, C10-137, or C10-142 at least 2.0 in. (51 mm) larger on each side than the damage area. Make the film smooth over the damage area. Hold the film at each corner with small pieces of tape C10-040 or C10136. Put tape along all the edges of the film. If the film is folded, hold the folds down with a piece of tape. Make sure that the tape around the edge covers the film edge at the fold. See Figure 3, Page 25.
STANDARD PRACTICES MANUAL AS907-1-1A 7 Rub the surface of the tape firmly with your fingers. Push any air bubbles to the edge of the tape. Make sure all edges are firmly pushed down. Make sure all the edges are held down with tape so that no water can go in the damage area. NOTE: Composite masking method No. 3 masking an uncleaned part to prevent contamination from uncleaned areas and to prevent resin spills. NOTE: COMPOSITE MASKING METHOD NO. 2 MOISTURE PREVENTION DURING STORAGE, WASHING, OR CLEANING (4) Composite Masking Method No. 3. This procedure gives instructions for masking around the damage on an uncleaned part to prevent contamination from uncleaned areas and to prevent resin spills. (a) General 1 This masking may be done for several different reasons. It may be that the part is large, or is still located on wing so that overall cleaning is not practical and the dirty area requires masking to prevent cross contamination. Also if a wet lay up repair is being performed or liquid or paste adhesives are used the remainder of the part will need to be protected from spills and drips. It is necessary to estimate the size of the largest repair patch or ply that will be put on the outside so that the masking does not interfere with the accomplishment of the repair. If the masking proves to be too small it is a simple matter to increase the size. How firmly the outer edge of the material needs to be held down depends on where the repair is performed. If the repair is being done outside and if there is a possibility of the wind blowing the film off, more secure fixing will be required.
(b)
Composite Masking Method No.3 - Masking an Uncleaned Part to Prevent Contamination from uncleaned areas and to Prevent Resin Spills procedure. 1 2 3 4 Use a dry cloth C10-182. Remove all the water you can see and as much dirt as you can from around the repair area. Use Composite cleaning method 4 or 5 to clean where the film and tape will be put. Measure the size and shape of the damage area. Cut pieces of film C10-133, C10-137 or C10-142 to fit around the repair area for at least 24 inches (610 mm) larger on each side than the damage area. Do not put film on the damage area so that you can do the repair. Make the inside edge 1.0 in. (25 mm) larger than the outside edge of the estimated repair area.
STANDARD PRACTICES MANUAL AS907-1-1A 5 6 7 Make the film smooth over the area around the damage. Hold the film at each corner with small pieces of tape C10-040 or C10136. Put tape along all the edges of the film next to the repair area. If the film is folded, hold the folds down with a piece of tape. Make sure that the tape around the edge covers the film edge at the fold. See Figure 4, Page 26. Put tape on the outer edges of the film at equal distances as necessary to hold it in position. If the repair is in an open area, put tape along all the edges of the film. Rub the surface of the tape firmly with your fingers. Push any air bubbles to the edge of the tape. Make sure all edges are firmly pushed down. Make sure all the edges are held down with tape. NOTE: COMPOSITE MASKING METHOD NO. 4 MASKING A PREPARED REPAIR AREA WHEN IT IS NOT BEING WORKED ON (5) Composite Masking Method No. 4 This procedure gives instructions for masking of the prepared repair area when it is not being worked on. (a) General. 1 This masking is for shop or outdoor use and is to prevent airborne contamination from people working in adjacent areas and general atmospheric contamination. It also helps to prevent people from touching a prepared surface. This masking may be applied over the masking applied using Masking Method 3. In this case the tape should be attached to the existing masking.
10
(b)
Composite Masking Method No.4 - Masking A Prepared Repair Area When it is Not Being Worked. 1 2 Cut a piece of film C10-133, C10-137, or C10-142 approximately 6.0 in. (150 mm) bigger all around than the exposed repair area. Put the film over the repair and hold it in place with pieces of tape C10040 or C10-136. Put the tape at equal distances as necessary to hold it in position. If the repair is out in an open area where wind, rain or dust could fall on it, put tape along all the edges of the film. If the film is folded, hold the folds down with a piece of tape. Make sure that the tape around the edge covers the film edge at the fold. NOTE: COMPOSITE MASKING METHOD NO. 5 MASKING TO PREVENT EXCESS RESIN ON PART DURING CURE
STANDARD PRACTICES MANUAL AS907-1-1A (6) Composite Masking Method No. 5. This procedure gives instructions for masking to prevent excess resin being pushed onto the part during cure. (a) General. 1 If a lot of flash is expected a heavy duty flashbreaker tape should be used to prevent the tape being trapped under the repair adhesive. When bonding small details, all the non bonding surfaces of the detail should be covered in tape.
(b)
Composite Masking Method No.5 - Masking to Prevent Excess Resin on Part During Cure procedure. 1 2 Make a decision where the resin or adhesive edge must be. Make an allowance for an adhesive fillet when making overlap joints. Apply pieces of tape C10-040 or C10-136 along the edge to cover the part up to the surrounding masking.
Masking a Damaged Area for Temporary Continued Service Figure 1
Removal or Masking from Damaged Area Figure 2
Masking a Damaged Area to Protect Against Moisture Figure 3
Masking Around the Damaged Area Figure 4
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-46-01-350-303 D. Composite Cleaning Methods. (1) Composite Cleaning General. (a) The following sections describe methods of cleaning parts at various stages of the repair process. The methods are prefaced with the words Composite Cleaning Method 1, etc., so that they can be more easily referred to and will not be effected by renumbering of the sections of the document at future revisions. Method numbers will be controlled and if deleted will not be reassigned. The methods are not interchangeable and shall only be used when specified in an approved repair procedure or with the agreement of the OEM or regulatory authority. For complete descriptions of the materials and equipment referenced, refer to SUBTASK 70-46-01-350-301, Tools, Equipment, and Consumable Materials. NOTE: COMPOSITE CLEANING METHOD NO. 1 STEAM CLEANING (2) Composite Cleaning Method No. 1. CAUTION: DO NOT USE THIS METHOD ON PARTS THAT CONTAIN HONEYCOMB UNLESS THE FACESHEET OF THE HONEYCOMB AREA HAS HOLES IN IT TO ALLOW THE WATER TO COME OUT AND THE HONEYCOMB IS NOT MADE FROM ALUMINUM. (a) General. This procedure gives the instructions for steam cleaning of composites. NOTE: For the cleaning of composite acoustic panels use TASK 70-22-04110-016, Special Cleaning Procedure No. 4 - Cleaning UrethaneCoated Acoustic Panels. For the steam cleaning of parts other than composite parts, use TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning. 1 Steam cleaning combines the mechanical force of the spray jet with the chemical and physical action of the hot cleaning solution to remove oils, greases, and light soil from parts. When setting up a steam cleaning operation to clean composites, do some trials on a part with thermocouples attached and record the temperature achieved. The temperature of the part should not exceed 1228F (508C). This method may be used for the cleaning of single skin composite components and sandwich panels with acoustically treated areas provided that the acoustic areas have perforated face sheets and are not covered with a wire mesh screen. This method is not recommended for the sandwich construction panels without perforated skins or adequate drainage paths where water may enter through the damage
(b)
(c)
STANDARD PRACTICES MANUAL AS907-1-1A area or through porosity in thin skins and spread along at core to skin disbands where it is almost impossible to remove. Particular care should be taken in the use of this cleaning method with parts with aluminum core or fittings, as residues of alkaline cleaners will cause corrosion of the aluminum. 4 The advantages of this method are its speed for the cleaning of large parts and its combination of physical and detergent cleaning action. The disadvantages are that the steam pressure and temperature must be carefully controlled in order to avoid damage to the composite and that drying is required after cleaning. Care is required to ensure that there are no residual chemical deposits after drying. This method is only suitable for initial part cleaning and should not be used for cleaning of areas prepared for bonding.
5 (b)
Composite Cleaning Method No.1 - Steam Cleaning Procedure. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHALL WEAR GOGGLES, FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
Prepare the solution in the solution tank to TASK 70-00-99-801-025, Solution S1025. WHEN USING THE SPRAY GUN, WEAR GOGGLES, FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
WARNING:
Adjust the water, steam, solution and temperature controls to the required setting to get a wet spray and a temperature of 1608-2208F (708-1058C). Hold the spray gun approximately 10.0-12.0 in. (250-300 mm) from surface and inclined at about 45 degrees to the surface. Move the spray head over the surface until the part is clean. The temperature of the part must not become greater than 1228F (508C). If you are not sure what the temperature will be, do a test before you clean the part. You may use a stiff bristle brush C10-108 to remove dirt that can not be removed with the spray. Rinse the parts with hot water using the spray gun with the cleaning solution supply shut off. Dry the part with cloths C10-182 to remove all the moisture that you can see.
4 5 6
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG (207 KPA). WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT YOURSELF OR OTHERS.
7 8
Use clean, dry, compressed air that does not contain oil to remove any moisture that remains in areas that are difficult to get access to. Make sure that the part is clean. Look for remaining dirt trapped in holes and areas that are difficult to get access to. If the part is not clean repeat steps 2 to 8. Determine if further drying is required. NOTE: Composite cleaning method No. 2 hot or cold water wash pressure spray cleaning.
(3)
Composite Cleaning Method No. 2. This procedure gives instructions for hot or cold water wash pressure spray cleaning. NOTE: For the cleaning of parts other than composite parts using a similar technique use TASK 70-21-22-110-042, Cleaning Method No. 22 - Light Duty Aqueous Cleaning. (a) General. 1 All the same general points that apply to steam cleaning apply to this method, see Method 1 paragraph (1). Hot water washing does however subject the parts to lower temperatures during cleaning and water vapor is less likely to permeate the part.
(b)
Composite Cleaning Method No. 2 - Hot or Cold Water Wash Pressure Spray Cleaning procedure.
STANDARD PRACTICES MANUAL AS907-1-1A WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHALL WEAR GOGGLES, FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
CAUTION: DO NOT USE THIS METHOD ON PARTS THAT CONTAIN HONEYCOMB UNLESS THE FACESHEET OF THE HONEYCOMB AREA HAS HOLES THAT ARE NOT COVERED WITH SCREEN SO THAT THE WATER CAN COME OUT CAUTION: IF AN ALKALINE CLEANER IS BEING USED DO NOT USE THIS METHOD ON PARTS THAT CONTAIN ALUMINUM HONEYCOMB AND RINSE THOROUGHLY ANY FITTINGS THAT ARE MADE OF ALUMINUM. 1 Prepare Turco 5948R C04-152 in the solution tank to TASK 70-00-99801-142, Solution Sheets, Solution Sheet S1142. Alternatively, prepare Daraclean 282 C04-168 in the solution tank to TASK 70-00-99-801-145, Solution Sheets, Solution Sheet S1145. WHEN USING THE SPRAY GUN, WEAR GOGGLES, FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
WARNING:
Adjust the water, solution and temperature controls to the required setting to get a constant, water and solution, mixed spray at a temperature of 1608-1808F (708-828C) for the Turco 5948R C04-152 or 1208-1408F (498-608C) for the Daraclean 282 C04-168. Hold the spray gun approximately 10.0-12.0 in. (250-300 mm) from surface and inclined at about 45 degrees to the surface. Move the spray head over the surface until the part is clean. The temperature of the part must not become greater than 1228F (508C). If you are not sure what the temperature will be, do a test before you clean the part. You may use a stiff bristle brush to remove dirt that can not be removed with the spray. Rinse the parts with water using the spray gun with the cleaning solution supply shut off. Dry the part with cloths C10-182 to remove all the moisture that you can see. WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG (207 KPA). WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT YOURSELF OR OTHERS.
4 5 6
WARNING:
Use clean, dry, compressed air that does not contain oil to remove any moisture that remains in areas that are difficult to get access to.
STANDARD PRACTICES MANUAL AS907-1-1A 8 Make sure that the part is clean. Look for remaining dirt trapped in holes and areas that are difficult to get access to. If the part is not clean repeat steps 4 to 6. Determine if further drying is required. NOTE: Composite cleaning method No. 3 hot or cold water hand wash cleaning. (4) Composite Cleaning Method No. 3. This procedure gives instructions for hot or cold water hand wash cleaning. NOTE: For the cleaning of parts other than composite parts using a similar technique use TASK 70-21-14-110-012, Cleaning Method No. 14 Manually-Assisted Detergent Cleaning. (a) General. 1 Water hand wash cleaning combines hand rubbing with the chemical and physical action of the cleaning solution to remove oils, greases, and light soil from parts. This method may be used for the cleaning of single skin composite components and sandwich panels with or without acoustically treated areas. Care should be taken not to apply more water than is necessary to clean and rinse the part especially with thin skinned honeycomb sandwich structures or where porosity is suspected. Particular care should be taken with parts with aluminum core or fittings, as residues of alkaline cleaners could cause corrosion of the aluminum. The advantage of this method is its flexibility in that it can be performed with a minimum of equipment. The disadvantages are that it is labor intensive and is very reliant on the diligence of the operator to obtain good results. Care is required to ensure that there are no residual chemical deposits after drying. This method is only suitable for initial part cleaning and should not be used for cleaning of prepared areas.
4 (b)
Composite Cleaning Method No. 3 - Hot or Cold Water Hand Wash Cleaning procedure. WARNING: ALKALINE SOLUTIONS ARE VERY ACTIVE AND CAUSE SERIOUS BURNS. AVOID CONTACT WITH SKIN, EYES, AND CLOTHING. IF CONTACT OCCURS, WASH IMMEDIATELY WITH ABUNDANT QUANTITY OF WATER. AVOID BREATHING VAPORS. OPERATOR SHALL WEAR GOGGLES, FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
Prepare Turco 5948R C04-152 in a polypropylene bucket to TASK 7000-99-801-142, Solution Sheets, Solution Sheet S1142 at a temperature of 1608-1808F (708-828C). Alternatively prepare Blue-Gold C04-164 in a polypropylene bucket to TASK 70-00-99-801-143, Solution Sheets,
STANDARD PRACTICES MANUAL AS907-1-1A Solution Sheet S1143 at a temperature of 1308-1508F (548-668C). Prepare a bucket of water at the same temperature as the diluted solution. WARNING: WHEN HAND WASHING, WEAR GOGGLES, FACE SHIELD, GLOVES, PROTECTIVE CLOTHING AND PROTECTIVE SHOES.
CAUTION: DO NOT IMMERSE THE PART IN THE WATER. DO NOT POUR WATER ONTO THE PART OR INTO CAVITIES IN THE PART. 2 Make a cloth C10-182 moist with the solution. Use the cloth to put the solution on the surface to remove the dirt and oil until the part is clean. NOTE: A stiff bristle brush may be used to remove dirt that can not be removed with the cloth. 3 Make a clean cloth C10-182 moist with water and wipe over the surface to rinse the part. Take care not to put more water on the part than is necessary to remove the cleaning solution. Dry the part with cloths C10-182 to remove all the moisture that you can see. WHEN USING COMPRESSED AIR FOR CLEANING, COOLING, OR DRYING, DO NOT EXCEED 30 PSIG (207 KPA). WEAR EYE PROTECTION AND DO NOT DIRECT COMPRESSED AIR AT SELF OR OTHERS.
WARNING:
5 6
Use clean, dry, compressed air that does not contain oil to remove any moisture that remains in areas that get access to. Make sure that the part is clean. Look for remaining dirt trapped in holes and areas that are difficult to get access to. If the part is not clean repeat steps 2 to 5. NOTE: COMPOSITE CLEANING METHOD NO. 4 WIPE CLEANING USING COMMERCIAL SOLVENT - ONE CLOTH METHOD
(5)
Composite Cleaning Method No. 4. This procedure gives instructions for wipe cleaning with a commercial solvent one cloth method. (a) General. 1 2 This method of cleaning is most commonly used in small local areas and for degreasing composite parts immediately prior to bonding. The advantages of this method are that it can be carried out easily with no special equipment and has been widely used and shown to provide a reliable method of degreasing prior to bonding. No water is introduced onto the part surface so no further drying is required although care should be taken to ensure that all the solvent has had time to evaporate from the wiped surface.
STANDARD PRACTICES MANUAL AS907-1-1A 3 The disadvantages of the method are that the solvents used are toxic and often highly flammable, some also contribute to the CFC emissions. The high volatility of some of the solvents can cause the solvent to evaporate prior to the next wipe so that the grease is spread over the surface instead of being lifted from it.
(b)
Composite Cleaning Method No.4 - Wipe cleaning with a commercial solvent - One cloth method procedure. 1 Get some cloths C10-182. SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE. USE ONLY WITH ADEQUATE VENTILATION AND AVOID EYE CONTACT OR REPEATED OR PROLONGED CONTACT WITH THE SKIN.
WARNING:
2 3 4 5 6 7 8 9
Get MEK C04-001, MIBK C04-170 acetone C04-003, or isopropyl alcohol C04-035. Put solvent on cloth C10-182 to make the cloth moist. Do not use so much solvent that drops of solvent fall from the cloth. Move the cloth lightly in one direction across the part that is to be cleaned. Look at the cloth. If the cloth is dirty, turn the cloth to a clean area and wipe the area again. Do this procedure until a clean area of the cloth stays clean. Do the last wipe with a dry cloth before the solvent on the part dries. See Figure 5, Page 35. Use cotton swabs in the small areas to make sure that all areas are clean. Let the part dry a minimum of 15 minutes. NOTE: Composite cleaning method No. 5 wipe cleaning using commercial solvent - two cloth method.
(6)
Composite Cleaning Method No. 5. This procedure gives instruction for wipe cleaning with a commercial solvent - two cloth method. (a) General. 1 All the same general points that apply to the one cloth method apply to this method, see Composite Cleaning Method 4, paragraph (1). This method is preferred with the faster evaporating solvents as a way of wiping the surface before the solvent evaporates.
(b)
Composite Cleaning Method 5 - Wipe cleaning with a commercial solvent Two cloth method procedure.
STANDARD PRACTICES MANUAL AS907-1-1A 1 Get some cloths C10-182. SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE. USE ONLY WITH ADEQUATE VENTILATION AND AVOID EYE CONTACT OR REPEATED OR PROLONGED CONTACT WITH THE SKIN.
WARNING:
2 3 4 5 6 7 8 9
Get MEK C04-001, MIBK C04-170 acetone C04-003, or isopropyl alcohol C04-035. Put solvent on a cloth C10-182 to make the cloth moist. Do not use so much solvent that drops of solvent fall from the cloth. Move the first cloth lightly in one direction across the part that is to be cleaned. Use a second dry cloth to wipe the part before the solvent on the part dries, see Figure 5, Page 35. Do this procedure until a clean part of the cloth stays clean. Do the last wipe with a clean dry cloth before the solvent on the part dries. Use cotton swabs in the small areas to make sure that all areas are clean. Let the part dry a minimum of 15 minutes.
Two-Cloth Cleaning Method Figure 5
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-46-01-350-304 E. Honeycomb Cleaning Methods. (1) Cleaning Honeycomb Core General. (a) This section addresses the cleaning of the honeycomb core replacement plug that is used when replacing damaged or corroded core in a sandwich construction part and the cleaning of honeycomb exposed during the repair process. Honeycomb Cleaning Methods 1 and 2 are for the cleaning of replacement core plugs. Honeycomb Cleaning Methods 3 and 4 may also be used for the cleaning of existing core in the repair area from which the skin material has become disbonded or has been removed as part of the repair procedure. Several types of honeycomb core are used in aircraft structure. The two most widely used types are aluminum honeycomb core and aramid fiber reinforced honeycomb core. Other types such as glass fiber or carbon fiber reinforced honeycomb core should be treated in the same way as described for aramid reinforced honeycomb core. Satisfactory cleaning of honeycomb core is difficult and checking of the cleanliness by simple testing is not possible. One way of overcoming this problem is to buy honeycomb core that is clean and put the core in sealed polyethylene bags in a dust controlled room, which may be the clean room. The bagged core should be stored flat on racks in an area where the outside of the bags will not be contaminated with large amounts of dust or oils. When the honeycomb is required it is removed from the bag, the amount that is needed cut off and the remainder returned to the bag and resealed. All handling is with clean gloves. No oil or other cutting fluid is used when machining the core and the dust generated is drawn away with vacuum cleaning equipment. The prepared honeycomb is returned to polyethylene bags until it is required for bonding. If all these steps are carried out with care no further cleaning is required. Some methods of cleaning contaminated honeycomb core are described below. No one method is universally applicable. Some solutions are only suitable for small pieces, others only make sense if there is sufficient quantity to justify the investment and environmental controls. The following sections describe the methods of cleaning core. The methods are prefaced with the words Honeycomb Cleaning Method 1, etc., so that they can be more easily referred to and will not be effected by renumbering of the sections of the document at future revisions. Method numbers will be controlled and if deleted will not be reassigned. The methods are not interchangeable and shall only be used when specified in an approved repair procedure or with the agreement of the OEM or regulatory authority. NOTE: HONEYCOMB CLEANING METHOD NO. 1 VAPOR DEGREASING
(b) (c)
(d)
(e)
(f)
(g)
(h)
STANDARD PRACTICES MANUAL AS907-1-1A (2) Honeycomb Cleaning Method No. 1 - Vapor degreasing This procedure gives instructions for the cleaning of a honeycomb core replacement plug that is used when replacing damaged or corroded cores in a sandwich construction part and the cleaning of honeycomb exposed during the repair process. NOTE: This cleaning method is included for compatibility with ARP 4916. Because of the ozone depleting properties of 1,1,1 Trichloroethane this method is not referenced in any Honeywell repair document. When ARP 4916 is approved and distributed this procedure will be deleted from the Standard Practices Manual. (a) General. 1 This method of cleaning is normally only used for aluminum honeycomb core and when large quantities need to be cleaned. Because of the imminent ban on 1-1-1 trichloroethane C10-030 in many countries this cleaning method should be regarded as an interim measure and many manufacturers of aluminum honeycomb bonded structures control the cleanliness of their honeycomb as described above so that users can avoid this type of cleaning.
(b)
Honeycomb Cleaning Method No.1 - Vapor degreasing procedure. 1 Put the core into a rack that can support the honeycomb. Make sure that the core can not bend and that the cell sides are vertical or at a maximum of 30 degrees from vertical. See Figure 6, Page 41. SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE. USE ONLY WITH ADEQUATE VENTILATION AND AVOID EYE CONTACT OR REPEATED OR PROLONGED CONTACT WITH THE SKIN.
WARNING:
2 3 4 5 6 7 8
Lower the honeycomb into the solvent 1-1-1 trichloroethane C04-030 gas slowly. The rate shall not be more than 12 ft/minute (3 m/minute). Keep the honeycomb in the gas until the gas does not make small drops of liquid form on the honeycomb. Remove the honeycomb from the gas. Wait until all the solvent has drained from the honeycomb. Look at the honeycomb. If the honeycomb is not clean, allow the honeycomb to cool, and repeat steps 2 to 4. Allow the honeycomb to cool for 2 hours minimum. Wear clean cotton gloves C10-139 to remove the cleaned honeycomb. Put the honeycomb in a clean polyethylene bag and seal the bag. Keep the honeycomb in the bag until you are ready to use it. NOTE: HONEYCOMB CLEANING METHOD NO. 2 SOLVENT EDGE DIP
STANDARD PRACTICES MANUAL AS907-1-1A (3) Honeycomb Cleaning Method No. 2 - Solvent edge dip. (a) General. 1 This method works well for all types of core in small sizes, typically less that 12 inch (300 mm) square. However the large surface area of solvent causes a solvent vapor hazard and a large quantity of solvent has to be disposed of for a small amount of cleaning. Clean solvent shall always be used as the cleaning action relies on the oil being dissolved into the solvent. Any oil on the surface will be coated onto the cell walls as the honeycomb is removed, unlike the vapor degrease where vapor condenses into clean solvent which runs off the honeycomb taking the contamination off the part.
(b)
Honeycomb Cleaning Method No.2 - Solvent edge dip procedure. 1 Get a tray that is 1.0 in. (25 mm) deep minimum. SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE. USE ONLY WITH ADEQUATE VENTILATION AND AVOID EYE CONTACT OR REPEATED OR PROLONGED CONTACT WITH THE SKIN.
WARNING:
2 3 4 5 6 7 8 9
Get MEK C04-001, MIBK C04-170, acetone C04-003 or isopropyl alcohol C04-035. Put the solvent in the tray until it is 0.5 inch (12 mm) deep. Wear clean cotton gloves C10-139 to hold the honeycomb. Put the honeycomb in the tray with the cell walls vertical. The honeycomb must fit in the tray without being compressed or bent. Move the honeycomb gently from side to side. Carefully lift the honeycomb out of the tray and put the core on a wire rack. Allow the honeycomb to drain for 30 minutes minimum. Remove the solvent from the tray and discard it safely. NOTE: HONEYCOMB CLEANING METHOD NO. 3 SOLVENT WIPE
(4)
Honeycomb Cleaning Method No. 3 - Solvent wipe. (a) General. 1 This method is not very good for cleaning aluminum honeycomb, however it can be used with success on aramid honeycomb. It also works on existing honeycomb that has had the skin removed and has the film adhesive still filleted on the cell walls. The bonding surface to be prepared in this case is actually the surface of the existing adhesive. Where it is possible to turn the part so that the open ends of the cell
STANDARD PRACTICES MANUAL AS907-1-1A face down, honeycomb cleaning method 4 is preferred especially where there is no old filleted adhesive. (b) Honeycomb Cleaning Method No.3 - Solvent wipe procedure. 1 Get a cloth C10-182. SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE. USE ONLY WITH ADEQUATE VENTILATION AND AVOID EYE CONTACT OR REPEATED OR PROLONGED CONTACT WITH THE SKIN.
WARNING:
2 3 4 5 6 7 8
Get MEK C04-001, MIBK C04-170, acetone C04-003 or isopropyl alcohol C04-035. Put solvent on the cloth C10-182 to make the cloth moist. Do not use so much solvent that drops of solvent fall from the cloth. Put the cloth on the edges of the honeycomb cells. Put a dry cloth on the part to dry the area where the solvent was put. Do this procedure until a clean part of the cloth stays clean after it is removed from the honeycomb. Use a dry cloth last. Let the honeycomb dry a minimum of 15 minutes. NOTE: HONEYCOMB CLEANING METHOD NO. 4 SOLVENT SPRAY
(5)
Honeycomb Cleaning Method No. 4 - Solvent spray. (a) General. 1 This method is good for cleaning honeycomb core plugs or honeycomb exposed during the repair, however it can only be used where it is possible to turn the part so that the open ends of the cell face down. If the honeycomb exposed during repair has the adhesive fillets remaining, honeycomb cleaning method 3 is preferred.
(b)
Honeycomb Cleaning Method No.4 - Solvent spray procedure. 1 Get a spray bottle suitable for the solvent that you are going to use SOLVENTS ARE VOLATILE, TOXIC, AND HIGHLY FLAMMABLE. USE ONLY WITH ADEQUATE VENTILATION AND AVOID EYE CONTACT OR REPEATED OR PROLONGED CONTACT WITH THE SKIN.
WARNING:
2 3
Get MEK C04-001, MIBK C04-170, acetone C04-003 or isopropyl alcohol C04-035. Put the solvent in the spray bottle.
STANDARD PRACTICES MANUAL AS907-1-1A 4 5 6 7 Turn the honeycomb so that the face of the cells is on the bottom and at an angle that lets you spray the cell walls. See Figure 7, Page 42 Spray the solvent up into the honeycomb and let the solvent drain out. Turn the honeycomb and repeat step 5 until all the cell walls have been cleaned. Let the honeycomb dry a minimum of 30 minutes with the open face of the cells on the bottom.
Vapor Degreasing of Honeycomb Using a Wire Rack Figure 6
Spraying of Solvent into the Honeycomb Figure 7
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-46-01-350-305 F. Water Break Test. (1) General. A water break test is used to determine if any residual oils or greases remain on surfaces to be bonded. This test is normally used after all cleaning has been completed. (2) General. (a) The water break test is a simple way of determining if a surface is grease free. It should be used with caution on bonding surfaces adjacent to honeycomb because water entering the honeycomb can be difficult remove. In these cases it is difficult to ensure that the repair area is thoroughly dry. The test works well on normal composite abraded surfaces however if the surface is polished to a very smooth finish it can be difficult to pass the test even with a clean surface. Conversely if the surface is very rough the surface tension of the water film may be interrupted making assessment of the water breaks more difficult. Good sensitivity can be obtained in composite laminates abraded with grits in the range 80 to 400 grit.
(b)
(3)
Water Break Test Procedure. (a) Alternative procedure Available. Put de-ionized or distilled water in a clean polyethylene bottle with a small spray nozzle and spray the water onto the prepared surface until the surface is just covered. Alternative procedure. Put de-ionized or distilled water on a clean cloth C10182 and move the cloth across the surface to put a thin layer of water on the surface. Look at the water on the surface. 1 The water shall form a thin layer over the surface with no areas where the surface tension causes the water to separate into drops or beads of water to form. The water shall not leave any part of the surface uncovered. See Figure 8, Page 44.
(b)
(c)
2 (d) (e) (f) (g)
Leave the water on the surface for 30 seconds. The water shall remain on all of the surface. If the water separates or drops or beads have formed within 30 seconds repeat the cleaning procedure and repeat the test. After you do the test, dry the surface with a dry cloth C10-182. Allow the surface to dry for 30 minutes minimum before bonding.
Water Break Test Figure 8
SHOTPEENING - SHOTPEENING TASK 70-47-01-380-016 1. Shot Peening SUBTASK 70-47-01-99G-016 A. General. (1) Shot peening is a process which utilizes metal shot, glass beads, or ceramic beads to beneficially condition a component surface. The media is propelled against a surface by air pressure. In effect, this action forms an external skin, stretched tightly over the subsurface of the material; thereby, increasing its resistance to stress corrosion and cyclic fatigue. The media composition and size, intensity, and coverages required for the surface conditioning of specific parts are stipulated in the applicable manual. Peening is typically performed with dry medias. However, wet glass bead peening is an acceptable alternative to dry glass bead peening. The different medias are used to impart intensities in different ranges. Cast steel shot is typically used to impart intensities in the Almen A range. Ceramic and glass bead medias are generally used to peen components with intensities specified in the Almen N range. Ceramic shot is a substitute for glass beads in peening operations in the Almen N range. It should be understood that, due to mass and size differences, the ceramic media will peen differently at the parameters used for glass bead media. When utilizing ceramic media, new machine parameters will need to be developed. It has been demonstrated that the ceramic media will impart a deeper stress layer at a given Almen intensity than that of a glass bead process. As a result, peening processes which are performed on parts containing thin section geometries (such as airfoil leading edges) should have intensities targeted at the lower end of the allowable intensity range. Peening is normally accomplished by automatic or semi-automatic machines and processes. Manual peening (holding the shot nozzle in the operators hand and moving the nozzle) is not recommended because of poor repeatability. Manual peening is not permitted on rotating or life limited hardware. Conditioned Carbon Steel Wire Media (Cut Wire Shot) is as an alternate to Cast Steel Shot. Cut wire shot is manufactured by cutting steel wire and conditioning to remove burrs and round the cut ends to form the shot balls. Cut wire shot is considerably more resistant to breakdown in use than cast steel shot. When changing from cast steel to cut wire peening medias, machine parameters will need to be redeveloped to insure that intensity and coverage requirements are met. Conditioned cut wire media may be substituted for cast steel shot whenever cast steel is permitted. However, when conditioned cut wire media is specified in the process document, only that media may be used for that specific repair.
(2)
(3)
(4)
(5)
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SHOTPEENING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-47-01-380-161 B. Equipment. (1) The peening machine incorporates movable nozzles to direct the stream of media, a rotating or traversing table to move the work through the media stream, a feed and propulsion mechanism for the media, a separator for removing scattered or defective media from circulation, and a timing device to record/control the duration of exposure. Special tooling such as a lance and media deflector should be provided for shot peening the inside of bores, slots or hollow parts, and a nozzle extension should be available for use in reaching certain difficult areas.
SUBTASK 70-47-01-380-162 C. Materials. (1) Shot and beads are essentially spherical, and are capable of producing the required peening action without excessive fracturing of particles. Various shot and bead sizes are available to permit the selection of different peening intensities stipulated in the applicable Engine/Shop Manual. Air- driven systems with multiple nozzles are preferred. (a) Cast Steel Shot. 1 Cast steel shot shall conform to size requirements for S110 or S130, as specified in SAE J827, MIL-S-851, or AMS 2431/2. See Figure 1, Page 6 for shot size definitions. Steel shot shall be purchased to a hardness of Rc 55 to 65.
2 (b)
Conditioned Carbon Steel Cut Wire Shot. 1 2 Cut wire shot material shall conform to requirements of SAE specifications 1013, 1015, 1016, 1017, 1019, or 1020 of SAE J403. Cut wire shot size CCW14 is to be used as equivalent to Cast Steel S110. CCW20 is to be used as alternate to Cast Steel S170. CCW31 is to be used when specified in the applicable Engine/Shop Manual. Wire diameters and size distributions are listed in Table 1, Page 3. Cut wire media shall have a hardness (after conditioning) of Rockwell C50 to C55. Cut wire shall be conditioned prior to purchase so that the number of unconditioned or partially conditioned particles to not exceed the requirements of Figure 2, Page 7. Cut wire sources are listed in TASK 70-80-04-800-015, C04 Consumable Products, CCW14 C04-166, CCW20 C04-167, and CCW31 C04-178.
3 4 5
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Table 1. Wire Diameter and Size Distribution Shot Screening Tolerance in Millimeters (mm) 5 Percent on Screen - See Note (1) 0.45 0.60 0.90 Shot Screening Tolerance in Millimeters (mm) Minimum 90 Percent on Screen - See Note (1) 0.25 0.40 0.65
Size CCW 14 CCW 20 CCW 31
Wire Nominal Diameter and Tolerance in Millimeters (mm) 0.35 0.02 0.50 0.02 0.80 0.02
Reference Diameter Inches - See Note (2) 0.014 0.020 0.031
NOTE: (1) It is permitted to use any screen system provided the sizes are within 0.001 inch (0.254 mm) of the specified millimeter size. To meet the screening requirements, screen systems such as Tyler standard, market grade screen cloth, tensile bolting cloth of those screen systems that conform to DIN4188 (German) or ASTM E 11 can be used. NOTE: (2) The diameter in inches is for reference only and corresponds to the nominal diameter requirement in millimeters.
(c)
Glass Beads. 1 Glass beads used for peening shall conform to the requirements of SAE J1173, MIL-G-9954, or AMS 2431/6. See Figure 3, Page 8 for glass bead size definitions.
(d)
Ceramic Beads. 1 2 3 4 Ceramic beads used shall conform to requirements of SAE J1830 or AMS 2431/7. Bead size shall conform to requirements in Figure 4, Page 9. Recommended beads are C04-161, C04-162, or C04-179. It is recommended that new ceramic bead material be checked for deformed beads. Lots containing beads which exhibit teardrops or satellites should not be used. These deformed beads may cause surface irregularities.
(e)
Material Process Quality Checks. 1 Cast Steel Shot. a Cast steel shot should be visually examined at least once per shift for deformed or broken shot. Typical test is to collect a single layer of shot material on a piece of cellophane tape
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STANDARD PRACTICES MANUAL AS907-1-1A within a 0.25 inch (6.35 mm) square area. Using a 10X or 20X magnifier, count the number of deformed (sharp cornered, teardrop, hollow, or elongated greater than a two to one length to width ratio) or broken shot pieces. There shall be no more than 32 deformed or broken pieces for S110 and no more than 23 pieces for S130 shot. See Figure 5, Page 10. b Uniformity of shot in machine shall meet the uniformity requirements listed in Table 2, Page 4 and Table 3, Page 4. Shot not meeting this criteria shall be discarded or reclassified.
Table 2. Uniformity of Shot in Machine (Cast Shot) Maximum 20% Passing the US Standard Screen Size (Number / Dimension) 20 / 0.0331 inch (0.841 mm) 30 / 0.0232 inch (0.589 mm) 40 / 0.0165 inch (0.419 mm) 45 / 0.0138 inch (0.350 mm) 50 / 0.0117 inch (0.297 mm) 80 / 0.0070 inch (0.178 mm) Maximum Number of Broken or Deformed Shot Acceptable (Number / Area Dimensions) 16 / 0.5 x 0.5 inch (13 x 13 mm) 32 / 0.5 x 0.5 inch (13 x 13 mm) 16 / 0.25 x 0.25 inch (6.4 x 6.4 mm) 23 / 0.25 X 0.25 inch (6.4 X 6.4 mm) 32 / 0.25 x 0.25 inch (6.4 x 6.4 mm) 45 / 0.25 x 0.25 inch (6.4 x 6.4 mm)
Cast Shot Sizes 330 230 170 130 110 70
Glass Beads.
Dry glass bead peening operations shall operate with less than 10 percent broken bead total. Broken bead content shall be determined by separation and weighing, or by visual inspection. It is recommended that dry bead peening operations be checked every two hours. The entire bead charge should be replaced when the broken bead content exceeds 10 percent.
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Table 3. niformity of Shot in Machine (Cut Wire) Maximum Number of Broken, Unconditioned, or Partially Conditioned Shot Available (Number / Area Dimensions) 11 / 1.0 x 1.0 inch (25.0 x 25.0 mm) 5 / 1.0 x 1.0 inch (25.0 x 25.0 mm) 8 / 1.0 x 4.5 inch (25.0 x 114.0 mm)
Cut Wire CCW 14 CCW 20 CCW 31
No./Dim. N/A N/A N/A N/A N/A N/A
Wet glass bead peening operations shall operate with a slurry consisting of 35 to 45 percent glass bead, remainder water. Glass content should be measured at fifteen to thirty minute intervals using a visual test on a graduated cylinder. The entire slurry charge should be replaced every two hours.
Ceramic Beads. a Ceramic bead charges shall be operated with less than 10 percent broken beads. The entire bead charge should be replaced when the broken bead content exceeds ten percent. Tests similar to 3.A.(5)(a)1 are used to verify broken bead content.
Cut Wire Shot. a Cut wire should be visually examined at least once per shift for deformed or broken shot (see Figure 2, Page 7). The number of allowable unacceptable pieces per sample is defined in Table 2, Page 4 and Table 3, Page 4. Recommended magnification for media inspection is 10-20X.
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Cast Steel Shot Numbers and Screening Tolerances Figure 1
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Acceptable and Unacceptable Shapes of Media for Conditioned Cut Wire Shot Figure 2
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Glass Bead Shot Numbers and Screening Tolerance Figure 3
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Ceramic Shot for Peening - Sizes Figure 4
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Acceptable and Unacceptable Shapes of Media for Cast Steel Shot Figure 5
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-47-01-380-163 D. Procedure. (1) Equipment Check. Check the peening machine and its connected services for proper operation as follows: (a) Ascertain that machine is loaded with proper size, type and quality of media. WEAR EYE PROTECTION WHEN USING COMPRESSED AIR. DO NOT POINT THE NOZZLE IN YOUR DIRECTION OR THE DIRECTION OF OTHERS. THIS CAN CAUSE INJURY TO PERSONS AND DAMAGE TO EQUIPMENT.
WARNING:
(b) (c) (d) (e) (f) (2)
Be sure that air supply (volume) is sufficient for operation, and that pressure can be adjusted from 30 to 100 psi (206.9-689.5 kPa). See that media flows freely from all nozzles for a few seconds after a short run, and that air pressure shuts off before opening door. Check rotating table to be sure it can be adjusted from 5 to 40 rpm. Make sure that air timing control is functioning accurately. Determine that nozzles are not excessively worn.
Preparation of Part for Peening. (a) Part to be shot peened must be repaired, heat treated, machined, ground, polished, and burrs and sharp corners removed as necessary before shot peening. Part must be within dimensional and surface finish limits unless otherwise specified. When required, magnetic-particle or fluorescent-penetrant inspection must be completed before shot peening. Part must be clean and free from all dirt, grease and oil. Mask part, using masking fixtures if available, or mask designated areas with clothback tape, C10-021. Make sure that edges of tape are in firm contact with the part. The tolerance of the masking position shall be 0.250 in. (6.35 mm) maximum, unless otherwise specified. A minimum of three tape layers is recommended. Record part number, serial number, location of each, and method of application so that part can be remarked after peening.
(b) (c) (d)
(e) (3)
Machine Setup. (a) (b) Ensure that machine contains proper media size as stipulated in instructions for specific part. Place part and holding fixture in machine.
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STANDARD PRACTICES MANUAL AS907-1-1A CAUTION: DO NOT DIRECT NOZZLES TOWARD OTHER NOZZLES, HOSES, NOZZLE HOLDERS OR WINDOWS OF THE MACHINES. MAKE SURE THAT NOZZLE POSITION DOES NOT INTERFERE WITH ROTATION OF ALMEN FIXTURE, HOLDING FIXTURE OR PART AT ANY POINT WITHIN THE OSCILLATION RANGE OF THE NOZZLES. (c) (d) Position limit switches, when oscillation is required, to provide necessary distance and location of stroke with respect to the part. Leaving nozzles in position, remove part, and replace with proper Almen strip fixture. Check nozzle position to be sure of proper alignment with Almen strips. Adjust as necessary.
(4)
Peening Time Determination. The peening time shall be the longer of the time required for full surface coverage (see paragraph 4.F.) and the time required for Almen strip saturation. Peening operations requiring fixture with multiple Almen strips shall meet saturation and coverage requirements at all strip locations. The peening time is governed by the longest time required to reach coverage or saturation on any of the strips on the fixture. Intensity Determination. See Figure 6, Page 15. NOTE: Two kinds of test specimens C10-110 and C10-205 (Almen strips for shotpeening) are used: A and N. Steel shot is used to obtain intensities for which the A specimen is used; but ceramic and glass beads are used for intensities in the N range. The specimens differ only in thickness. NOTE: Peening intensity is measured as curvature (arc height) of the standard test specimen in thousandths of an inch. For example, intensity 10 A2 indicates an arc height of 0.010 inch (0.25 mm) on an Almen A test strip, measured on a No. 2 gage. The designation called out in a repair procedure may be either 10A or 0.010A. (a) The saturation point shall be determined as follows: 1 The saturation point is determined from a saturation curve. See Figure 6, Page 15. It is the minimum duration of peening which, when doubled, increases the Almen strip arc height by not greater than 10 Percent except that 15 percent maximum may be used in the following situations: a b c For gravity accelerated peening of titanium fan blades. For glass bead peening of fan and compressor airfoils. For steel shot peening with intensity equal to or less than 15N (5A equivalent), provided that the saturation curves substantiating the process are drawn as smooth curves through mean values, calculated from 10 arc height measurements for each point. Confirmation of the saturation point may be aided by an A strip curve run under identical conditions to the N curve, with 5 measurements per point.
(5)
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STANDARD PRACTICES MANUAL AS907-1-1A 2 Almen test strips, as shown in Figure 7, Page 16, shall be flat within 0.0005 in. (0.013 mm) for A Almen strips, and 0.0007 in. (0.018 mm) for N Almen strips. If a system of compensating for initial out-offlatness is used, strips out-of-flatness up to 0.001 in. (0.03 mm) may be used. Mechanically deforming strips to meet the flatness requirement is not permitted. Almen test strips shall be mounted on holders or on fixtures incorporating such holders conforming to the requirements of Figure 8, Page 17. The type of fixture (simple, simulative, or scrap part) used to support the Almen strips shall be as specified in the repair. Almen support blocks shall be bolted securely or welded to the fixtures. Shaded strips shall be used for situations shown in Figure 9, Page 18. In these cases, partially masked N strips shall be used. Calibration to the required part intensity shall be carried out using the N strip metal, masked with 0.090 in. (2.29 mm) minimum thickness to expose the same area as the Almen fixture, and peening on a flat plate along with a full standard strip. After peening, the arc height of each Almen strip shall be measured in an Almen gauge conforming to the dimensional relationship of the four contact balls, and the indicator anvil and ball hardness of Figure 10, Page 19. A peened Almen strip shall not be re-peened after it has been removed from a holder. During initial process development, a separate saturation determination curve, such as that shown in Figure 6, Page 15, shall be made for each location n the part where verification is required. There shall be at least four Almen strips peened for different lengths of time to determine each curve. The number of Almen strips shall be sufficient to clearly establish the shape of the saturation determination curve, and to determine the saturation time. One point shall be in the area of the knee of the curve. If an Almen strip location is peened in more than one operation, intensity shall be determined at the saturation point for each operation. If two operations peening one location are exact mirror images resulting from inverting the part, the saturation point may be generated by combining the two operation if saturation is not achieved in each separately.
(6)
Coverage Determination. (a) Full coverage is required on all surfaces where peening is specified. Coverage shall be verified for all surfaces requiring peening as follows: 1 Visual inspection of accessible surfaces shall show a continuous pattern of overlapping dimples at 10X minimum magnification. Inaccessible surfaces may be inspected using illuminated borescope or angled, lighted mirrors.
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STANDARD PRACTICES MANUAL AS907-1-1A 2 As an alternate, fluorescent tracer inspection of surfaces shall be accomplished by reviewing a previously coated, then peened surface under a suitable black light. Complete coverage is achieved when no fluorescence occurs under black light. A minimum acceptable condition shows isolated flecks of fluorescent indications.
(b)
Coverage time is the time required to achieve the uniform surface pattern in 4.F.(1)(a). Full coverage is defined as time required for 100 percent coverage. Multiple coverages are times in access of time required to achieve 100 percent coverage. For example, 125 percent coverage is 1.25 times the time for full coverage, 200 percent coverage is 2.0 times the time for full coverage. Use coverage time for 125 percent unless otherwise specified by the applicable Engine/Shop Manual.
(c) (7)
Peening the Parts. (a) Install the part, mounted in the holding fixture, back into the machine. Check nozzle position to be sure that nozzles are still properly directed toward the area of the part to be peened. Adjust if necessary. Peen the part by operating the machine in accordance with the cycle determined in paragraph 4.E. Reference Figure 11, Page 20, Figure 12, Page 21, Figure 13, Page 22, Figure 14, Page 23, and Figure 15, Page 24 for examples of recommended peening techniques for various applications.
(b) (c)
(8)
Quality Check. (a) Verify complete peening of required area(s) of the part(s) by examining under 10 power magnification. Surfaces should have a uniform peened or hammered appearance on all areas of equal hardness. If proper coverage has not been achieved, check equipment setup as directed in paragraph 4.A. Repeen as directed in paragraph 4.F. Perform visual inspection of all edges to assure that no burrs or rollover of edges has occurred. If burrs or rollover are detected, the part edges should be blended to remove burrs and the part repeened.
(b) (c)
(9)
Cleanup. (a) After peening, remove all masking and residue. Blow off all shot, beads, or fragments, using clean, dry shop air. Remark part number and serial number by the original method if they were obliterated by peening. Apply preservative as required.
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Intensity Determination Figure 6
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Almen Strips C10-110 and C10-205 Figure 7
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Almen Strip Holders Figure 8
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Requirements for Shaded Almen Strips in Scrap Part Fixtures Figure 9
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Almen Strip Test Gage Figure 10
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Direct Impingement Peening of Holes with L/D Greater than 1 Figure 11
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One Sided Direct Impingement Peening of Holes with L/D</= 1 Figure 12
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Two Sided Direct Impingement Peening of Holes with L/D</= 1 Figure 13
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Direct Impingement Peening of Rectangular Cavities Figure 14
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Direct Impingement Peening of Difficult Access Cavities and Flanges Figure 15
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WET ABRASIVE BLAST - WET ABRASIVE BLAST SURFACE FINISHING TASK 70-47-02-380-017 1. Wet Abrasive Blast Surface Finishing SUBTASK 70-47-02-99G-017 A. General. (1) This procedure is recommended for increasing the coefficient of friction between 2 faying surfaces of a bolted assembly. It should be used when specified by the applicable Engine/Shop Manual. NOTE: As an alternate method, dry abrasive blasting per TASK 70-47-03-380-018, Dry Abrasive-Blast Surface Finishing may be used in lieu of wet blasting. SUBTASK 70-47-02-380-171 B. Equipment. (1) The following equipment, or its functional equivalent, is recommended. (a) (b) Manually operated blast cabinet. Vapor blast gun, Model S, having a suction nozzle (A37-10) with a 1/2 inch (12.7 mm) inside diameter at the discharge end and a 7/32 inch (5.56 mm) ID air jet. NOTE: The nozzle liner should be replaced when its inside diameter at outlet end is worn to 5/8 inch (15.8 mm). (c) Source of compressed air should be sufficient to maintain controlled nozzle pressure of 60-70 psi (414-483 kPa) during blasting.
SUBTASK 70-47-02-380-172 C. Material. (1) The abrasive material should be 120-150 grit aluminum oxide. It should be prepared for use as follows: (a) Add one gallon of water to 3-1/3 pounds of abrasive (12 gallons of water to 40 pounds of abrasive).
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WET ABRASIVE BLAST SURFACE FINISHING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (b) If the abrasive is not procured with ready-mixed inhibitor (sodium nitrate, sodium chromate, etc.) and suspension (anti-set) agents, add them. NOTE: The abrasive content should be maintained at approximately 30-40 percent by volume. NOTE: Grit size should be monitored and if finer than 150, it should be replaced. SUBTASK 70-47-02-380-173 D. Procedure. (1) Parts must be completely finish machined and free of burrs and sharp corners before abrasive blasting. Parts should meet all surface finish requirements before blasting. Proceed as follows: (a) Clean all parts so that they are completely free of dirt, oil and grease. Steam cleaning ( TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning) is preferred in all cases, and is mandatory for titanium parts. Vapor degreasing ( TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing) is acceptable for cleaning non-titanium parts. Mask all markings that are to be retained after blasting such as identification and inspection markings. No other masking is required unless otherwise specified by the applicable manual. Wet blast the parts in the following manner: CAUTION: NOZZLE PRESSURE OF 60-70 PSI (414-483 KPA) TO BE MAINTAINED DURING BLASTING TO AVOID EXCESSIVE EROSION. 1 Direct the blast nozzle at 40-60 degrees to the part, and 3-5 inches (76.2-127.0 mm) from it. When blasting disks or spacers, direct the blast radially outward to avoid blasting into dovetails, and to cut across circular tool marks. Avoid letting the abrasive blast dwell in one place on the workpiece. If the blast cabinet incorporates a rotating work table, it should be turning during the blasting operation. Blast only those surfaces specified by the applicable manual. Unless otherwise specified by the applicable manual, the surface roughness value after blasting to be 40-60 AA microinches (1.0-1.5 micrometers). Make sufficient passes to remove existing machined surface finish and attain a uniform mat surface texture.
(b)
(c)
3 4
(d)
Completely remove all residual grit after blasting. Agitate parts while submerged in rinse tank, or use spray rinse. Blow dry with shop air, and apply rust inhibitor as necessary. Visually check blasted surface for uniformity of finish, or compare with another part selected as standard.
(e)
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WET ABRASIVE BLAST SURFACE FINISHING Page 2 Dec 01/03
DRY ABRASIVE BLAST - DRY ABRASIVE BLAST SURFACE FINISHING TASK 70-47-03-380-018 1. Dry Abrasive Blast Surface Finishing SUBTASK 70-47-03-99G-018 A. General. (1) This procedure is recommended for increasing the coefficient of friction between 2 faying surfaces of a bolted assembly. It should be used when specified in the applicable Engine/Shop Manual. NOTE: As an alternate method, wet abrasive blasting per TASK 70-47-02-380-017, Wet Abrasive-Blast Surface Finishing, may be used in lieu of dry blasting. SUBTASK 70-47-03-380-181 B. Equipment. (1) The following equipment, or its functional equivalent, is recommended: (a) (b) Manually operated blast cabinet. Blasting gun having a suction nozzle with a 1/2 inch (13 mm) inside diameter at the discharge end and a 7/32 inch (6 mm) inside diameter air jet. NOTE: The nozzle lines shall be replaced when inside diameter at outlet end is worn to 5/8 inch (15.8 mm). (c) Source of compressed air should be sufficient to maintain controlled nozzle pressure of 25-30 psi (172-207 kPa) during blasting.
SUBTASK 70-47-03-380-182 C. Materials. (1) The abrasive material should be 120-150 grit aluminum oxide. NOTE: Grit size should be monitored and if finer than 150, it should be replaced. SUBTASK 70-47-03-380-183 D. Procedure. (1) Parts must be completely finish machined and free of burrs and sharp corners before abrasive blasting. Parts should meet all surface finish requirements before blasting. Proceed as follows: (a) Clean all parts so they are completely free of dirt, oil, and grease. Steam cleaning ( TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning) is preferred in all cases, and is mandatory for titanium parts. Vapor
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DRY ABRASIVE BLAST SURFACE FINISHING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A degreasing ( TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing) is acceptable for cleaning non-titanium parts. (b) Mask all markings that are to be retained after blasting, such as identification and inspection markings. No other masking is required unless otherwise specified by applicable Engine/Shop Manual. Dry blast the parts in the following manner: CAUTION: NOZZLE PRESSURE OF 25-30 PSI (172-207 KPA) TO BE MAINTAINED DURING BLASTING TO AVOID EXCESSIVE EROSION. 1 Direct the blast nozzle at 40-60 degrees to the part, and 3-5 inches (76.2-127.0 mm) from it. When blasting disks or spacers, direct the blast radially outward to avoid blasting into dovetails, and to cut across circular tool marks. Avoid letting the abrasive blast dwell in one place on the workpiece. If the blast cabinet incorporates a rotating work table, it should be turning during the blasting operation. Blast only those surfaces specified by the applicable manual. Holes and corner radii are to be protected during blasting. Unless otherwise specified by the applicable Engine/Shop Manual, the surface roughness value after blasting to be 40-60 AA microinches (1.01.5 micrometers). Make sufficient passes to remove existing machined surface finish and attain a uniform mat surface finish.
(c)
3 4
(d) (e)
Completely remove all residual grit after blasting. Visually check blasted surface for uniformity of finish.
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DRY ABRASIVE BLAST SURFACE FINISHING Page 2 Dec 01/03
ROTARY FLAP PEENING - ROTARY FLAP PEENING TASK 70-47-04-380-019 1. Rotary Flap Peening SUBTASK 70-47-04-99G-019 A. General. CAUTION: THIS PROCEDURE IS NOT TO BE USED FOR PEENING CRITICAL OR LIFE LIMITING AREAS. (1) Many engine components are shot peened at time of manufacture as a method to achieve improved cyclic life. Repair of these parts often requires local blending to remove surface imperfections. Blending may partially or completely remove the compressive surface layer induced by shot peening. An acceptable method of restoring the compressive layer in noncritical areas, as an alternate to standard shop peening procedure per TASK 70-47-01-380-016, Shot Peening, is rotary flap peening. This procedure is to be used only when specifically directed by the applicable manual.
SUBTASK 70-47-04-380-191 B. Equipment. (1) The following equipment is required and may be obtained as shown: (a) (b) (c) (d) No. 2 Almen Gage. Metal Improvement Co. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. Timing Device (Commercial). Magnetic Almen Strip Holder, 3M No. 9016, or equivalent. 3M Company. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. Hand operated grinder or flexible shaft driven by a electric or compressed air motor with adjustable shaft speed control (Commercial). DUMORE Corp. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. DUMORE Corp. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003.
1 Flexible Shaft Grinder Series 6-1/4HP (Low Speed) Model 6-411 2 Table-Top Speed Control Model 1-310
(e) (f)
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Mandrel, Rotopeen, 3M No. 7212, or equivalent. 3M Company. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. A hand-held tachometer used to determine shaft rpm.
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ROTARY FLAP PEENING Page 1 Dec 01/03
Tachometer
Shimpo Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003.
SUBTASK 70-47-04-380-192 C. Materials. No. C10-110 C10-111
Consumable Product A. Almen Test Strips, Type A, 0.050-0.052 inch (1.27-1.32 mm) thick. B. Rotary Peen Flap Assembly, 1 1/4 x 9/16 inch (32 x 14 mm), 3M No. TC330 SUBTASK 70-47-04-380-193 D. Procedure. (1)
Preparation of Part for Rotary Flap Shot Peening. (a) (b) Part to be peened must be repaired and blended to remove burrs and sharp corners from area to be peened. Magnetic-particle inspection or fluorescent-penetrant inspection (preceded by appropriate etching) when required must be completed before shot peening. Areas not to be peened, adjacent to areas being peened, shall be masked to avoid contact with rotary flap. Area of part to be peened must be clean and free of all dirt, grease or oil.
(c) (d) (2)
Determination of Peening Requirements. (a) Determine, from applicable manual repair procedure, the required peening intensity. NOTE: Peening intensity is measured as curvature (arc height) of the standard test specimen in thousandths of an inch. For example, intensity 10 A2 indicates an arc height of 0.010 inch (0.3 mm) on an Almen A test strip, measured on a No. 2 gage. (b) Position an Almen test strip in the Almen gage and set the indicator to zero. Reverse the strip so that opposite surface is up and check for out-of-flatness. If out-of-flatness exceeds 0.001 inch (0.03 mm), select a new strip and repeat the check. Position strip in magnetic Almen strip holder. See SUBTASK 70-47-04-380191, Equipment.
(c)
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STANDARD PRACTICES MANUAL AS907-1-1A (d) Install and center flap assembly in mandrel with mandrel secured in chuck of flexible shaft or hand operated grinder. Select an initial tool speed. Refer to Figure 1, Page 4. Set tool speed under load and peen test strip along its entire length for a period of 2 minutes. Mandrel will be positioned parallel to and within 0.100-0.125 inch (2.54-3.18 mm) of surface being peened. Refer to Figure 2, Page 5. The tool or shaft should be moved continuously in an overlapping circular motion to maximize uniformity of coverage. Refer to Figure 3, Page 6. NOTE: Refer to Figure 4, Page 7 for reference. However, because of inherent variables of manually controlled mandrel position, each operator must establish a saturation curve that will assure the intensity required for each job. (e) (f) Determine Almen strip arc height by placing test strip on Almen gage and record reading. Repeat steps (d) and (e) using new test strips and increasing time by 2 minutes per strip until sufficient data points are available to establish a saturation curve. Refer to Figure 5, Page 8. If saturation point thus determined is not within intensity limits of part to be peened, set tool speed to a new setting (increase tool speed to increase intensity and vice-versa) and determine the new saturation curve. Repeat this procedure until adequate peening intensity, within limits specified by applicable manual repair procedure is achieved. Refer to Figure 6, Page 9. Check for uniformity of coverage with 10 power magnification. Calculate peening time for repair parts by multiplying saturation time by 1.25 (125 percent) unless otherwise directed by applicable instructions for the parts.
(g)
(h) (i)
(3)
Peening Parts. The following is intended for peening areas no larger than 2 sq inches (12.9 sq cm). If the area to be peened is larger than 2 sq inches (12.9 sq cm), it must be divided into sections, less than 2 sq inches (12.9 sq cm). Each section must be completely peened before proceeding to next section. Overlap at section boundaries is required. (a) If area to be peened is flat, position this area in a horizontal plane. If area is on a curved surface, position with approximate center of area uppermost for maximum accessibility. Peen designated area on part using same parameters (tool speed and time) and technique as used to establish saturation curve. Peening of part must be done by same operator who established peening parameters with test strips. Periodically check rotary flap for missing balls. Replace flap if more than 2 balls are missing from either side.
(b)
(c)
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Preening Intensity/Tool Speed RPM Figure 1
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Mandrel/Positioning Figure 2
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Typical Overlapping - Circular Motion Pattern for Peening Figure 3
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Typical Saturation Curves Figure 4
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Test Strip - Saturation Intensity Figure 5
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100 Percent Coverage (Saturation) - Arc Height Exposure Figure 6
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-47-04-380-194 E. Quality Assurance. (1) Establish peening requirements for intensity required each time a lot of similar parts is to be peened. Determine the peening requirements per SUBTASK 70-4704-380-193, Procedure. Establish parameters each time operator is changed, such as shift change or job reassignment. At least one intensity determination as defined in paragraph 4.B. shall be made to represent each tool and its equipment for each 30 minutes of continuous operation or fraction thereof, and for each change in intensity. Refer to SUBTASK 70-47-04380-193, Procedure. Check peened area with 10 power magnification to assure complete coverage. If coverage is not complete of individual indentations do not overlap, repeat the peening operation per 4.C. Refer to SUBTASK 70-47-04-380-193, Procedure.
(2) (3)
(4)
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COLD-WORKING REPAIR - COLD-WORKING REPAIR TASK 70-47-05-350-023 1. Cold-Working Repair SUBTASK 70-47-05-99G-023 A. General. (1) Cold-working is an operation in which materials are reworked to original contour (as removal of dents). This procedure is used to repair engine parts (mostly sheet metal) which have been damaged or changed from their original contour. No heat is applied to the material.
SUBTASK 70-47-05-350-024 B. Procedure. (1) Inspect the part to be repaired per applicable manual.
CAUTION: DO NOT USE METAL HAMMERS TO RESHAPE PARTS TO THEIR ORIGINAL CONTOUR. (2) (3) (4) Using plastic or other soft-faced mallets, pliers and similar hand tools, return the part to its original contour within usable limits specified in applicable manual. After cold-working, inspect the reworked area for cracks, observing limits in the applicable engine manual. Compare with a similar undamaged part. Refer to applicable engine manual for repair limits for the part being cold-worked.
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COLD-WORKING REPAIR Page 1 Dec 01/03
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COLD-WORKING REPAIR Page 2 Dec 01/03
THREADED INSERTS - THREADED INSERTS TASK 70-48-00-350-004 1. THREADED INSERTS SUBTASK 70-48-00-99G-015 A. General. (1) Threaded inserts of various types are used to restore stripped or worn threads in a part, or to provide added strength to tapped threads in light materials. The inserts consist of threaded bushings, some types of which are inserted in specially tapped holes, and others of which are self-tapping. Specific types are used in different applications on engine parts to take advantage of particular features such as strength or type of material, ease of application, or other characteristics. The type to be used in a particular application is designated in the applicable Engine/Shop Manual.
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THREADED INSERTS Page 1 Dec 01/03
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THREADED INSERTS Page 2 Dec 01/03
HELI-COIL INSERTS - HELI-COIL INSERTS TASK 70-48-01-350-004 1. Heli-Coil Inserts SUBTASK 70-48-01-99G-004 A. General. (1) Heli-Coil standard inserts and Screw-Lock inserts are precision wound helical coils of 18-8 stainless steel wire. The wire has a diamond-shaped cross-section to fit the standard 60-degree V-form thread, and is available in all standard sizes in National Fine and National Coarse series up to 1-1/2 inch (38 mm) diameter, as well as tapered pipe thread sizes. NOTE: Heli-Coil inserts are available from Emhart Fastening Technologies. Refer to step D. of Subtask 70-80-00-800-003. SUBTASK 70-48-01-350-041 B. Installation. (1) Before installing a Heli-Coil insert, determine the thread size and depth of the original tapped hole. Select the proper insert and installation tools by referring to the chart in Figure 1, Page 3. NOTE: The same insert is used for all classes of fits or tolerance ranges. Each variation in fit is determined by the tapped hole into which the Heli-Coil insert is screwed. (a) If replacing a Heli-Coil insert that is already in position, extract the old insert with the proper extracting tool shown in Figure 1, Page 3 under the column headed Extracting Tool No. Position the extractor blade so that one side of the blade is a quarter-turn from the end of the top thread of the insert. Strike lightly with a hammer to seat the extractor, then turn counterclockwise while bearing down on the extractor. Proper extraction of the insert does not damage the tapped thread. If replacing stripped or damaged threads in the basic material, drill out the threads to at least the minimum depth shown in Figure 2, Page 4, Drilling Data column, using the tap drill indicated. Using a countersink, break sharp corners of the drilled hole. Select the appropriate tap from Figure 2, Page 4, Tapping column, and tap to at least the depth L of the insert shown in Figure 1, Page 3. Tapping procedure is the same as standard thread tapping.
(b)
CAUTION: DO NOT PUSH DOWNWARD WHILE TURNING THE INSERTING TOOL. DO NOT REVERSE MANDREL TO REMOVE TANG. (c) Place the selected insert on either the prewinder inserting tool or the threaded-mandrel type inserting tool. Guide the insert to engage the threaded hole, and turn the tool clockwise until the top coil of the insert is
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HELI-COIL INSERTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A one-quarter to one-half turn below the top surface of the hole. Follow the manufacturers directions for installing the insert on the inserting tool. (d) Using the appropriate tang break-off tool shown in Figure 1, Page 3, remove the tang from the insert if it is installed in a through hole. In blind holes, the tang may be left on the insert if it does not interfere with proper bottoming of the bolt or stud.
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Heli-Coil Inserts and Installation Tool Figure 1
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Heli-Coil Taps, Gages and Installation Data Figure 2
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LOK-THREAD INSERTS - LOK-THREAD INSERTS TASK 70-48-02-350-005 1. Lok-Thread Inserts SUBTASK 70-48-02-99G-005 A. General. (1) Lok-Thread inserts are available from: Maclean Maynard. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. The inserts can be replaced when unserviceable, as specified in the applicable manual. Use the following procedure for replacement.
SUBTASK 70-48-02-350-051 B. Procedure. (1) (2) Remove damaged or stripped insert, using an ordinary screw extractor. Remove burrs and dirt from hole, and resize threads with a tool of the kind shown in Figure 1, Page 2. This tool restores the threads to their original pitch and minor diameters by causing the metal to cold-flow. Apply corrosion protection or lubricant to the tapped hole and replacement insert in accordance with instructions for the specific part being repaired. Install replacement insert so that its top surface is flush to 0.10 inch (0.25 mm) below the surrounding surface. Tighten the insert to the torque value specified for the part being repaired. Use an oversized insert if required to meet the specified torque. See Figure 2, Page 3, Figure 3, Page 4, and Figure 4, Page 5.
(3) (4)
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LOK-THREAD INSERTS Page 1 Dec 01/03
Thread Sizing Tool Figure 1
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Bushing Driver - Typical Figure 2
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Lok-Thread Bushings Figure 3
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Lok-Thread Installation Data Figure 4
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TAP-LOK INSERTS - TAP-LOK INSERTS TASK 70-48-03-350-006 1. Tap-Lok Inserts SUBTASK 70-48-03-99G-006 A. General. (1) Tap-Lok inserts can be replaced when loose or damaged. When these inserts are replaced in nonferrous castings, removal of the old inserts causes enlargement of the hole in which it was installed. To compensate for this wear, oversized inserts shall be used as replacements. Tap-Lock inserts are available from Groov-Pin Corporation and from Pentacon Aerospace Group. Refer to the List of Suppliers in Step D. in Subtask 70-80-00-800003.
(2)
SUBTASK 70-48-03-350-061 B. Procedure. (1) (2) Remove loose or damaged insert by unscrewing it with the aid of a screw extractor, or drill it out. Select replacement insert by referring to the Illustrated Parts Catalog (IPC). If replacement inserts are not identified in those publications, appropriate selection may be made by referring to Figure 1, Page 3. NOTE: The part numbers in Figure 1, Page 3 could be obsolete - use the Honeywell part number if possible. (3) Whenever an oversize insert must be replaced, drill out the hole to the diameter shown on the appropriate line of Figure 1, Page 3. Do not drill to a depth greater than that of the original hole, and be sure that at least 0.060 inch (1.52 mm) wall thickness remains after drilling. NOTE: It is not necessary to drill out holes when replacing a standard-sized insert with a 0.005 inch (0.13 mm) oversized insert. (4) (5) (6) (7) Countersink drilled holes to the major diameter of the insert to facilitate starting the replacement bushing. If the basic material is magnesium, treat surfaces of the hole with dichromate solution. Coat the external threads of the replacement insert with zinc chromate primer C03001 or Loctite Sealant C01-012. Using the Tap-Lok insert driver (see Figure 2, Page 4), drive the insert to 0.0050.040 inch (0.13-1.02 mm) below surrounding surfaces. Tap-Lok inserts are self-
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TAP-LOK INSERTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A tapping. Tap-Lok insert drivers are obtainable from the Groov-Pin Corporation and from Pentacon Aerospace Group. Refer to the List of Suppliers in Step D. of .
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Tap-Lok Replacement Inserts Figure 1
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Tap-Lok Insert Driver Figure 2
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LOK-THREAD STUDS - LOK-THREAD STUDS TASK 70-48-05-350-008 1. Lok-Thread Studs SUBTASK 70-48-05-99G-008 A. General. (1) Lok-Thread studs use a special, self-locking form of screw head which locks itself by flowing parent material of the tapped hole into the tooth flank voids by means of an interference fit on the minor diameter. Several methods of replacement may be used, depending on whether the nut end or Lok-Thread end of the stud is damaged, and on the condition of the tapped hole in the casing. The following procedures describe the type of repair to be used in each case. Lok Thread studs are available from the Maclean Maynard. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003.
(2)
SUBTASK 70-48-05-350-081 B. Materials and Equipment. (1) Refer to Tables 1, Page 3, 2, Page 3, 3, Page 4, 4, Page 5, and 5, Page 5 for LokThread stud dimensions and tap sizes.
SUBTASK 70-48-05-350-082 C. Procedure. (1) Replace studs with damaged nut threads or looseness with the tapped hole as follows: (a) (b) (c) Measure stand-out heights of stud to be replaced or one of the remaining studs in the same stud circle (dimension C, Figure 1, Page 6). Remove damaged stud with a stud removal tool and torque wrench. Observe torque. Inspect tapped hole for burrs, foreign material, and thread condition. Clean if necessary. If the threads are damaged, follow the procedure in paragraph C.(2). If removal torque of the damaged stud exceeded the minimum installation torque shown in Figure 1, Page 6, obtain a new standard size replacement part. If the torque value was low, select a 0.003 inch (0.08 mm), 0.006 inch (0.15 mm), 0.009 inch (0.23 mm) or 0.012 inch (0.30 mm) oversize replacement part from the Illustrated Parts Catalog (IPC). If the replacement stud becomes finger-tight when approximately halfway installed, remove and coat stud thread with zinc chromate primer C03-001or loctite sealant, grade A C01-187.
(d)
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STANDARD PRACTICES MANUAL AS907-1-1A (e) Drive the stud to the stand-out height of the original stud, or to the height of the remaining studs in the same stud circle. The torque required to install the stud to the required stand-out height must be within the values shown in Tables 1, Page 3, 2, Page 3, 3, Page 4, 4, Page 5, and 5, Page 5 in order to ensure proper locking action, and to prevent torsional failure of the stud during installation. If the installation torque is high, remove the stud and inspect for foreign material. Clean hole if necessary. Recoat the stud threads and reinstall. If the torque is low, install the next largest oversize stud. If satisfactory installation torque cannot be obtained with the largest available oversize stud, repair in accordance with paragraph C.(2).
(f) (g)
(2)
Repair aluminum parts with damaged internal threads in the tapped hole as follows: (a) Measure and record tap drill depth and thread depth of damaged hole, or as an alternate to measuring the thread depth of the tapped hole, determine thread depth requirement as follows: 1 2 3 (b) Measure and record length of replacement stud (dimension A, Figure 1, Page 6). Determine stand-out height of stud being replaced per step C.(1)(a). (dimension C, Figure 1, Page 6). Minimum thread depth = A-C.
Drill out damage and install threaded plug in accordance with TASK 70-4809-350-012, Repair of Blind Threaded Holes in Aluminum Castings. To allow final machining at the centerline of the original hole location, either drill a pilot hole through the center of the threaded plug before installing or keep the part centered under spindle, install threaded plug and center drill pilot hole. Tap drill, chamfer and tap to the requirements of Figure 2, Page 7. Depth of tap drill and minimum thread depth should be the same as recorded in paragraph C.(2)(a). Use flat bottom drill and bottoming tap to ensure meeting this requirement. NOTE: To make sure that tooling selected will produce a hole with the required assembly torque, it is recommended that a test hole be made in a scrap piece of the same material. If installation torque is outside the required limits, it may be increased by using a smaller modified minor diameter. A larger modified minor diameter will produce lower torque.
(c)
(d)
Install new stud in accordance with paragraph C.(1).
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Table 1. Data For Straight Studs Modified Minor diameter Lok-Thread Stud-End 6-32 8-32 10-24 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 3/8-11 Nominal Sizes Nut-End 6-32 8-36 10-32 1/4-28 5/16-24 3/8-24 7/16-20 1/2-20 9/16-18 5/8-16 Aluminum in. (mm) 0.1105 (2.807) 0.1120 (2.845) 0.1355 (3.442) 0.1375 (3.493) 0.1520 (3.861) 0.1550 (3.937) 0.2060 (5.232) 0.2089 (5.306) 0.2645 (6.718) 0.2675 (6.795) 0.3215 (8.166) 0.3245 (8.242) 0.3770 (9.576) 0.3800 (9.652) 0.4350 (11.049) 0.4380 (11.125) 0.4920 (12.497) 0.4960 (12.598) 0.3480 (12.919) 0.3520 (14.021) Magnesium in. (mm) 0.1120 (2.845) 0.1130 (2.870) 0.1380 (3.505) 0.1390 (3.531) 0.1555 (3.950) 0.1570 (3.988) 0.2080 (5.283) 0.2100 (5.334) 0.2665 (6.769) 0.2685 (6.820) 0.3230 (8.204) 0.3255 (8.268) 0.3780 (9.601) 0.3810 (9.677) 0.4360 (11.074) 0.4390 (11.151) 0.4925 (12.510) 0.4965 (12.611) 0.5490 (13.945) 0.5530 (14.046) Installation Torque lb-in. (Nm) 15-32 (1.7-3.6) 20-60 (2.3-6.8) 30-90 (3.4-10.2) 45-225 (5.1-25.4) 90-450 (10.2-50.8) 120-500 (13.656.5) 150-1300 (16.9146.9) 225-2100 (25.4237.3) 300-3000 (33.9339.0) 430-4200 (5.1474.5)
Table 2. Stepped Stud Data (Difference: One Thread Size) Modified Minor diameter Lok-Thread Stud-End 8-32 10-24 1/4-20 Nominal Sizes Nut-End 6-32 8-36 10-32 Aluminum in. (mm) 0.1360 (3.454) 0.1380 (3.505) 0.1540 (3.912) 0.1555 (3.950) 0.2070 (5.258) 0.2085 (5.296) Magnesium in. (mm) 0.1380 (3.505) 0.1395 (3.543) 0.1555 (3.950) 0.1570 (3.988) 0.2085 (5.296 0.2105 (5.347) Installation Torque lb-in. (Nm) 15-32 (1.7-3.6) 20-60 (2.3-6.8) 30-90 (3.4-10.2)
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Table 2. Stepped Stud Data (Difference: One Thread Size) (Cont) Modified Minor diameter Lok-Thread Stud-End 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 Nominal Sizes Nut-End 1/4-28 7/16-24 3/4-24 7/16-20 1/2-20 9/16-18 Aluminum in. (mm) 0.2665 (6.769) 0.2685 (6.820) 0.3235 (8.217) 0.3250 (8.255) 0.3790 (9.627) 0.3805 (9.665) 0.4370 (11.100) 0.4385 (11.138) 0.4940 (12.548) 0.4965 (12.611) 0.5510 (13.995) 0.5530 (14.046) Magnesium in. (mm) 0.2675 (6.795) 0.2695 (6.845) 0.3245 (8.242) 0.3260 (8.280) 0.3800 (9.652) 0.3815 (9.690) 0.4380 (11.125) 0.4395 (11.163) 0.4940 (12.548) 0.4960 (12.598) 0.5420 (13.767) 0.5435 (13.805) Installation Torque lb-in. (Nm) 45-225 (5.1-25.4) 90-450 (10.2-50.8) 120-300 (13.656.5) 150-1300 (16.9146.9) 225-2100 (25.4237.3) 300-3000 (33.9339.0)
Table 3. Stepped Stud Data (Difference: Two Thread Sizes) Modified Minor diameter Lok-Thread Stud-End 10-24 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 Nominal Sizes Nut-End 6-32 8-36 10/32 1/4-28 5/16-24 3/8-24 7/16-20 1/2-20 Aluminum in. (mm) 0.1545 (3.924) 0.1565 (3.975) 0.2085 (5.296) 0.2110 (5.359) 0.2670 (6.782) 0.2690 (6.833) 0.3245 (8.242) 0.3260 (8.280) 0.3800 (9.652) 0.3815 (9.690) 0.4380 (11.125) 0.4395 (11.163) 0.4955 (12.586) 0.4975 (12.637) 0.5520 (14.021) Magnesium in. (mm) 0.1565 (3.975) 0.1575 (4.000) 0.2100 (5.334) 0.2115 (5.372) 0.2685 (6.820) 0.2700 (6.858 0.3255 (8.268) 0.3270 (8.306) 0.3805 (9.665) 0.3820 (9.703) 0.4390 (11.151) 0.4405 (11.189) 0.4955 (12.586) 0.4970 (12.624) 0.5530 (14.046) Installation Torque lb-in. (Nm) 15-32 (1.7-3.6) 20-60 (2.3-6.8) 30-90 (3.4-10.2) 45-225 (5.1-25.4) 90-450 (10.2-50.8) 120-500 (13.656.5) 150-1300 (16.9146.9) 275-2100 (31.1237.3)
EFFECTIVITY: ALL
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Table 4. Stepped Stud Data (Difference: Three Thread Sizes) Modified Minor diameter Lok-Thread Stud-End 1/4-20 5/16-18 3/8-16 7/16-14 1/2-13 9/16-12 5/8-11 Nominal Sizes Nut-End 6-32 8-36 10-32 1/4-28 5/16-24 3/8-24 7/16-20 Aluminum in. (mm) 0.2105 (5.347) 0.2115 (5.372) 0.2690 (6.833) 0.2700 (6.858) 0.3245 (8.243) 0.3265 (8.293) 0.3805 (9.665) 0.3825 (9.716) 0.4390 (11.151) 0.4400 (11.176) 0.4965 (12.611) 0.4980 (12.649) 0.5530 (14.046) 0.5545 (14.084) Magnesium in. (mm) 0.2105 (5.347) 0.2115 (5.372) 0.2690 (6.833) 0.2750 (6.985) 0.3250 (8.255) 0.3265 (8.293) 0.3810 (9.677) 0.3825 (9.716) 0.4390 (11.151) 0.4400 (11.176) 0.4965 (12.611) 0.4980 (12.649) 0.5530 (14.046) 0.5545 (14.084) Installation Torque lb-in. (Nm) 15-32 (1.7-3.6) 20-60 (2.3-6.8) 30-90 (3.4-10.2) 45-225 (5.1-25.4) 90-450 (10.2-50.8) 120-500 (13.656.5) 150-1300 (16.9146.9)
Table 5. Lok-Thread Tapping Data Tap Size (UNC) 1/4-20, GH-3 5/6-18, GH-3 3/8-16, GH-3 7/16-14, GH-3 9/16-12, GH-3 5/8-11, GH-3 3/4-10, GH-3 Minor Diameter inch (millimeter) 0.1980-0.2028 (5.029-5.151) 0.2654-0.2683 (6.741-6.815) 0.3225-0.3252 (8.192-8.260) 0.3770-0.3800 (9.576-9.652) 0.4945-0.4965 (12.560-12.611) 0.5500-0.5520 (13.970-14.021) 0.6680-0.6700 (16.967-17.018)
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Lok-Thread Stud Installation Requirements Figure 1
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Matching Requirements for Threaded Hole Repair Figure 2
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FLUID-FITTING INSERTS - RING-LOCKED FLUID-FITTING (ROSAN) INSERTS TASK 70-48-07-350-010 1. Ring-Locked Fluid-Fitting (Rosan) inserts SUBTASK 70-48-07-99G-010 A. General. (1) Ring-locked (Rosan) inserts can be replaced when damaged or otherwise unserviceable. Rosan fluid fitting inserts make use of an O-ring to seal the space between the insert and the parent material. A serrated ring, rather than tightness of fit, locks the insert in place; therefore, unserviceable parts can be replaced without damaging threads of the parent material, and oversized replacement parts are not required. NOTE: Rosan inserts are available from Fairchild Fasteners Direct. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. SUBTASK 70-48-07-350-101 B. Replacement Procedure. (1) Remove old insert as directed in the following Steps: CAUTION: BEFORE MACHINING, MASK OR PLUG INTERNAL PASSAGES TO PREVENT CONTAMINATION. (a) (b) Obtain drill bit of proper size from Figure 1, Page 4. The drill bit must be centered with the insert internal threads. Set drill stop so that the drill bit diameter will penetrate 0.160 inches (4.06 mm) below the parent material surface. Drill until insert has separated, which will normally be about 0.140 inches (3.56 mm) below the parent material surface. NOTE: This drilling operation will separate the insert in the O-ring gland area thereby not touching the parent material cavity or the lockring. (c) (d) Lift the upper portion of the insert out. Using a screw extractor or similar device, unscrew the bottom half of the insert from the cavity. The lockring will still be in the parent material.
CAUTION: DO NOT PRY OUT LOCKRING. THIS COULD DAMAGE THE 20 DEGREE ANGLE OF THE CAVITY SEALING SURFACE AND ALSO COULD ENLARGE OR DAMAGE PARENT MATERIAL SERRATIONS AND AFFECT THE SECURITY OF A REPLACEMENT LOCKRING. (e) Select a removal counterbore tool from Figure 1, Page 4. This tool pilots in the minor diameter of the cavity thread and bores into the lockring without touching the parent material serrations.
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RING-LOCKED FLUID-FITTING (ROSAN) INSERTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (f) Bore into the lockring 0.050-0.055 inches (1.27-1.40 mm) deep. This will leave a thin wall and external serrations on lockring and separate the lockring pilot. Using a thin pointed punch, collapse the remaining portion of the lockring radially inward being careful not to mark the parent material. Remove lockring and lockring pilot. Remove all loose or hanging burrs in counterbore area and clean cavity. Purge unit or system.
(g)
(h) (i) (2)
Install a new insert in the following manner: (a) (b) (c) (d) Select a replacement insert, lockring, and O-ring of the same size as those being replaced. Lubricate internal surfaces of the machines cavity with an approved engine oil, completely wetting all surfaces. Place lockring over the insert, pilot side down, as shown in Figure 2, Page 5, location P. Place a pilot sleeve (bullet) over the threaded end of the insert. NOTE: It is preferable that the bullet be made of Teflon, and that it be threaded to mate with the external thread of the insert. The largest diameter of the bullet should be no more than 0.025 inch (0.64 mm) larger than the nominal diameter of the insert threads to prevent overstretching the O-ring. (e) (f) Immerse both the insert assembly and the O-ring in an approved engine oil, then slide the O-ring completely over the bullet and into the O-ring groove. Remove the bullet.
CAUTION: DO NOT TURN THE INSERT ASSEMBLY COUNTERCLOCKWISE AFTER THE O-RING HAS BEGUN TO ENTER THE MACHINED CAVITY. IT WILL DAMAGE THE O-RING. IF O-RING IS THUS DAMAGED, BACK OUT THE INSERT ASSEMBLY, REPLACE THE O-RING [STEPS (D) THROUGH (F)] AND REPEAT STEP (G). (g) Using the appropriate wrench shown in Figure 1, Page 4, screw the insert assembly into the machined cavity until it is hand tight. Place a 0.005 inch (0.13 mm) thick shim between the lockring and the parent material during installation to prevent the lockring teeth from entering the parent material serrations (shim is not required on parts with repaired internal cavities). Tighten the insert, still using the 0.005 inch (0.13 mm) thick shim to the low torque limit shown in Figure 1, Page 4. Visually check to see if the lockring external serrations are aligned with the serrations in the parent material. If the serrations are not aligned; continue to tighten until the next tooth segment is aligned.
(h)
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STANDARD PRACTICES MANUAL AS907-1-1A (i) Place the appropriate locking driving tool (see Figure 1, Page 4, Installation Tooling) over the wrench body and drive the lockring into the parent material. NOTE: On parts with repaired internal cavities, torque insert to within the torque limits specified, then drive the lock-ring. The lockring will cut the serrations in the parent material. This Step is only for parts repaired per SUBTASK 70-48-07-350-102, Parts Repair Procedure. (j) Remove the lock-ring drive tool and then the wrench.
EFFECTIVITY: ALL
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Insert Replacement Data Figure 1
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Installation of O-Ring Figure 2
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-48-07-350-102 C. Parts Repair Procedure. (1) Repair aluminum parts with damaged internal threads in parent material as follows: (a) (b) Mask or plug internal passages to prevent contamination. Drill out damage and install threaded plug in accordance with TASK 70-4809-350-012, Repair of Blind Threaded Holes in Aluminum Castings, or TASK 70-48-10-350-013, Repair of Threaded Through-Holes in Aluminum Castings. To allow final machining of the boss on the centerline of the original hole either drill a pilot hole through the center of the threaded plug before installing it, or keep the boss centered under spindle after drilling out damage, install threaded plug, then center drill pilot hole. Machine boss at the original hole location to accept a standard size insert. See Figure 3, Page 7 for machining requirements. NOTE: The port contour cutter tools listed in Figure 1, Page 4 will facilitate machining of the internal cavity. After tap drilling 0.015-0.030 inch (0.38-0.76 mm) undersize the contour cutter will finish the thread minor diameter and all other characteristics in one operation. The part is then tapped per Figure 3, Page 7. (2) Install new insert in accordance with SUBTASK 70-48-07-350-101, Replacement Procedure.
(c)
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Machining Requirements for Threaded Hole Repair Figure 3
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EFFECTIVITY: ALL
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THIN-WALL INSERTS - THIN-WALL INSERTS TASK 70-48-08-350-011 1. Thin-Wall Inserts SUBTASK 70-48-08-99G-011 A. General. (1) (2) (3) (4) This chapter defines the procedure and provides the data for replacement for thinwall inserts. Thin-wall inserts are used to ensure retention of bolts installed in any material. This retention is achieved by distortion of the internal threads of the inserts. The insert is secured by swaging its serrated end in the smooth or serrated recess pre-machined into the part.
SUBTASK 70-48-08-350-051 B. Equipment. (1) (2) Reference No. SR19D SR25D SR31D SR37D SR050 SRW19D SRW25D SRW31D SRW37D SRW50D Reference No. SRW19T SRW25T SRW31T SRW37T SRW50 SR19W-A SR25W-A SR31W-A SR37W-A SR50W-A Radial Drilling Machine, Arbor Press. Specific Tooling Available Commercially: Description Step Drill for Pilot Hole drilling
Description Tap
Insert Removal/Installation Wrench
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THIN-WALL INSERTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SR19S-A SRW19S-A SR25S-A SRW25S-A SR31S-A SRW31S-A SR37S-A SRW37S-A SR50S-A SRW50S-A SR19R SRW19R SR25R SRW25R SR31R SRW31R SR37R SRW37R SR50R SRW50R SRPBT19 SRPBT25 SRPBT31 SRPBT37 Reference No. SRPBT19-3 SRPBT25-3 SRPBT31-3 SRPBT37-3 SRPBT19WP SRPBT25WB SRPBT31WB SRPBT37WB SRPBT50WB1 SRPBT19 SRPBT25 SRPBT31 SRPBT37 SR19CSD-A SR25CSD-A SR31CSD-A SR37CSD-A SR50CSD-A SRW19CSD-A SRW25CSD-A SRW31CSD-A SRW37CSD-A (a) Swage Tool
Insert Removal Tool
Manually-operated Broaching Tool
Description Cutter
Gage
All the above tools and Wobbling Drift Tool Holder Type WB (Reference No. W 37600) are available from:
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Fairchild Fasteners Direct Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. (b) Wobbling Drift Tool Holder Type WB (Reference No. W 37600) is also available from: Index-Werkeeg Hahn and Tessky Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. SUBTASK 70-48-08-350-052 C. Material (1) Thin-wall inserts are available from the following manufactures or their representatives: Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003.
Fairchild Fasteners Direct
SUBTASK 70-48-08-350-053 D. Procedure. NOTE: Unless otherwise indicated in the applicable Engine/Shop Manual, damaged inserts should be replaced by identical inserts or, if the condition of the recess does allow this, by oversized inserts selected from the IPC. (1) Remove Defective Insert. (a) Drill out the swaged part of insert using the appropriate removal tool. See Figure 1, Page 6 for Rosan inserts and or Figure 2, Page 7 for Microdot inserts. Remove insert using removal/installation wrench. See Figure 3, Page 8. Clean insert recess to remove all loose particles.
(b) (c) (2)
Check Insert Recess. (a) Perform visual check of condition of insert recess, and if necessary a dimensional check to ensure that a new insert can be installed. See Figure 4 (Sheet 1 of 2), Page 9. NOTE: If recess condition is not satisfactory, provide for installation of oversized insert. (b) Where deterioration is only slight, the threads may be rechased using a tap. 1 Tappings for insert installation have unified profile and are Class 3B (except for inner diameter which is larger). Tapping is performed using standard taps, except for oversized inserts which require special taps. See Figure 5, Page 11.
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STANDARD PRACTICES MANUAL AS907-1-1A (3) Rework Insert Recess. (a) Drill pilot hole. 1 Measure depth of pilot hole and compare with value in Figure 4 (Sheet 1 of 2), Page 9 for diameter concerned. a Where measured depth corresponds to value of Figure 4 (Sheet 1 of 2), Page 9, redrill to new dimensions in Figure 4 (Sheet 1 of 2), Page 9 using special drill from Figure 5, Page 11. Where measured depth does not correspond to values in Figure 4 (Sheet 1 of 2), Page 9, redrill to new diameters per Figure 4 (Sheet 1 of 2), Page 9. Do not exceed existing depth. Use standard drills, the special drills in Figure 5, Page 11 cannot be used.
Recut hole entry facing per Figure 4 (Sheet 1 of 2), Page 9. NOTE: This only applies when the workpiece was so machined previously.
(b)
Broach recess entry. NOTE: The entry of the insert recess may be serrated. The purpose of the serrations is to facilitate swaging of the insert in hard materials. The broaching operation is only applied to recess entries which were serrated originally. 1 Broach recess entry per Figure 6, Page 12 or Figure 7 (Sheet 1 of 2), Page 13 according to hardness of material.
(c)
Tap recess. 1 Perform tapping of recess per Figure 4 (Sheet 1 of 2), Page 9 and Figure 5, Page 11. NOTE: The first tap may mark the counterbore. Ensure that the following taps engage correctly in the threading already started.
(4)
Install New Inserts. (a) Check parts before installation. 1 2 3 Tappings must be clean and free from tears and all foreign particles. Outer threads of inserts must be clean and free from burrs or roughness. There should be lubricant on the inserts (silver plating or lubricating compound). Discard defective parts. Do not add any other lubricant during installation.
(b)
Install insert.
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STANDARD PRACTICES MANUAL AS907-1-1A 1 2 Screw insert into its recess using the installation wrench per Figure 3, Page 8. Swage insert using swage tool and either pressing or striking until the nylon stop seats against the part face. See Figure 3, Page 8.
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Removal Tool Reference Number for Rosan Inserts Figure 1
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Replacement Data for Microdot (Kaylock) Inserts Figure 2
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Installation/Removal Tools: Reference Numbers Figure 3
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Insert Recess Dimensions Figure 4 (Sheet 1 of 2)
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Insert Recess Dimensions Figure 4 (Sheet 2)
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Drill and Tap Reference Numbers Figure 5
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Broaching of Pilot Holes in All Materials (Except Titanium) of Hardness Lower than HB 250 Figure 6
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Broaching of Pilot Holes in Titanium and Material of Minimum Hardness HB 250 Figure 7 (Sheet 1 of 2)
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Broaching of Pilot Holes in Titanium and Material of Minimum Hardness HB 250 Figure 7 (Sheet 2)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-48-08-350-054 E. Parts Repair Procedure. (1) Repair aluminum parts that have damaged internal threads in the parent material as follows: (a) If threaded hole in parent material has been damaged, repair by installing threaded plug as directed in TASK 70-48-09-350-012, Repair of Blind Threaded Holes in Aluminum Castings, or TASK 70-48-10-350-013, Repair of Threaded Through-Holes in Aluminum Castings. Machine boss at original hole location to accept standard size insert. See Figure 4 for machining requirements. NOTE: In order to locate centerline of original hole, machine pilot hole through center of threaded plug or keep part centered under spindle until plug has been installed, then center drill pilot hole. (2) Install new insert in accordance with SUBTASK 70-48-08-350-053, Procedure.
(b)
SUBTASK 70-48-08-350-055 F. Quality Assurance. (1) Check insert installation using a gage per Figure 8, Page 16 as follows: (a) Check swaging by inserting the gage end marked G into the insert swaging counterbore. NOTE: Swaging is correct when gage shoulder is flush with face of workpiece. (b) Check position by inserting the gage end marked U into the insert swaging counterbore. NOTE: Position is correct when there is clearance between gage shoulder and face of workpiece.
EFFECTIVITY: ALL
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Checking Installed Inserts Figure 8
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REPAIR OF BLIND THREADED HOLES - REPAIR OF BLIND THREADED HOLES IN ALUMINUM CASTINGS TASK 70-48-09-350-012 1. Repair of Blind Threaded Holes in Aluminum Castings SUBTASK 70-48-09-99G-012 A. General. (1) Blind threaded holes that have been damaged in aluminum castings can be repaired when sufficient metal remains. See Figure 1, Page 2. The method is similar to installing a commercially available threaded insert into the hole, except that the hole is prepared and a bushing fabricated as described below.
EFFECTIVITY: ALL
70-48-09
REPAIR OF BLIND THREADED HOLES IN ALUMINUM CASTINGS Page 1 Dec 01/03
Repair of Blind Threaded Holes Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-48-09-350-121 B. Preparation of Hole. (1) Select a tap drill that will drill out all damage, leaving a wall thickness of at least 0.125 inch (3.18 mm) after tapping, and allowing for 0.063 inch (1.60 mm) minimum wall thickness of the installed tapped bushing. See Figure 1, Page 2. Carefully position the tap drill over the center of the hole, and drill out the boss to the depth of the original hole. Tap the hole in 2 operations, using a plug tap of the proper size to start the threads, and a bottoming tap to continue full threads to the bottom of the hole.
(2) (3)
SUBTASK 70-48-09-350-122 C. Fabrication of Plug. (1) Fabricate a threaded plug from aluminum, AMS 4117, AMS 4218, or AMS 4219 or aluminum bronze, AMS 4640, using the following procedure: (a) Machine and thread plug as required to mate with the threads tapped in SUBTASK 70-48-09-350-121, Preparation of Hole. Finished length of the plug must be at least 0.100 inch (2.54 mm) longer than the threaded depth of the hole. Chamfer end of plug. (Optional.) Drill a pilot hole through the entire length of the plug along its axial centerline. Diameter of the hole is not critical, as long as it is smaller than the tap drill to be used for the final internal threads of the bushing, and large enough to serve as a pilot hole. The hole must be concentric with external thread diameter within 0.007 inch (0.18 mm). NOTE: The pilot hole also acts as a vent when the plug is being screwed into the boss. (c) (Optional.) Cut or mill a diametral slot in the unchamfered end of the plug, not more than 0.063 inch (1.60 mm) deep, to permit the use of a screwdriver for assembly.
(b)
SUBTASK 70-48-09-350-123 D. Installation of Plug. (1) Install the threaded plug in the tapped hole as follows: See Figure 1, Page 2. (a) (b) (c) (d) Coat the plug and threaded hole lightly with epoxy adhesive. Refer to TASK 70-43-17-360-002, Epoxy Repair of Mating Surfaces and Inserts. Screw plug into threaded hole until plug bottoms. Wipe off excess epoxy resin immediately, and let epoxy on threads cure for 24 hours at room temperature. After curing, machine plug flush with face of boss.
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STANDARD PRACTICES MANUAL AS907-1-1A (e) Drill a hole 0.093-0.094 inch (2.36-2.39 mm) diameter and 0.250-0.260 inch (6.35-6.60 mm) deep at the pitch line of the threaded hole and plug. See Figure 1, Page 2. Machine an aluminum (AMS 4218, AMS 4219 or AMS 4640) pin 0.093 inch (2.36 mm) in diameter and 0.240 inch (6.1 mm) long. Insert pin in hole, and peen or stake opening to retain. Remove any raised metal. Tap-drill, chamfer and tap the plug to the location and dimension of the original threaded hole. Finished wall thickness of the bushing after tapping must be at least 0.063 inch (1.60 mm). Touch up the repaired surfaces, using the chemical surface refinishing process. Refer to TASK 70-43-07-380-007, Chemical Touch-Up Surface Refinishing Process for Aluminum. Pressure check if function of part requires it. No leakage is permissible.
(f)
(g)
(h)
(i)
EFFECTIVITY: ALL
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REPAIR OF THREADED THROUGH-HOLES - REPAIR OF THREADED THROUGH-HOLES IN ALUMINUM CASTINGS TASK 70-48-10-350-013 1. Repair of Threaded Through-Holes in Aluminum Castings SUBTASK 70-48-10-99G-013 A. General. (1) Open or through threaded holes that have been damaged in aluminum castings can be repaired when sufficient metal remains. See Figure 1, Page 2. The method is similar to installing a commercially available threaded insert into the hole, except that the hole is prepared and a bushing fabricated as described below.
EFFECTIVITY: ALL
70-48-10
REPAIR OF THREADED THROUGH-HOLES IN ALUMINUM CASTINGS Page 1 Dec 01/03
Repair of Open or Through Holes Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-48-10-350-131 B. Preparation of Hole. (1) Select a tap drill that will drill out all damage, leaving a wall thickness of at least 0.125 inch (3.18 mm) after tapping, and allowing for 0.063 inch (1.60 mm) minimum wall thickness of the installed tapped bushing. See Figure 1, Page 2. Carefully position the drill over the center of the hole, and drill through the entire depth of the boss. Using a standard plug tap of the appropriate size, tap the hole until all truncated threads of the tap extend beyond the bottom surface of the casting.
(2) (3)
SUBTASK 70-48-10-350-132 C. Fabrication of Plug. (1) Fabricate a threaded plug from aluminum, AMS 4117, AMS 4218, or AMS 4219, or aluminum bronze, AMS 4640, using the following procedure. (a) Machine and thread a plug as required to mate with the threads tapped in SUBTASK 70-48-10-350-131, Preparation of Hole. Finished length of plug must be at least 0.100 inch (2.54 mm) longer than threaded depth of hole. Chamfer end of plug. (Optional.) Drill a pilot hole through the entire length of the plug along its axial centerline. Diameter of the hole is not critical, as long as it is smaller than the tap drill to be used for the final internal threads of the bushing, and large enough to serve as a pilot hole. The hole must be concentric with external thread diameter within 0.007 inch (0.18 mm). (Optional.) Cut or mill a diametral slot in the unchamfered end of the plug, not more than 0.063 inch (1.60 mm) deep, to permit the use of a screwdriver for assembly.
(b)
(c)
SUBTASK 70-48-10-350-133 D. Installation of Plug. (1) Install the threaded plug in the tapped hole as follows: See Figure 1, Page 2. (a) (b) (c) (d) Coat the plug and threaded hole lightly with epoxy adhesive. Refer to TASK 70-43-17-360-002, Epoxy Repair of Mating Surfaces and Inserts. Screw plug into threaded hole until bottom of plug is flush with bottom surface of casting, using screwdriver or similar type of tool as required. Wipe off excess epoxy resin immediately, and let epoxy on threads cure for 24 hours at room temperature. After curing, machine the plug flush with face of boss.
EFFECTIVITY: ALL
70-48-10
STANDARD PRACTICES MANUAL AS907-1-1A (e) Drill a hole 0.093-0.094 inch (2.36-2.39 mm) diameter and 0.250-0.260 inch (6.35-6.60 mm) deep at the pitch line of threaded hole and plug. See Figure 1, Page 2. Machine an aluminum (AMS 4218, AMS 4219, or AMS 4640) pin 0.093 inch (2.36 mm) in diameter and 0.240 inch (6.1 mm) long. Insert pin in hole, and peen or stake opening to retain. Remove any raised metal. Tap drill, chamfer and tap the plug to the location and dimension of the original threaded hole. Finished wall thickness of the bushing, after tapping, must be at least 0.063 inch (1.57 mm). Touch up the repaired surfaces, using the chemical surface refinishing process. Refer to TASK 70-43-07-380-007, Chemical Touch-Up Surface Refinishing Process for Aluminum. Pressure check if function of part requires it. No leakage is permissible.
(f)
(g)
(h)
(i)
EFFECTIVITY: ALL
70-48-10
KEY-LOCKED INSERTS - INSTALLATION OF KEY-LOCKED INSERTS TASK 70-48-11-350-014 1. Installation of Key-Locked Inserts SUBTASK 70-48-11-99G-014 A. General. (1) Locked-in (key-locked) thread inserts are used to provide a wear resistant internal thread in parts made of aluminum and titanium alloys. In parts made of other alloys, they are used to repair holes with mismatched or damaged threads. This style of insert is installed into a threaded hole in the part and then locked with keys to prevent the insert from turning and becoming detached. The insert can be easily replaced if it is damaged or otherwise unserviceable without causing damage to the threaded hole into which it is installed. An oversize insert is usually not necessary unless the threaded hole in the part is damaged. These inserts are available with or without locking keys and in different materials and coatings. They are available in military standard (MS) parts, national aerospace standard (NAS) parts, supplier catalog parts, or special design parts by the engine manufacturer. When installing inserts, refer to the applicable manual repair, or the Illustrated Parts Catalog (IPC), for the correct replacement insert or the correct oversize insert.
(2)
SUBTASK 70-48-11-350-141 B. Procedure. (1) Remove the used insert as follows: Refer to Figure 1, Page 4. (a) Drill a hole in the insert concentric with the internal thread. Use a drill bit of the size and drill to the depth that is specified in Figure 1, Page 4. NOTE: The drill bit size is equal to the distance between two opposite insert keys. (b) (c) (d) (e) (2) Using a small punch and a hammer to move the keys inward and break them off. Remove the remaining part of the insert with a standard screw extractor. Clean the threaded hole until it is free of chips, burrs and unwanted material. If the threaded hole in the part is not damaged, install the new insert. Paragraph B.(3). tells you the procedure.
If the threaded hole in the part is damaged, prepare the hole for the installation of a new insert as follows:
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INSTALLATION OF KEY-LOCKED INSERTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (a) Get the correct oversize insert as specified in the applicable manual repair, or in the IPC. 1 If the part is aluminum and an oversize insert is not available, repair the threaded hole. Refer to TASK 70-48-09-350-012, Repair of Blind Threaded Holes in Aluminum Castings, or TASK 70-48-10-350-013, Repair of Threaded Through-Holes in Aluminum Castings. Machine (drill, countersink and tap) the hole for a standard size insert.
(b)
Machine the threaded hole in the part for the new insert. Use the data in Figure 2 (Sheet 1 of 2), Page 5 that applies to the size, pitch and length of the external threads on the new insert. NOTE: When the threaded hole in the part is a blind hole, do not tap drill deeper than the bottom of the first hole.
(c)
If the part is not aluminum, broach the keyways for the insert as follows: 1 2 3 4 Thread the insert into the hole until the insert is flush to 0.030 inch (0.76 mm) below the surface of the part. Turn the insert as necessary to keep the maximum distance from the locking keys to the nearest edge of the part. Refer to Figure 3, Page 7. Temporarily mark the angular position of one of the keys, then remove the insert. Align the cutter on the broaching tool with the temporary mark as you put the tool into the threaded hole. Broach the keyways to the dimensions shown in Figure 3, Page 7. You may use a hammer or press to move the broaching tool. NOTE: Broaching tools may be ordered from the following suppliers. Specify the minor diameter of the threaded hole in which the insert is installed, and the number of locking keys in the insert. Fairchild Fasteners Direct Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003.
(3)
Install the new insert as follows: (a) Refer to the IPC or the applicable repair in the applicable manual for the part number of the new insert. NOTE: The new insert must be the same type (locking or nonlocking) and must have the same internal threads as the used insert. Refer to Figure 4, Page 8 for identify the types and styles of inserts. (b) Put the new insert into the installation tool. Refer to Figure 5, Page 9. NOTE: Installation tools are available from the suppliers given in paragraph B.(2)(c)4. Specify the sizes of the internal and external threads, and the number of keys in the inserts.
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STANDARD PRACTICES MANUAL AS907-1-1A WARNING: ZINC CHROMATE PRIMER IS FLAMMABLE AND POISONOUS. KEEP IT AWAY FROM SPARKS, FLAMES, AND HEAT. WHEN USING ZINC CHROMATE PRIMER, WEAR GLOVES AND DO NOT BREATHE THE FUMES. DO NOT GET IT IN YOUR MOUTH OR EYES, OR ON YOUR SKIN. FAILURE TO OBEY THIS INSTRUCTION CAN RESULT IN INJURY TO PERSONS AND DAMAGE TO EQUIPMENT.
(c) (d)
If the part is aluminum, coat the external threads of the new insert with zinc chromate primer C03-001 and install the insert while the primer is wet. Thread the insert into the hole until it is 0.010-0.030 inch (0.25-0.76 mm) below the surface of the part and the locking keys are aligned with one of the keyways. In hard materials, the keys of the new insert must be aligned with the keyways in the tapped hole. In soft materials, it is not necessary to align the keys with the keyways. They may be turned approximately 45 degrees from their initial location. If the replacement insert is not 0.010-0.030 inch (0.25-0.76 mm) below the surface of the part, pre-assemble the other parts to find the correct location before the keys are set. Remove the installation tool, turn the opposite end of the tool toward the hole, and then move the locking keys downward by tapping on the end face of the tool with a hammer. The keys must be 0.010-0.030 inch (0.25-0.76 mm) below the surface of the part.
(e)
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Removal of existing Insert Figure 1
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Dimensions for Threaded Holes (Inches) Figure 2 (Sheet 1 of 2)
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Dimensions for Threaded Holes (Millimeters) Figure 2 (Sheet 2)
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Dimensions for Broaching Keyways Figure 3
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Identification of Insert Types Figure 4
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Installation of Inserts Figure 5
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KEY-LOCKED STUDS - INSTALLATION OF KEY-LOCKED STUDS TASK 70-48-12-350-021 1. Installation of Key-Locked Studs SUBTASK 70-48-12-99G-021 A. General. (1) The locked-in (key-locked) stud is installed into a threaded hole machined in the parent material of the part, then locked by means of keys which prevent turning and unscrewing. This style of stud can be easily replaced if damaged, or is otherwise unserviceable without damage to the threaded hole in which the stud is installed. The use of oversize studs is usually not necessary unless damage has occurred to the threaded hole in parent material. Locked-in (key-locked) studs are available with and without safety wire holes in the nut end thread and in a variety of thread sizes and materials. They are available in military standard (MS) parts, supplier catalog parts, or special design parts by the engine manufacturer. When installing studs refer to the applicable manual repair or to the Illustrated Parts Catalog (IPC) for the proper replacement stud or for the proper oversize stud.
(2)
SUBTASK 70-48-12-350-211 B. Procedure. (1) Remove existing stud as follows: See Figure 1, Page 4. (a) (b) (c) Cut off the nut end thread flush to slightly above the surface of the parent material. Center drill a starter hole concentric with the remaining portion of the nut end. Drill to the size and depth shown in Figure 1, Page 4. NOTE: The drill bit size is equal to the distance between diametrically opposite keys. CAUTION: DO NOT DRILL INTO THE PARENT MATERIAL. (d) (e) (f) (g) Drill through the stud end with a drill bit for the size of screw extractor to be used. Use small punch and hammer, deflect the keys inward and break them off. Remove remaining portion of the stud end with a standard screw extractor. Remove chips, burrs and foreign material from threaded hole, and inspect thread condition.
EFFECTIVITY: ALL
70-48-12
INSTALLATION OF KEY-LOCKED STUDS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (h) (2) If threads are damaged, repair per paragraph B.(2).
Repair damaged threaded holes for installation of studs as follows: (a) Obtain the proper oversize stud as specified in the applicable manual repair or the IPC. NOTE: On aluminum parts if an oversize stud is not available, repair the threaded hole per TASK 70-48-09-350-012, Repair of Blind Threaded Holes in Aluminum Castings, or TASK 70-48-10-350-013, Repair of Threaded Through-Holes in Aluminum Castings, and machine for an original size stud. (b) Machine (drill, countersink and tap) a hole for the stud in accordance with the data in Figure 2, Page 5 as applicable for the size, pitch and length of the external threads of the stud to be installed. NOTE: When the hole in the part is a blind hole, do not tap drill deeper than the bottom of the original hole. (c) If the part is other than aluminum or magnesium, broach keyways for the stud as follows: 1 2 3 4 Thread the stud into the hole until the stud end is 0.010-0.030 inch (0.250.76 mm) below the surface. Turn the stud as necessary to maximize the distance from the locking keys to the nearest edge of the part. See Figure 3, Page 6. Temporarily mark the angular position of any key, then remove the stud. Place the broach tool into the threaded hole with its cutter aligned with the temporary mark then broach the keyways to dimensions shown in Figure 3, Page 6. The broaching tool may be driven with a hammer or press. Tools for broaching the keyways may be ordered from the listed suppliers by specifying the minor diameter of the threaded hole in which the stud is installed and the number of locking keys in the stud. Fairchild Fasteners Direct. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003.
(3)
Install replacement stud as follows: (a) Refer to the IPC or to the applicable repair in the manual for the part number of the replacement. NOTE: The replacement stud must be the same type as the original stud (with or without safety wire holes and with same nut end threads and length).
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STANDARD PRACTICES MANUAL AS907-1-1A (b) Place the stud into the installation tool. See Figure 4, Page 7. NOTE: The installation tools may be ordered by specifying the internal and external threads and the number of keys in the stud, from the source listed to order broaching tools. (c) When the part in which the stud is to be installed is aluminum or magnesium, coat the external threads of the stud with zinc chromate primer C03-001 and install stud while the primer is wet. Thread the stud into the hole until 0.010-0.030 inch (0.25-0.76 mm) below the surrounding surface and with the locking keys aligned with any existing keyways. In hard materials, the keys of the new stud must be aligned with the keyways in the tapped hole. In soft materials, the keys need not be aligned with the existing keyways, and may be relocated approximately 45 degrees from the original location. If replacement stud does not meet the requirement of being 0.010-0.030 inch (0.25-0.76 mm) below the surface, trial-assemble other parts to determine the correct orientation before the keys are set. Position the installation tool to allow its end face to rest on the keys. Strike the end of the tool to drive the keys inward. The keys must be flush to 0.030 inch (0.76 mm) below the surrounding surface.
(d)
(e)
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Removal of Studs Figure 1
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Dimension for Threaded Holes Figure 2
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Dimensions for Broaching Keyways Figure 3
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Installation of Studs Figure 4
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SHANK NUT REPAIR - SHANK NUT REPAIR TASK 70-48-13-350-024 1. Shank Nut Repair SUBTASK 70-48-13-99G-024 A. General. (1) The following procedure must be used to repair shank nuts that are damaged beyond usable limits specified in the applicable manual.
SUBTASK 70-48-13-350-241 B. Equipment. (1) Flaring tool.
SUBTASK 70-48-13-350-242 C. Materials. (1) Use only approved replacement parts specified in applicable manual.
SUBTASK 70-48-13-350-243 D. Procedure. (1) (2) (3) Remove shank nuts from their mounting flanges by drilling into the base of flared shank of the nut. Select proper drill size for the part being replaced (refer to applicable manual). Replace shank nuts as shown in Figure 1, Page 2.
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SHANK NUT REPAIR Page 1 Dec 01/03
Shank Nuts - Replacement Figure 1
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SHANK NUT REPAIR Page 2 Dec 01/03
ANCHOR NUTS AND WING BOLTS - REMOVAL OF ANCHOR NUTS AND WING BOLTS TASK 70-48-14-350-025 1. Removal of Anchor Nuts and Wing Bolts SUBTASK 70-48-14-99G-025 A. General. (1) The following procedure must be used for replacing damaged anchor nuts and wing bolts.
SUBTASK 70-48-14-350-251 B. Equipment. (1) None required.
SUBTASK 70-48-14-350-252 C. Materials. (1) None required.
SUBTASK 70-48-14-350-253 D. Procedure. (1) Removal of Rivets Which Hold Damaged Nuts. (a) (b) Remove rivets from same side of flange on which nuts are located unless removal from that side is difficult and could result in damage to part. Determine diameter of rivet to be removed and select proper drill size (see Table 1, Page 1). Table 1. Table 1 Drill Sizes For Rivet Removal Drilling in Protruding Head Side Inch (mm) 1/16 (1.588) 3/32 (2.381) 1/8 (3.175) 5/32 (3.969) Drilling in Counter-Sunk Head Side Inch (mm) 3/64 (1.191) 1/16 (1.588) 3/32 (2.381) 1/8 (3.175)
Diameter Inch (mm) 1/16 (1.588) 3/32 (2.381) 1/8 (3.175) 5/32 (3.969)
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REMOVAL OF ANCHOR NUTS AND WING BOLTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (c) (d) (e) (f) (g) (2) Remove any raised burrs or identification bumps from rivet heads. File a small flat on head of round-head rivets. Center-punch rivet head as close to center as practical. Use a 1/4 inch (6.35 mm) drill motor and drill selected in paragraph (b) and drill through rivet head. Do not drill any deeper than height of rivet head. Using a pin punch as close in diameter as the drilled hole as possible, insert punch into drilled hole and pop rivet head off by tilting the punch sideways. Using a pin punch and hammer, remove remaining portion of rivet. Remove damaged nut or bolt.
Removal of Rivets That Are Recessed Into A Countersunk Hole. (a) (b) (c) Remove any raised burrs or identification marks from rivet head. Determine size of rivet to be removed and select proper drill size (see Table 1, Page 1). Center-punch rivet head as close to the center as practical.
CAUTION: EXTREME CARE MUST BE EXERCISED TO ENSURE THAT ONLY RIVET HEAD IS BEING COUNTERSUNK. (d) (e) (f) Drill a hole in counter-sunk head through rivet head. Use a 1008 countersink and remove rivet head. Drive remaining portion of rivet out using a pin punch and hammer. Remove damaged nut or bolt.
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70-48-14
REMOVAL OF ANCHOR NUTS AND WING BOLTS Page 2 Dec 01/03
EXPANSION PLUGS AND TAPERED PINS - REPLACEMENT OF EXPANSION PLUGS AND TAPERED PINS (LEE PLUGS) TASK 70-48-15-350-026 1. Replacement of Expansion Plugs and Tapered Pins (Lee Plugs) SUBTASK 70-48-15-99G-026 A. General. (1) (2) Expansion plugs and tapered pins (Lee plugs) are manufactured by the Lee Company, Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003. The plugs are sealed and locked in the holes in the casting (mounting holes) by a series of annular lands and grooves machined in the OD of the expansion plugs; the plugs are expanded when the tapered pins are driven into the mating ID of the plugs. Usually plugs can be replaced on mounting holes up to 5 times without reworking the holes. However, pressure-testing should always follow plug replacement in used holes. Subsequent plugging shall be done using oversize plugs 0.010 inch (0.25 mm) larger in diameter than standard size after resizing the mounting holes.
(3)
(4)
SUBTASK 70-48-15-350-261 B. Equipment. (1) Use the special equipment listed in Figure 1, Page 2 and Figure 2 (Sheet 1 of 2), Page 3, required to replace plugs and tapered pins. The tools listed in these figures are manufactured by the Lee Company. Refer to the List of Suppliers in Step D. of Subtask 70-80-00-800-003.
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70-48-15
REPLACEMENT OF EXPANSION PLUGS AND TAPERED PINS (LEE PLUGS) Page 1 Dec 01/03
Drilling and Tapping Tools for Tapered Pins and Expansion Plugs (Lee Plugs) Figure 1
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Extraction Kits for Expansion Plugs and Tapered Pins (Lee Plugs) Figure 2 (Sheet 1 of 2)
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Extraction Kits for Expansion Plugs and Tapered Pins (Lee Plugs) Figure 2 (Sheet 2)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-48-15-350-262 C. Materials. (1) None required.
SUBTASK 70-48-15-350-263 D. Procedure. (1) Remove tapered pin (4) Figure 3, Page 7 using the tools (or equivalent) specified in Figure 1, Page 2, as follows: CAUTION: WHEN DRILLING TAPERED PIN, BE SURE THAT DEPTH OF HOLE DRILLED INTO PIN IS SLIGHTLY LESS THAN LENGTH OF PIN. THIS PREVENTS THE TAP DRILL FROM BOTTOMING AGAINST EXPANSION PLUG WHERE FURTHER ROTATION OF THE TAP DRILL WILL EITHER PULL THE PIN OUT ONTO THE DRILL OR BREAK THE DRILL. (a) Drill a hole into the tapered pin (4) Figure 3, Page 7 using the tap drill specified in Figure 1, Page 2. Set a stop so that the depth of the hole is slightly less than the length of the pin.
CAUTION: TO PREVENT THREAD DAMAGE TO THE PIN REMOVAL BOLT (1) FIGURE 3, PAGE 7, USE BOTH PLUG AND BOTTOMING TYPE TAPS TO TAP THREADS INTO THE PIN. (b) (c) Tap a hole in the pin using a tap thread size according to Figure 1, Page 2. Install striker (3) Figure 3, Page 7 on pin removal bolt (1) Figure 3, Page 7 and thread bolt into the pin.
CAUTION: BE SURE THAT STRIKER IS NOT PUSHED SIDEWAYS; THIS CAN BEND OR BREAK THE REMOVAL BOLT. (d) Actuate striker against bolthead to remove pin.
CAUTION: TO PREVENT THREAD DAMAGE TO PIN REMOVAL BOLT (1), FIGURE 3, PAGE 7 USE BOTH PLUG AND BOTTOMING TYPE TAPS TO TAP THREADS INTO PIN. (e) (f) Tap threads in expansion plug(s) using both plug and bottoming type taps specified in Figure 1, Page 2. Install striker (3) Figure 3, Page 7 on plug removal bolt (2) Figure 3, Page 7 and thread bolt into the plug.
CAUTION: BE SURE THAT STRIKER IS NOT PUSHED SIDEWAYS; THIS CAN BEND OR BREAK THE REMOVAL BOLT. (g) (2) Actuate striker against head of bolt to remove plug.
Refer to Figure 4, Page 8, and install expansion plugs as follows:
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STANDARD PRACTICES MANUAL AS907-1-1A (a) Clean and dry the hole in casting (mounting hole) (1) Figure 4, Page 8 and inspect for roughness. Surface finish of hole must be approximately 32 to 63 microinch circular lay, with no longitudinal scratch marks. If hole is too rough or is oversized, resize the hole and use an oversized plug, color-coded red [0.010 inch (0.25 mm) larger in diameter than the standard size plug, colorcoded green] to provide a positive seal. Use standard size pins with oversized plugs. Firmly support the item to be plugged. Insert expansion plug (5) Figure 4, Page 8 into hole in casting (1) Figure 4, Page 8 and lightly tap plug with pin punch (3) Figure 4, Page 8 that has a diameter that bottoms on the flat portion of the base in the ID of the plug. Press plug until it is firmly seated on the shoulder of the mounting hole. NOTE: Tapered pins are factory-prewaxed for easy installation. Do not degrease. Keep pin-handling to a minimum. (d) (e) Insert tapered pin (4) Figure 4, Page 8, small end first, into tapered hole of plug. Do not tilt pin. Drive the tapered pin with a vented driver (2) Figure 4, Page 8 that has a diameter larger than the diameter of the pin but smaller than the diameter of the plug. Surface A must not be more than 0.005 inch (0.13 mm) above or below surface B.
(b) (c)
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Expansion Plug - Removal Figure 3
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Expansion Plug - Installation Figure 4
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ROSAN STUDS - REPLACEMENT OF ROSAN STUDS TASK 70-48-16-350-027 1. Replacement of Rosan Studs SUBTASK 70-48-16-99G-027 A. General. (1) The following procedure must be used to replace Rosan studs which are damaged or loose.
SUBTASK 70-48-16-350-271 B. Equipment. (1) Refer to Table 1, Page 1 for Rosan Studs sizes, required to replace studs.
SUBTASK 70-48-16-350-272 C. Materials. No. C03-001 C03-081, C03-082, C03-084, or C03-092
Consumable Product Zinc chromate primer Chromated conversion coating SUBTASK 70-48-16-350-273 D. Procedure. (1) (2) (3) (4)
Determine stud size and tooling needed from Table 1, Page 1. Remove defective part (refer to Figure 1, Page 3). Threaded hole must be clear and not damaged. Up to one full thread may be missing. Refinish the threaded hole with chromated conversion coating. Refer to TASK 7043-07-380-007, Chemical Touch-Up Surface Refinishing Process for Aluminum. NOTE: Replacement of Rosan studs and lockrings must be made with same size parts as those removed and in the same manner as originally installed.
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REPLACEMENT OF ROSAN STUDS Page 1 Dec 01/03
Table 1. Rosan Stud Sizes/Tooling Standard Stud Sizes Stud End Diameter 0.190 0.250 0.250 0.250 0.3125 0.3125 0.375 0.375 0.4375 0.4375 0.500 0.5625 (5) (6) Nut End Diameter 0.164 0.164 0.190 0.250 0.190 0.250 0.250 0.3125 0.3125 0.375 0.4375 0.500 Rosan Tool Part Number Removal Tool SM81-16 SM81-16 SM91-16 SM91-16 SM91-16 SM101-18 SM101-18 SM111-20 SM111-20 SM121-22 SM131-24 SM141-26 Wrench R1103W R1103W R1104W R1104W R1104W R1105W R1105W R1106W R1106W R1107XW R1108W R1110W Drive Tool S81D10 S81D10 S91D10 S91D10 S91D10 S101D12 S101D12 S111D12 S111D12 S121D12 S131D14 S141D14
Coat the stud end threads of stud with zinc chromate primer C03-001. Install the replacement part(s) as described in Figure 2, Page 4.
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Rosan Stud - Removal Figure 1
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Rosan Stud - Installation Figure 2
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KELOX INSERTS - REPLACEMENT OF KELOX INSERTS TASK 70-48-17-350-028 1. Replacement of Kelox Inserts SUBTASK 70-48-17-99G-028 A. General. (1) The following procedure must be used to replace Kelox inserts which are damaged or loose.
SUBTASK 70-48-17-350-281 B. Equipment. (1) Refer to Figure 1, Page 2 for Kelox Inserts sizes, required to replace inserts.
EFFECTIVITY: ALL
70-48-17
REPLACEMENT OF KELOX INSERTS Page 1 Dec 01/03
Kelox Thread Insert Sizes Figure 1
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-48-17-350-282 C. Materials. No. C03-001 C03-081, C03-082, C03-084, or C03-092
Consumable Product Zinc chromate primer Chromated conversion coating SUBTASK 70-48-17-350-283 D. Procedure. (1)
Determine type and identification of insert (refer to Figure 1, Page 2). Proceed as follows: (a) (b) (c) Remove defective part (refer to Figure 2, Page 4). Threaded hole must be clear and not damaged. Up to one full thread may be missing. Refinish the threaded hole with chromated conversion coating. Refer to TASK 70-43-07-380-007, Chemical Touch-Up Surface Refinishing Process for Aluminum. Coat the external threads with zinc chromate primer C03-001. Install the replacement part(s) as described in Figure 2, Page 4.
(d) (e)
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Kelox Insert Stud - Replacement Figure 2
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KELOX STUDS - REPLACEMENT OF KELOX STUDS TASK 70-48-18-350-029 1. Replacement of Kelox Studs SUBTASK 70-48-18-99G-029 A. General. (1) The following procedure must be used to replace Kelox studs which are damaged or loose.
SUBTASK 70-48-18-350-291 B. Equipment. (1) Refer to Figure 1, Page 2 for Kelox Studs sizes, required to replace studs.
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REPLACEMENT OF KELOX STUDS Page 1 Dec 01/03
Kelox Stud - Sizes Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-48-18-350-292 C. Materials. No. C03-001 C03-081, C03-082,C03-084, or C03-092
Consumable Product Zinc chromate primer Chromated conversion coating SUBTASK 70-48-18-350-293 D. Procedure. (1)
Determine type and identification of stud. Proceed as follows: (a) (b) (c) Remove defective part (refer to Figure 1, Page 2 in TASK 70-48-17-350-028, Replacement of Kelox Inserts). Threaded hole must be clear and not damaged. Up to one full thread may be missing. Refinish the threaded hole with chromated conversion coating. Refer to TASK 70-43-07-380-007, Chemical Touch-Up Surface Refinishing Process for Aluminum. Coat the external threads with zinc chromate primer C03-001. Install the replacement part(s) as described in Figure 1, Page 2 in TASK 7048-17-350-028, Replacement of Kelox Inserts.
(d) (e)
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ROSAN RING LOCKED INSERT - ROSAN RING LOCKED INSERT REPLACEMENT TASK 70-48-19-350-031 1. Rosan Ring Locked Insert Replacement SUBTASK 70-48-19-99G-031 A. General. (1) This repair provides the instructions for the removal and replacement of Rosan ring locked inserts.
SUBTASK 70-48-19-350-311 B. Tools, Equipment, and Materials. NOTE: Equivalent alternatives can be used for Tools, Equipment, and Consumable Materials. (1) Tools and Equipment. (a) Special Tools. See Figure 1, Page 2 for the listings of the tools required depending upon the exact type of insert that is being repaired. The tools may be obtained from: Rexnord Specialty Fastener Div. Rosan Products 3130 Harvard St. Santa Ana, CA 92799 USA (b) Standard Tools Drill bits. See Figure 1, Page 2 for size. (c) (d) (2) (3) (4) (5) Locally Manufactured Tools. None required. Equipment. None required.
Consumable Materials. None required. Expendable Parts. None required. SPD Identification. None required. Reference Data. (a) (b) MS51993: Military Standard; Insert, High Strength, Ring Locked. MS51995: Military Standard; Ring Locked Inserts and Studs, Installation, and Removal.
EFFECTIVITY: ALL
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ROSAN RING LOCKED INSERT REPLACEMENT Page 1 Dec 01/03
Tooling for MS51991 Inserts Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-48-19-350-312 C. Dimensional Information. (1) None.
SUBTASK 70-48-19-350-313 D. Set-up Information. (1) None.
SUBTASK 70-48-19-350-314 E. Procedure. (1) Ring locked (Rosan) inserts can be replaced when damaged or otherwise unserviceable. Rosan inserts use a serrated ring rather than tightening to lock the insert in place. Unserviceable parts can therefore be replaced without damage to the threads of the parent material. This feature eliminates the need, except in extreme cases, for oversized replacement parts. Replacement Procedure. Remove old inserts as follows: CAUTION: BEFORE MACHINING, MASK OR PLUG INTERNAL PASSAGES TO PREVENT CONTAMINATION. (a) (b) (c) (d) (e) Use the proper size drill bit selected from Figure 1, Page 2. Ensure the part is properly secured to prevent movement during the drilling process. Secure the removal drill in the chuck and align with the centerline of the insert. Set the spindle speed at 300 to 700 RPM. Drill through the lockring and the neck of the insert to destroy the serration interlock. See Figure 2, Page 5. 1 2 (f) Do not drill beyond the depth of the counterbore in the parent material. See Figure 3, Page 6 for counterbore depth. Use a drill stop to ensure that the counterbore depth is not exceeded.
(2)
Drive a square screw extractor into the insert and apply removal torque. See Figure 2, Page 5. NOTE: When insert thread flanks bear against the lower surface of the lockring, continued removal torque will cause the lockring to be jacked out. Insert removal may then be completed.
(g)
If the lockring has been drilled completely through and fails to lift out with the insert, collapse the remaining portion with a punch and remove.
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STANDARD PRACTICES MANUAL AS907-1-1A (h) (3) Remove any burrs in the counterbore area and clean the cavity.
Install a new insert using the following steps: (a) Use the same size and type of Rosan insert and lock ring as was removed to replace parts. NOTE: See Figure 2, Page 5 for the interchangeability between MS part number designations and Rosan part number designations. (b) (c) (d) When the part in which the insert is to be installed is aluminum, coat the external threads of the insert with zinc chromate primer C03-001. Install the insert while the primer is wet. Use the appropriate wrench listed in Figure 1, Page 2 to install the insert into the machined, tapped cavity to the depth shown in Figure 4, Page 7. NOTE: Location of the flange is important so that the lockring drive tool will not make contact with surface A. Any impact or pressure on this surface may cause damage to the threads in the parent material and result in a loose fit. (e) (f) Use the appropriate drive tool listed in Figure 1, Page 2 to install the lockring to the depth shown in Figure 4, Page 7. See Figure 2, Page 5 for a listing of the appropriate MS and Rosan lockrings. 1 Use the last two digits of the insert number to match for the appropriate new lockring. For example, with insert MS51991E206, use lockring MS51990E106P.
(g)
Rotate the new lockring if necessary before driving to align the serration on the lockring with the serration in the parent material from the previous lockring.
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Standard Dimensions for Hole Preparation Figure 2
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Machining Requirements for New Inserts Figure 3
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Interchangeability Tables MS Versus Rosan Figure 4
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Drilling Procedure Figure 5
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INDENTATION STAKING - INDENTATION STAKING TASK 70-48-20-350-001 1. Indentation Staking SUBTASK 70-48-20-99G-001 A. General. (1) This procedure gives the general instructions and procedures for staking when the process is specified in the applicable manual. NOTE: Use this procedure only when instructed by the applicable manual. This procedure can cause substantial fatigue strength reduction. In general, this procedure is to be used only in low stress areas and must not be used on stress corrosion sensitive alloys. SUBTASK 70-48-20-350-001 B. Definitions. (1) Stake - To move or compress metal, usually around a pin, shaft, or other part, to hold it in position. There can be a groove or depression into which metal is displaced; for example, against a flat surface like the side of a hexagon.
SUBTASK 70-48-19-350-002 C. General Rules. (1) General. (a) (b) (c) (2) Prevent movement in a staking operation so the parts do not twist. If it is necessary to heat-treat parts, make sure it is done before the staking operation. Parts must be supported during staking operation to prevent unwanted distortion.
Staking. (a) Staking Indentation. Stake the part by putting indentations in the metal around the edge of the part. The staked part is specified in the applicable manual. The indentations are usually equally spaced around the circumference or near the external edge of the part. Refer to Figure 1, Page 3. (b) Uniformity of Staking. Make sure staking indentations are equal in appearance, diameter, and apparent depth.
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INDENTATION STAKING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (c) Raised Metal. If metal removal is not specified for a given area, then any raised metal as a result of the staking is permitted. (d) Tool End Radius. Make sure the staking tools follow the limits shown in the Tool End Radius drawing. Refer to Figure 2, Page 4. (3) Restraint. Staking is used to hold parts against a push-out force (except where parts are held in blind holes) or to tightly attach them. Unless other tolerances are specified in the applicable manual, make sure the held part will resist a minimum push-out force of 10 pounds (44.5 Newtons) without movement or dimensional change. (4) Workmanship. Make sure there are no flakes or feathered edges after staking which could result in loose material. Do not reject a part with only light or random surface pitting, stretch marks, or tool marks.
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Typical Staking to Form a Retaining Clip Figure 1
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Staking Tool End Radius Figure 2
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-48-20-350-003 D. Quality Assurance Provisions. (1) Visual Examination. (a) Visually inspect each staked area for cracks at a magnification of 10X. No cracks are permitted. Indications smaller than 0.02 inches (0.5 mm) in length are not interpretable.
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THERMAL SPRAYING - THERMAL SPRAYING TASK 70-49-00-340-001 1. Thermal Spraying SUBTASK 70-49-00-99G-001 A. General. (1) Thermal spray is a general term describing a group of coating processes that are used to apply a tightly bonded coating by spraying molten or semi-molten metallic and nonmetallic particles. The methods used to melt the coating materials include combustion, wire arc, and plasma. The materials may be supplied as powder, wire, or rod stock. The thermal spray coating process is used widely in the repair and modification of hardware. The most frequent uses for the thermal spray coatings include, but are not limited to: (a) (b) (c) (d) (e) (2) Repair or restoration of worn or damaged surfaces. A clearance control coating, abradable and/or abrasive. A thermal barrier coating. An aid in correcting the balance of rotating hardware. An anti-wear and/or anti-galling coating in high load or rubbing conditions.
General Requirements. (a) The thermal spray process is monitored by: 1 2 3 4 (b) The general thermal spray requirements in this procedure (70-49-00), The specific thermal spray procedure (for example, TASK 70-49-10340-011, Thermal Spraying Nickel-Aluminum (Powder)), The specific testing procedures (for example, TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings), and The general testing requirements in TASK 70-70-00-700-001, Testing and Quality Analysis.
Original Equipment Manufacturer (OEM) specifications can cover the same procedures and requirements for thermal spray and are frequently more stringent. It is therefore acceptable to use processing and quality systems formulated for the coating of new aircraft engine hardware and approved by major engine manufacturers to meet the intent of the repair standard practices concerning thermal spray.
(3)
The application methods used most frequently are:
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THERMAL SPRAYING Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (a) Flame spraying with a spray gun that uses an oxyacetylene or oxyhydrogen flame. 1 The flame spray gun has a standard oxyacetylene or oxyhydrogen torch and a nozzle that supplies the compressed air required to propel the molten metal. The coating material goes into the gun as a powder or a wire.
2 (b)
Plasma arc spraying with a plasma generator/gun. 1 2 In the plasma spray gun, a mixture of gases is supplied through a constricted electric arc. The electric arc is created between an axial cathode made from thoriated tungsten and a copper electrode that forms the exhaust nozzle. The plasma-generating atmosphere may be argon, nitrogen, hydrogen, or helium. The coating material is injected as a powder, either directly into the gun or a few millimeters downstream of the anode exit. Power required: For current needs: 20 to 40 kW. For future needs: 40 to 100 kW. 6 The power supply system shall maintain a regular, smooth, and equal flow rate.
3 4 5
(c)
High velocity oxy-fuel (HVOF). 1 The process uses the continuous internal combustion of oxygen and a fuel gas. This pressurized combustion propels a hot exhaust jet stream at a high velocity. Powder is injected into the jet stream, where it is heated and accelerated toward the part to be sprayed. An HVOF system should consist of: a b An HVOF gun system with a satisfactory controller. A gas controller that can supply up to 1,000 SCFH oxygen, 1,600 SCFH hydrogen, 300 SCFH propylene, and if required, 800 SCFH air. The unit shall also provide a power control for the gun and an air delivery rate. A pressurized powder feeder that can supply powder at a typical rate of 4-15 lbs/hr (2-7 kg/hr). An air source that can supply up to 800 SCFH clean, filtered air.
2 3
c d
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STANDARD PRACTICES MANUAL AS907-1-1A (d) Electric arc wire spray system, Praxair / TAFA Concord. 1 An arc wire gun control unit that uses pneumatically or electrically driven motors to supply spooled wire to the arc wire gun manually or automatically. The gun control unit shall also have a power control for the arc wire gun and give the rate at which air is supplied. Two consumable electrodes are supplied to an atomizing air stream in the gun, where a DC arc is formed between them. The atomizing gas (usually compressed air) goes directly across the arc and molten wire tips, shearing off the droplets and forming a highvelocity spray stream. An electric arc power feed that can supply 50-350 amps at 20-38 opencircuit volts. A clean, filtered air source that can supply 50 SCFM at 80 psi (552 kPa).
2 3
4 5 (4)
Various safety precautions should be addressed before performing the thermal spray coating process: (a) Personal protection, including a respirator and ear protection, should be used by personnel performing this process. Eye protection equivalent to welders goggles should also be used by personnel who are viewing the thermal spray process while it is being performed. Because fine powdered metals are used in this process, steps should be taken to reduce or eliminate the possibility of ingesting or absorbing these materials. IF A WATER-CURTAIN EXHAUST SYSTEM IS USED, THE COLLECTED OVERSPRAY PARTICLES OF SOME METALS (MAGNESIUM, ALUMINUM, IRON, ETC.) CAN REACT WITH WATER TO FORM HYDROGEN. HYDROGEN IS HIGHLY COMBUSTIBLE AND IT CAN BECOME EXPLOSIVE WHEN MIXED WITH AIR. TAKE PRECAUTIONS AGAINST THIS FIRE AND EXPLOSION HAZARD.
(b)
WARNING:
(c) (d)
A continuous-flow exhaust system should be supplied to remove the fumes and overspray particles. The training of thermal spray personnel shall include a segment on thermal spray process safety. The segment shall describe, and give the proper use of, the personal protection devices that are used in the thermal spray process.
SUBTASK 70-49-00-340-011 B. Processing Qualification. (1) General. (a) Initial qualification for thermal spray involves two areas: Equipment and Operators.
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STANDARD PRACTICES MANUAL AS907-1-1A (b) It is possible and acceptable that qualifications of operators and equipment can occur on a simultaneous basis. This would allow a qualification set-up to be used for validation of both operators and equipment. Installations for thermal spraying shall be applicable to the work to be performed. They shall agree with existing aircraft industry specifications as well as the applicable regulations that exist in the country where the repair shop is located.
(2)
Equipment Qualification Requirements. NOTE: Qualification tests are intended to make sure that the thermal spray equipment can apply satisfactory coatings again and again. (a) Initial Qualification 1 Qualify each thermal spray system for all of the powders/wires that shall be applied with that system. Qualify the system as follows: a Coat a first set of test specimens that are representative the part material/coating combination. Record all parameters that apply to the thermal spraying process. Figure 1, Page 7 is a sample form for recording equipment qualification data. NOTE: A set of test specimens is defined as one test specimen for each type of test that is required for that coating. In TASK 70-70-00-700-001, Testing and Quality Analysis, refer to Table 1, Page 2 for the types of tests that are required, and Table 2, Page 7 for a cross-reference of test specimen material to part material. b c d Shut the thermal spray equipment down completely after coating the first set of test specimens. Coat a second set of test specimens, using the same thermal spray parameters as were used to coat the first set of specimens. Test both sets of test specimens. The coatings must agree with the requirements of: The general thermal spray requirements in this procedure (70-49-00), The specific thermal spray procedure (for example, TASK 70-49-10-340-011, Thermal Spraying Nickel-Aluminum (Powder), The specific testing procedures (for example, TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and The general testing requirements in TASK 70-70-00-700001, Testing and Quality Analysis. e Record the results of the test. Refer to Figure 2, Page 8 for a sample test report.
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STANDARD PRACTICES MANUAL AS907-1-1A f (b) If the spray parameters that were used for the initial equipment qualification are changed, the equipment shall be qualified again.
Equipment Requalification. The thermal spray coating equipment shall be requalified for any one of the following reasons: 1 2 3 4 The coating equipment has not been used within a 12 month period. Three sets of tests of the same coating equipment, one after the other, do not agree with the requirements. The coating equipment is dismantled and repositioned. The coating equipment receives a major overhaul or replacement of a major component. This may include, but is not limited to, a gas head, a combustion gas gun body, a rectifier, or a control console. The equipment settings are modified.
5 (c)
Records. A card shall be attached to the coating equipment after qualification to show agreement with the requirements that are specified here. Figure 3, Page 9 is a sample machine qualification card that shows the necessary information.
(3)
Qualification of Personnel. (a) General. 1 An experienced operator who can use the thermal spraying equipment correctly again and again is very important to the quality of the coating that is applied. It is recommended that a formal training program be developed to make sure that the thermal spray operators receive sufficient practical experience to apply high-quality coatings again and again. The training should also address safety issues related to the different thermal spray processes.
(b)
Initial Qualification Tests. 1 These test are intended to make sure that the skill of a thermal spray operator is sufficient and that he can apply satisfactory coatings again and again. Each operator shall be qualified for each thermal spray process (plasma, HVOF, electric arc, etc.) that he will perform. Tests are performed as follows: NOTE: It is not necessary for the operator to be tested on each coating material that he may apply. a Test the operator on the following families of coatings: Metals, General.
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STANDARD PRACTICES MANUAL AS907-1-1A Ceramics. Abradables. Metal-Based Carbides. b Coat a first set of test specimens that are representative of the coating(s). NOTE: A set of test specimens is defined as one test specimen for each type of test that is required for that coating. In TASK 70-70-00-700-001, Testing and Quality Analysis, refer to Table 1, Page 2 for the types of tests that are required, and Table 2, Page 7 for the test specimen material, which may be any of those listed. c d e Shut the thermal spray equipment down completely after coating the first set of test specimens. Coat a second set of test specimens. Test both sets of test specimens. The coatings must agree with the requirements of: The general thermal spray requirements in this procedure (70-49-00), The specific thermal spray procedure (for example, TASK 70-49-10-340-011, Thermal Spraying Nickel-Aluminum (Powder)), The specific testing procedures (for example, TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings), and The general testing requirements in TASK 70-70-00-700001, Testing and Quality Analysis. (c) Requalification Tests. 1 Each operator should receive training at intervals to make sure that he can apply satisfactory coatings again and again. The frequency of the training and testing shall be established by the repair source. NOTE: An initial frequency of six to twelve months is generally sufficient.
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Thermal Spray Equipment Qualification Form (Sample) Figure 1
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Thermal Spray Equipment Qualification Test Results Form (Sample) Figure 2
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Machine Qualification Card (Sample) Figure 3
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-00-340-013 C. Thermal Spray Procedure. (1) Consumable Materials. (a) The repair shop should have a procedure for the control of the powders and wires that are used in the thermal spray process. This procedure should do the following: 1 2 Make sure that the certification from the powder manufacturer for each lot of material is correct. Perform a sprayability test on each lot to make sure that it will give an acceptable coating. The sprayability test shall be performed on the complete set of test specimens, as defined in TASK 70-70-00-700-001, Testing and Quality Analysis.
(b)
Commercial quality gases, as defined in TASK 70-00-06-800-007, Quality of Gases, are recommended. Longer nozzle life and greater stability for the plasma process will result if pure gases, as defined in TASK 70-00-06-800007, Quality of Gases, are used.
(2)
Preliminary Operations. (a) Powder shall be free of moisture and shall be a homogeneous mixture before spraying. If the powder contains moisture, the material can be dried in an oven at 1508F 158F (668C 88C) for a minimum of one hour. If the powder is not homogeneous, blend the material. For small quantities, rotate the powder within the container for 10-15 minutes. For large quantities, use a Vtype blender, or equivalent, to blend the powder. All repair operations on the base material, including cleaning, welding, heat treating, and surface treatments, shall be completed before thermal spray coating begins. No chemical coating or other operation that would harm the sprayed coating shall be performed. When building up worn areas by thermal spraying, machine the areas to a depth that will permit a sufficient coating thickness after processing. ACETONE AND METHYL-ETHYL-KETONE ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPORS OR CONTACT WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME.
(b)
(c)
WARNING:
CAUTION: DO NOT CLEAN PARTS MADE OF TITANIUM OR ITS ALLOYS IN CHLORINATED SOLVENTS OR OTHER HALOGEN-CONTAINING COMPOUNDS. (d) Before preparation for thermal spray operations, clean the parts thoroughly by one of these methods: TASK 70-21-22-110-042, Cleaning Method No. 22 Light Duty Aqueous Cleaning; TASK 70-21-03-160-001, Cleaning Method No. 3 - Steam Cleaning; TASK 70-21-02-110-002, Cleaning Method No. 2 - Vapor Degreasing; or TASK 70-21-01-110-001, Cleaning Method No. 1 - Solvent Degreasing.
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STANDARD PRACTICES MANUAL AS907-1-1A (e) Mask the areas of the part that are not to be sprayed. The masking may be fabricated shields, a pressure-sensitive tape like one of those in the C10-012 list, or masking putty C10-193. If tape or putty is used, check to make sure that all edges stay in firm contact with the part throughout the thermal spray process. DO NOT BREATHE PARTICLES FROM BLASTING OR LET THE PARTICLES TOUCH YOU. THE PARTICLES CAN CAUSE DAMAGE, INJURY, OR IRRITATION TO YOU. USE PERSONAL PROTECTION EQUIPMENT. USE LOCAL MECHANICAL EXHAUST VENTILATION OR AN APPROVED RESPIRATOR.
WARNING:
CAUTION: DO NOT USE STEEL GRIT ON TITANIUM. (f) Unless otherwise specified by the process document, roughen the surface by grit blasting as follows: 1 2 The grit should be aluminum oxide that is free from oil, moisture, dust, and other contaminates. The grit size should be 60 mesh C04-173 or 120 mesh C04-114. Grit sizes in the range of 60 to 120 mesh are permitted as approved alternatives. Finer grit may be used as specified in the process document, or if you make sure that it gives an adequate surface finish for bonding. Surface finishes are required as follows: Roughness Average (RA) Microinches (Micrometers) 80-150 (2.1-3.8) 80-150 (2.1-3.8) 80-150 (2.1-3.8) 80-150 (2.1-3.8) 200-300 (5.1-7.6) 200-300 (5.1-7.6) 3 4 The blasting pressures may range from 45 to 90 psi (310.5 to 621.0 kPa). The blasting angle should be approximately 608, but the angle may change from 458 to 758 during the blasting operation. ACETONE, METHYL-ETHYL-KETONE, AND ISOPROPYL ALCOHOL ARE TOXIC AND EXTREMELY FLAMMABLE. AVOID PROLONGED BREATHING OF VAPORS OR CONTACT WITH THE SKIN. KEEP AWAY FROM SPARKS OR FLAME.
Alloy/Base Material Nickel Base Cobalt Base Iron Base Titanium Base Aluminum Base Magnesium Base
WARNING:
Remove the dust particles from the part. Use dry shop air, a vacuum cleaner, or a lint-free cloth moistened with acetone C04-003, methylethyl-ketone C04-001, or isopropyl alcohol C04-035.
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STANDARD PRACTICES MANUAL AS907-1-1A 6 All the test specimens should be grit-blasted with the same parameters as the part being processed.
CAUTION: SURFACES THAT HAVE BEEN PREPARED FOR THERMAL SPRAYING SHALL BE KEPT ABSOLUTELY CLEAN. THE PREPARED SURFACES SHOULD BE HANDLED WITH LINT-FREE GLOVES. AREAS ON THE PREPARED SURFACE WHERE FINGERPRINTS ARE FOUND SHOULD BE RE-ROUGHENED. FOR ALL ALLOYS, THE DELAY BETWEEN SURFACE ROUGHENING AND SPRAYING SHOULD NOT EXCEED TWO HOURS. IF THE MAXIMUM DELAY TIME IS EXCEEDED, THE PART SURFACE SHOULD BE RE-ROUGHENED. (g) Examine the part(s) for shiny spots or other indications of insufficient roughness. If you find such indications, repeat the grit blasting and dust removal processes. Attach the test specimens to the part as specified in the process document. 1 The test specimen material shall be representative of the part material to be coated. Refer to Table 2 of TASK 70-70-00-700-001, Testing and Quality Analysis, for a cross-reference of test specimen material to part material. Put the specimens with the part so that they receive the spray from the same distance and angle, but do not prevent the application of the spray material in the areas of the part that are to be sprayed.
(h)
(i)
When required in the process document, mount the roughened part onto a spray fixture and preheat the part to 150-3008F (66-1408C), while preparing the thermal spray gun for the required coating. Check the temperature of the part with a calibrated surface-contact pyrometer. NOTE: The preheat temperature should not be higher than any prior aging or tempering temperature.
(3)
Spraying Procedure. (a) If required, apply a bond coat of the material to the thickness that is specified in the applicable manual. The requirements are as follows: 1 Bond coats should be applied in a manner to minimize the number of passes required to spray the material to the proper thickness and coverage. A maximum of 15 minutes is permitted for interruptions to measure the bonding coat thickness and examine the sufficiency of its coverage. If this time is more than 15 minutes, strip and recoat the part. Unless otherwise specified, a maximum of 2 hours is permitted between completion of the bonding coat and the beginning of the top coat application. If this time is more than 2 hours, strip and recoat the part.
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STANDARD PRACTICES MANUAL AS907-1-1A 4 (b) Use the parameters for the specific coating materials as guidelines for applying the bonding coat.
Apply a top coat of the material to the thickness that is specified in the applicable manual. The parameters listed for the different thermal coating materials are published not as rigid specifications, but as guides. Use them to develop thermal spraying methods that provide high-quality coatings again and again in the specific conditions of your repair shop. Consumable Reference Numbers C07-017 C07-003 C07-008 C07-013 C07-020 C07-002 C07-001 C07-005 C07-011 C07-016 C07-019 C07-012 C07-006 C07-014 C07-015 C07-021 C07-004 C07-010
Procedure Reference 70-49-01 70-49-02 70-49-03 70-49-04 70-49-05 70-49-06 70-49-07 70-49-08 70-49-09 70-49-10 70-49-11 70-49-12 70-49-13 70-49-14 70-49-15 70-49-16 70-49-17 70-49-18
Specification No.
Type of Material Aluminum powder Aluminum oxide powder Chromium carbide powder Copper-nickel powder Copper-nickel-indium powder
AMS 4395
Magnesium alloy wire Molybdenum powder Molybdenum wire Nickel-aluminum composite powder Nickel-aluminum composite powder Nickel-aluminum composite wire Nickel-chromium powder Nickel chromium wire 75:25 nickel-graphite powder 85:15 nickel-graphite powder Nickel-silicon-boron powder Silver alloy wire 50% tungsten carbide self-bonding blend powder Tungsten carbide 12% cobalt aggregate powder
70-49-19
C07-007
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Procedure Reference 70-49-20
Specification No.
Type of Material Chromium carbidenickel-aluminide composite powder Aluminum-nickelchromium composite powder Alumina/nickelaluminum powder
Consumable Reference Numbers C07-026
70-49-21
C07-022
70-49-22 70-49-23 70-49-24 70-49-25 AMS 4180
C07-018 C07-028 C07-009 C07-023
Aluminum wire 75% Tungsten carbide powder Aluminum bronze alloy thermal spray powder
70-49-26 70-49-27
MIL-W-6712 Type II
Aluminum bronze alloy wire Cobalt-molybdenum chromium-silicon powder (T400) Tungsten carbide 12% cobalt aggregate powder 75% chromium carbide, 25% nickel chromium (powder) Cobalt-molybdenum chromium-silicon powder (T800) Nickel-aluminummolybdenum composite powder Inconel 718 Alloy Powder Aluminum Oxide Powder (Superfine) Aluminum Silicon Polyester Powder Ni-Cr-Al-Y (powder) Zirconium OxideYttrium Oxide Powder
C07-024 C07-025
70-49-28
C07-007
70-49-29
C07-027
70-49-30
C07-031
70-49-31
C07-034
70-49-32 70-49-33 70-49-34 70-49-35
C07-038 C07-039 C07-037 C07-032 C07-035 C07-041
70-49-36
Inco 718 Powder (HVOF)
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Procedure Reference 70-49-37
Specification No.
Type of Material Tungsten Carbide 17% Cobalt (powder) (HVOF) Ni-Al Prealloyed Wire Ni-Cr-Al Prealloyed Wire Pure Aluminum Wire Co-Mo-Cr-Si Powder (T800) (HVOF) Cu-Zn-Ag Prealloyed Wire
Consumable Reference Numbers C07-040
70-49-38 70-49-39 70-49-40 70-49-43 70-49-44 70-49-45 70-49-46 AMS 5832C
C07-042 C07-043 C07-044 C07-047 C07-051 C07-049 C07-050
Inco 718 Prealloyed Wire Ni-Cr-Si-Fe (Metcolloy 33) (powder) (HVOF) Al-Si-Poly (powder) Co-Mo-Cr-Si (T400) (powder) (HVOF) Cu-Ni-In Wire Rene 80 (powder) (HVOF) Mo Wire Al-Bronze Wire
70-49-47 70-49-48 70-49-49 70-49-50 70-49-51 70-49-52 SUBTASK 70-49-00-340-016 D. Quality Control. (1) Equipment Calibration.
C07-037 C07-025 C07-054 C07-053 C07-055 C07-056
Devices such as controls, meters, and gages that are used to measure the thermal spray process parameters shall be calibrated at intervals prior to use. (2) To make sure that the thermal spray coating agrees with the minimum quality standards, visually examine the part itself and do the appropriate tests on the coating specimens. Specific test values are given in the applicable manual when applicable; however, all thermal spray coatings shall agree with the applicable requirements below: (a) Visual indications of oil seepage into the coating during the spraying operation shall be cause for rejection. The part may be stripped and recoated if the base material dimensions are not reduced below minimum and it is not harmed by the coating removal.
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STANDARD PRACTICES MANUAL AS907-1-1A (b) Visual examination of the sprayed surface shall show no lumps (berries), flaking, or spattered particles of material that are loosely bonded or not atomized. The sprayed surface shall be evenly coated and shall be free of cracks, blisters and voids. The wire brush test requirement has been deleted from the Standard Practices Manual. The bend test requirement has been deleted from the Standard Practices Manual. The tensile bond specimens that were sprayed with the part shall be tested. Refer to TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. The metallographic test specimen that was sprayed with the part shall be sectioned, mounted, and correctly prepared for metallographic examination. The structure of the specimen shall be free of excessive porosity and inclusions (oxides). The coating-substrate interface shall be tight and free of cracks and voids. Refer to TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. The lap shear test requirement has been deleted from the Standard Practices Manual. The hardness test specimen that was sprayed with the part shall be tested. Refer to TASK 70-71-03-700-004, Scratch-Hardness Testing of Thermal Spray Coatings, or TASK 70-34-03-220-009, Rockwell Hardness Testing.
(c) (d) (e)
(f)
(g) (h)
EFFECTIVITY: ALL
70-49-00
PURE ALUMINUM (POWDER) - THERMAL SPRAYING PURE ALUMINUM (POWDER) TASK 70-49-01-340-002 1. Thermal Spraying Pure Aluminum (Powder) SUBTASK 70-49-01-99G-002 A. General. (1) Pure aluminum forms an excellent surface finish, and is used for clearance control applications under 9508F (5108C). This procedure covers application of the powder form by plasma arc spraying. NOTE: Pure aluminum may also be applied as a wire for flame spraying per TASK 70-49-23-340-024, Thermal Spraying Pure Aluminum (Wire), or by electric arc per TASK 70-49-40-340-039, Electric Arc Wire Spraying Pure Aluminum (Wire). Those two procedures are acceptable alternatives. SUBTASK 70-49-01-340-021 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-01-340-022 C. Material. (1) Pure Aluminum Powder C07-017.
SUBTASK 70-49-01-340-023 D. Spraying Parameters. (1) Starting parameter sets will be listed in the spray equipment manuals or are readily available from the spray equipment manufacturers or powder suppliers. Modifications may be necessary for your location and product application. See sprayability testing per TASK 70-49-00-340-001, Thermal Spraying, and TASK 7070-00-700-001, Testing and Quality Analysis. When the final spray parameter settings are developed, all values should be recorded to ensure consistent achievement of high quality coatings.
SUBTASK 70-49-01-340-024 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations.
EFFECTIVITY: ALL
70-49-01
THERMAL SPRAYING PURE ALUMINUM (POWDER) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of
EFFECTIVITY: ALL
70-49-01
STANDARD PRACTICES MANUAL AS907-1-1A oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 1,200 psi (8.3 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-2 Less than or equal to X-1 None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 1, Page 13 Figure 6, Page 18 No figure for rating Figure 7, Page 19 No figure for rating No figure for rating No figure for rating Task TASK 005 TASK 005 TASK 005 TASK 005 TASK 005 TASK 005 TASK 005 Comments None None See definition for ratable size None See definition for ratable size See definition for ratable size See definition for ratable size
70-71-04-70070-71-04-70070-71-04-70070-71-04-70070-71-04-70070-71-04-70070-71-04-700-
EFFECTIVITY: ALL
70-49-01
EFFECTIVITY: ALL
70-49-01
ALUMINUM OXIDE - ALUMINA (POWDER) - THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER) TASK 70-49-02-340-003 1. Thermal Spraying Aluminum Oxide (Powder) SUBTASK 70-49-02-99G-003 A. General. (1) Aluminum oxide coating provides a hard clearance control surface that is both wear resistant and abrasive. This procedure covers application of the powder form by plasma arc spraying.
SUBTASK 70-49-02-340-031 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-02-340-032 C. Materials. (1) Aluminum Oxide Powder C07-003.
SUBTASK 70-49-02-340-034 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following:
EFFECTIVITY: ALL
70-49-02
THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for ceramic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for ceramic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (g) Unmelts.
EFFECTIVITY: ALL
70-49-02
STANDARD PRACTICES MANUAL AS907-1-1A Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 1,000 psi (6.9 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. (6) Wire Brush. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Interface Contamination Interface Separations Unmelts Acceptance Criteria Less than or equal to V-3 Less than or equal to I-2 None allowed Less than or equal to P-1 Rating Photograph Figure 1, Page 13 Figure 7, Page 19 No figure for rating Figure 8, Page 20, Figure 14, Page 26, and Figure 15, Page 27 No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size Shape of particles is defined in Figure 15, Page 27. See definition for ratable size See definition for ratable size
Transverse Cracks Delaminations
None allowed None allowed
TASK 70-71-04700-005 TASK 70-71-04700-005
EFFECTIVITY: ALL
70-49-02
EFFECTIVITY: ALL
70-49-02
CHROMIUM CARBIDE (POWDER) - THERMAL SPRAYING CHROMIUM CARBIDE (POWDER) TASK 70-49-03-340-004 1. Thermal Spraying Chromium Carbide (Powder) SUBTASK 70-49-03-99G-004 A. General. (1) Chromium carbide forms an excellent wear resistant coating in the 12008-16008F (6508-8708C) temperature range. This procedure covers application of the powder form by plasma arc spraying.
SUBTASK 70-49-03-340-042 C. Material. (1) Chromium Carbide Powder C07-008.
SUBTASK 70-49-03-340-044 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a)
EFFECTIVITY: ALL
Adhesion.
70-49-03
THERMAL SPRAYING CHROMIUM CARBIDE (POWDER) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity.
EFFECTIVITY: ALL
70-49-03
STANDARD PRACTICES MANUAL AS907-1-1A Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 3,000 psi (20.7 MPa) minimum. (5) Macrohardness. Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape, but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing, and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be 83, based on an average of at least five readings on a Rockwell R15N scale. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-3 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed Less than or equal to P-1 None allowed None allowed Rating Photograph Figure 1, Page 13 Figure 6, Page 18 No figure for rating Figure 7, Page 19 No figure for rating Figure 8, Page 20 No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None. See definition for ratable size See definition for ratable size See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-03
EFFECTIVITY: ALL
70-49-03
COPPER-NICKEL ALLOY (POWDER) - THERMAL SPRAYING COPPER-NICKEL ALLOY (POWDER) TASK 70-49-04-340-005 1. Thermal Spraying Copper-Nickel Alloy (Powder) SUBTASK 70-49-04-99G-005 A. General. (1) Copper-nickel alloy forms an effective coating for protection against fretting and wear of rubbing surfaces. This procedure covers application of the powder form by plasma arc spraying.
SUBTASK 70-49-04-340-052 C. Material. (1) Copper-Nickel Powder C07-013.
EFFECTIVITY: ALL
Adhesion.
70-49-04
THERMAL SPRAYING COPPER-NICKEL ALLOY (POWDER) Page 1 Dec 01/03
EFFECTIVITY: ALL
70-49-04
STANDARD PRACTICES MANUAL AS907-1-1A Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 2,900 psi (19.95 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-3 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed Less than or equal to P-1 None allowed None allowed Rating Photograph Figure 1, Page 13 Figure 6, Page 18 No figure for rating Figure 7, Page 19 No figure for rating Figure 8, Page 20 No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None. See definition for ratable size See definition for ratable size See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-04
EFFECTIVITY: ALL
70-49-04
COPPER-NICKEL-INDIUM (POWDER) - THERMAL SPRAYING COPPER-NICKEL-INDIUM (POWDER) TASK 70-49-05-340-006 1. Thermal Spraying Copper-Nickel-Indium (Powder) SUBTASK 70-49-05-99G-006 A. General. (1) Copper-nickel-indium forms an effective antifretting surface on rubbing areas of parts. This procedure covers application of the powder form by plasma arc spraying, using conventional equipment or the minigun variation. NOTE: Copper-nickel-indium can also be applied by electric arc per TASK 70-4949-340-048, Electric-Arc Wire Spraying Copper-Nickel-Indium (Wire) as an acceptable alternative. (2) Substantiation requirements are given in the repair procedures of the applicable Engine/Shop Manual.
SUBTASK 70-49-05-340-062 C. Material. (1) Copper-Nickel-Indium Powder C07-020.
SUBTASK 70-49-05-340-064 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test
EFFECTIVITY: ALL
70-49-05
THERMAL SPRAYING COPPER-NICKEL-INDIUM (POWDER) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-0055, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3 (f) Oxides and Oxide Clusters.
EFFECTIVITY: ALL
70-49-05
STANDARD PRACTICES MANUAL AS907-1-1A Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 2,000 psi (13.8 MPa) minimum. (5) Lap Shear Bond Strength. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. (6) Wire Brush. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Acceptance Criteria Less than or equal to V-3 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed Less than or equal to P-1 Rating Photograph Figure 1, Page 13 Figure 6, Page 18 No figure for rating Figure 7, Page 19 No figure for rating Figure 8, Page 20 Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-05
Table 1. Acceptance Limits for Thermal Spray (Cont) Feature Transverse Cracks Delaminations Acceptance Criteria None allowed None allowed Rating Photograph No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 Comments See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-05
MAGNESIUM ALLOY (WIRE) - THERMAL SPRAYING MAGNESIUM ALLOY (WIRE) TASK 70-49-06-340-007 1. Thermal Spraying Magnesium Alloy (Wire) SUBTASK 70-49-06-99G-007 A. General. (1) Magnesium alloy can be used for building up worn or damaged surfaces on magnesium alloy castings, and for cosmetic purposes. It is available in wire form for flame spraying.
SUBTASK 70-49-06-340-072 C. Material. (1) Magnesium Alloy Wire C07-002.
EFFECTIVITY: ALL
Adhesion.
70-49-06
THERMAL SPRAYING MAGNESIUM ALLOY (WIRE) Page 1 Dec 01/03
EFFECTIVITY: ALL
70-49-06
STANDARD PRACTICES MANUAL AS907-1-1A Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Transverse Cracks Delaminations Acceptance Criteria Uniform Uniform None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph No figure for rating No figure for rating No figure for rating Figure 7, Page 19 No figure for rating No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-06
EFFECTIVITY: ALL
70-49-06
MOLYBDENUM (POWDER) - THERMAL SPRAYING MOLYBDENUM (POWDER) TASK 70-49-07-340-008 1. Thermal Spraying Molybdenum (Powder) SUBTASK 70-49-07-99G-008 A. General. (1) Molybdenum forms a self-lubricating, wear resistant surface that is self-bonding; therefore, it is one of the most effective and frequently used bonding coats. It is available in both powder and wire forms. This procedure covers application of the powder form by plasma arc spraying. NOTE: Molybdenum may also be applied by wire for flame spraying per TASK 70-49-08-340-009, Thermal Spraying Molybdenum (Wire), or by electric arc per TASK 70-49-51-340-050, Electric-Arc Wire Spraying Pure Molybdenum (Wire). Those two procedures are acceptable alternatives. SUBTASK 70-49-07-340-081 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-07-340-082 C. Materials. (1) Molybdenum Powder C07-001.
EFFECTIVITY: ALL
70-49-07
THERMAL SPRAYING MOLYBDENUM (POWDER) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters.
EFFECTIVITY: ALL
70-49-07
STANDARD PRACTICES MANUAL AS907-1-1A Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 2,500 psi (17.2 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Transverse Cracks Delaminations Acceptance Criteria Uniform Uniform None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph No figure for rating No figure for rating No figure for rating Figure 7, Page 19 No figure for rating No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None. See definition for ratable size See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-07
EFFECTIVITY: ALL
70-49-07
MOLYBDENUM (WIRE) - THERMAL SPRAYING MOLYBDENUM (WIRE) TASK 70-49-08-340-009 1. Thermal Spraying Molybdenum (Wire) SUBTASK 70-49-08-99G-009 A. General. (1) Because molybdenum forms a surface that is self-lubricating, wear-resistant selfbonding, it is one of the most effective and frequently used bonding coats. It is available in both powder and wire forms. This procedure covers application of the powder form by flame spraying. NOTE: Molybdenum may also be applied as powder by plasma spraying per TASK 70-49-07-340-008, Thermal Spraying Molybdenum (Powder), or by electric arc per TASK 70-49-51-340-050, Electric-Arc Wire Spraying Pure Molybdenum (Wire). Those two procedures are acceptable alternatives. SUBTASK 70-49-08-340-091 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-08-340-092 C. Material. (1) Molybdenum Wire C07-005.
EFFECTIVITY: ALL
70-49-08
THERMAL SPRAYING MOLYBDENUM (WIRE) Page 1 Dec 01/03
EFFECTIVITY: ALL
70-49-08
STANDARD PRACTICES MANUAL AS907-1-1A Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 2,500 psi (17.2 MPa), minimum. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Transverse Cracks Delaminations Acceptance Criteria Uniform Uniform None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph No figure for rating No figure for rating No figure for rating Figure 7 No figure for rating No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-08
EFFECTIVITY: ALL
70-49-08
NICKEL-ALUMINIDE (POWDER) - THERMAL SPRAYING NICKEL-ALUMINIDE (POWDER) TASK 70-49-09-340-010 1. Thermal Spraying Nickel-Aluminide (Powder) SUBTASK 70-49-09-99G-010 A. General. (1) Nickel-aluminide powder is used as a bond coat for other coatings and as a buildup coating for repair of worn parts. It is being replaced by nickel-aluminum per TASK 70-49-10-340-011, Thermal Spraying Nickel-Aluminum (Powder), because nickelaluminum provides an improved coating. This procedure covers application of nickel-aluminide in the powder form by plasma arc spraying.
SUBTASK 70-49-09-340-102 C. Material. (1) Nickel-Aluminum Composite Powder C07-011.
EFFECTIVITY: ALL
70-49-09
THERMAL SPRAYING NICKEL-ALUMINIDE (POWDER) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in T TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity.
EFFECTIVITY: ALL
70-49-09
STANDARD PRACTICES MANUAL AS907-1-1A Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 2,500 psi (17.2 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Acceptance Criteria Less than or equal to V-1 Oxides shall be uniformly distributed. Reject cluster oxides as shown in Figure 6 view X-3. None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 25, Page 37 Figure 6, Page 18 Task TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None
Oxide Clusters Interface Contamination Interface Separations Transverse Cracks Delaminations
No figure for rating Figure 7, Page 19 No figure for rating No figure for rating No figure for rating
TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005
See definition for ratable size None See definition for ratable size See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-09
EFFECTIVITY: ALL
70-49-09
NICKEL-ALUMINUM (POWDER) - THERMAL SPRAYING NICKEL-ALUMINUM (POWDER) TASK 70-49-10-340-011 1. Thermal Spraying Nickel-Aluminum (Powder) SUBTASK 70-49-10-99G-011 A. General. (1) Nickel-Aluminum is used either to form a bond with various top coat systems, or for dimensional restoration. This procedure covers application of the powder form by plasma spraying. NOTE: Nickel-Aluminum may also be applied as wire by flame spraying per TASK 70-49-11-340-012, Thermal Spraying Nickel-Aluminum (Wire), or by electric arc spraying per TASK 70-49-38-340-037, Electric Arc Wire Spraying Nickel-Aluminum (Wire). Those two procedures are acceptable alternatives. SUBTASK 70-49-10-340-111 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-10-340-112 C. Material. (1) (2) Nickel-Aluminum Composite Powder, Class A C07-016. Nickel-Aluminum Pre-Alloyed Powder, Class B C07-016.
SUBTASK 70-49-10-340-114 E. Quality Assurance. (1) Thickness.
EFFECTIVITY: ALL
70-49-10
THERMAL SPRAYING NICKEL-ALUMINUM (POWDER) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3.
EFFECTIVITY: ALL
70-49-10
STANDARD PRACTICES MANUAL AS907-1-1A (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. If this coating is applied in a thickness range up to 0.015 inches (0.38 mm), the tensile bond strength for this coating at room temperature shall average 5,000 psi (34.5 MPa), minimum. If this coating is applied in a thickness range greater than 0.015 inches (0.38 mm), the tensile bond strength for this coating at room temperature shall average 4,000 psi (27.6 MPa), minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Acceptance Criteria Less than or equal to V-1 Oxides shall be uniformly distributed. Reject cluster oxides as shown in Figure 6 view X-3. None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 25, Page 37 Figure 6, Page 18 Task TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None
See definition for ratable size None. See definition for ratable size See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-10
EFFECTIVITY: ALL
70-49-10
NICKEL-ALUMINUM (WIRE) - THERMAL SPRAYING NICKEL-ALUMINUM (WIRE) TASK 70-49-11-340-012 1. Thermal Spraying Nickel-Aluminum (Wire) SUBTASK 70-49-11-99G-012 A. General. (1) Because the nickel-aluminum alloy forms a strong bond coat, it is very effective on titanium and super-alloys. It is also available as powder for plasma arc spraying, and as wire for flame spraying. This procedure covers application of the wire form by flame spraying. Refer to TASK 70-49-10-340-011, Thermal Spraying NickelAluminum (Powder), for its application as powder by plasma arc spraying. NOTE: Nickel-aluminum may also be applied as powder by plasma arc spraying per TASK 70-49-10-340-011, Thermal Spraying Nickel-Aluminum (Powder), or as wire by electric arc spraying per TASK 70-49-38-340-037, Electric Arc Spraying Nickel-Aluminum (Wire). Those two procedures are acceptable alternatives. SUBTASK 70-49-11-340-121 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-11-340-122 C. Material. (1) Nickel-Aluminum Wire C07-019.
EFFECTIVITY: ALL
70-49-11
THERMAL SPRAYING NICKEL-ALUMINUM (WIRE) Page 1 Dec 01/03
EFFECTIVITY: ALL
70-49-11
STANDARD PRACTICES MANUAL AS907-1-1A (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. If this coating is applied in a thickness range up to 0.015 inches (0.38 mm), the tensile bond strength for this coating at room temperature shall average 5,000 psi (34.5 MPa), minimum. If this coating is applied in a thickness range greater than 0.015 inches (0.38 mm), the tensile bond strength for this coating at room temperature shall average 4,000 psi (27.6 MPa), minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Acceptance Criteria Less than or equal to V-1 Oxides shall be uniformly distributed. Reject Cluster oxides as shown in Figure 6 view X-3. None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 25, Page 37 Figure 6 Task TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None
EFFECTIVITY: ALL
70-49-11
EFFECTIVITY: ALL
70-49-11
NICKEL-CHROMIUM (POWDER) - THERMAL SPRAYING NICKEL-CHROMIUM (POWDER) TASK 70-49-12-340-013 1. Thermal Spraying Nickel-Chromium (Powder) SUBTASK 70-49-12-99G-013 A. General. (1) Nickel-chromium alloy forms an excellent base for the attachment of instrumentation to engine parts. This procedure covers application of the powder form by plasma arc spraying. NOTE: Nickel-chromium may also be applied as a wire for flame spraying per TASK 70-49-13-340-014, Thermal Spraying Nickel-chromium (Wire). That procedure is an acceptable alternative. SUBTASK 70-49-12-340-131 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-12-340-132 C. Material. (1) (2) Nickel-Chromium Powder, Class A C07-012. Nickel-Chromium Powder, Class BC07-012.
EFFECTIVITY: ALL
70-49-12
THERMAL SPRAYING NICKEL-CHROMIUM (POWDER) Page 1 Dec 01/03
EFFECTIVITY: ALL
70-49-12
STANDARD PRACTICES MANUAL AS907-1-1A Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-1 Less than or equal to X-1 None allowed Less than or equal to I-2 None allowed Less than or equal to P-1 None allowed None allowed Rating Photograph Figure 1 Figure 6 No figure for rating Figure 7 No figure for rating Figure 8 No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None. See definition for ratable size See definition for ratable size See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-12
EFFECTIVITY: ALL
70-49-12
NICKEL-CHROMIUM (WIRE) - THERMAL SPRAYING NICKEL-CHROMIUM (WIRE) TASK 70-49-13-340-014 1. Thermal Spraying Nickel-Chromium (Wire) SUBTASK 70-49-13-99G-014 A. General. (1) Nickel-chromium alloy forms an excellent base for the attachment of instrumentation to engine parts. This procedure covers application of the wire form by flame spraying. NOTE: Nickel-chromium may also be applied as a powder form by plasma arc spraying per TASK 70-49-12-340-013, Thermal Spraying Nickel-Chromium (Powder). That procedure is an acceptable alternative. SUBTASK 70-49-13-340-141 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-13-340-142 C. Material. (1) Nickel-Chromium Wire C07-006.
EFFECTIVITY: ALL
70-49-13
THERMAL SPRAYING NICKEL-CHROMIUM (WIRE) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of
EFFECTIVITY: ALL
70-49-13
STANDARD PRACTICES MANUAL AS907-1-1A oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-1 Less than or equal to X-1 None allowed Less than or equal to I-2 None allowed Less than or equal to P-1 None allowed None allowed Rating Photograph Figure 1 Figure 6 No figure for rating Figure 7 No figure for rating Figure 8 No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None. See definition for ratable size See definition for ratable size See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-13
EFFECTIVITY: ALL
70-49-13
75:25 NICKEL-GRAPHITE (POWDER) - THERMAL SPRAYING 75:25 NICKEL-GRAPHITE (POWDER) TASK 70-49-14-340-015 1. Thermal Spraying 75:25 Nickel-Graphite (Powder) SUBTASK 70-49-14-99G-015 A. General. (1) Nickel-graphite blend forms a moderately heat resistant rub coating for clearance control applications. This procedure covers application of the powder form by flame spray application.
SUBTASK 70-49-14-340-152 C. Material. (1) 75:25 Nickel-Graphite Powder C07-014.
EFFECTIVITY: ALL
Adhesion.
70-49-14
THERMAL SPRAYING 75:25 NICKEL-GRAPHITE (POWDER) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. When specified by the applicable manual, test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 750 psi (5.2 MPa) minimum. (5) Macrohardness. Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape, but it should be at least 0.030 inch (0.76 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying,
EFFECTIVITY: ALL
70-49-14
STANDARD PRACTICES MANUAL AS907-1-1A or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing, and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness range for this coating shall be 30-50, based on an average of at least ten readings on a Rockwell R15Y scale. For this hardness scale, the specimen should have a top coat thickness of 0.080 inch (2.03 mm), minimum. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Acceptance Criteria Uniform; shall not be greater than B-1 or less than B-2 None allowed None allowed Rating Photograph Figure 5, Page 17 Task TASK 70-71-04700-005 Comments None
No figure for rating No figure for rating
TASK 70-71-04700-005 TASK 70-71-04700-005
See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-14
EFFECTIVITY: ALL
70-49-14
85:15 NICKEL-GRAPHITE (POWDER) - THERMAL SPRAYING 85:15 NICKEL-GRAPHITE (POWDER) TASK 70-49-15-340-016 1. Thermal Spraying 85:15 Nickel-Graphite (Powder) SUBTASK 70-49-15-99G-016 A. General. (1) Nickel-graphite blend forms a moderately heat resistant coating for clearance control applications. It is available in powder form for flame spray application.
SUBTASK 70-49-15-340-162 C. Material. (1) 85:15 Graphite Powder C07-015.
SUBTASK 70-49-15-340-164 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. When specified by the applicable manual, test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 1,200 to 3,000 psi (8.3 to 20.7 MPa) minimum. (5) Macrohardness. Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape, but it should be at least 0.030 inch (0.76 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying,
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STANDARD PRACTICES MANUAL AS907-1-1A or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing, and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness range for this coating shall be 50-70, based on an average of at least ten readings on a Rockwell R15Y scale. For this coating, the specimen should have a top coat thickness of 0.080 inch (2.03 mm), minimum. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Acceptance Criteria Nickel content shall not exceed View 2 or be less than View 1 None allowed None allowed Rating Photograph Figure 26, Page 38 Task TASK 70-71-04700-005 Comments None
No figure for rating No figure for rating
TASK 70-71-04700-005 TASK 70-71-04700-005
See definition for ratable size See definition for ratable size
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NICKEL-SILICON-BORON (POWDER) - THERMAL SPRAYING NICKEL-SILICON-BORON (POWDER) TASK 70-49-16-340-017 1. Thermal Spraying Nickel-Silicon-Boron (Powder) SUBTASK 70-49-16-99G-017 A. General. (1) Nickel-silicon-boron forms an impermeable glass-like coating that provides a high degree of oxidation and corrosion resistance to the base metal. The coating is also highly wear and abrasion resistant, although it is subject to remelting at temperatures below the melting point of the base metal. The material is available as powder for plasma arc.
SUBTASK 70-49-16-340-172 C. Material. (1) Nickel-Silicon-Boron Powder C07-021.
EFFECTIVITY: ALL
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THERMAL SPRAYING NICKEL-SILICON-BORON (POWDER) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. When specified by the applicable manual, test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed.
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STANDARD PRACTICES MANUAL AS907-1-1A (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 5,500 psi (37.9 MPa), minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-1 Less than or equal to X-1 None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 1 Figure 6 No figure for rating Figure 7, Page 19 No figure for rating No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size See definition for ratable size See definition for ratable size
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COPPER-ZINC-SILVER ALLOY (WIRE) - THERMAL SPRAYING COPPER-ZINC-SILVER ALLOY (WIRE) TASK 70-49-17-340-018 1. Thermal Spraying Copper-Zinc-Silver Alloy (Wire) SUBTASK 70-49-17-99G-018 A. General. (1) The Copper-Zinc-Silver alloy coating has good rubbing characteristics, and can be readily machined to close tolerances. The coating is frequently used as an abradable coating for stationary cooling and vent seals. This procedure covers the application of the wire form. NOTE: Copper-Zinc-Silver alloy may also be applied as a wire by electric arc per TASK 70-49-44-340-043, Electric-Arc Wire Spraying Copper-Zinc-Silver (Wire) as an acceptable alternative. SUBTASK 70-49-17-340-181 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-17-340-182 C. Material. (1) Silver Alloy Wire C07-004.
SUBTASK 70-49-17-340-184 E. Homogenization Heat Treatment. (1) Unless otherwise specified, the copper-zinc-silver alloy coated parts shall be heat treated at 8508-9008F (4548- 4828C) in air for two hours. The heat treatment shall be done before final machining or any other processing that might be impaired by the heat treatment.
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THERMAL SPRAYING COPPER-ZINC-SILVER ALLOY (WIRE) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-17-340-185 F. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005 Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e)
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Interface Contamination.
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STANDARD PRACTICES MANUAL AS907-1-1A Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 3,000 psi (20.7 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Acceptance Criteria Uniformly distributed in proportions less than G-1 Uniformly distributed in proportions less than G-1 None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 10, Page 22 Task TASK 70-71-04700-005 Comments None
Oxides
Figure 10, Page 22
TASK 70-71-04700-005
None
No figure for rating Figure 7 No figure for rating No figure for rating No figure for rating
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50 PERCENT TUNGSTEN CARBIDE - THERMAL SPRAYING 50 PERCENT TUNGSTEN CARBIDE SELFBONDING BLEND (POWDER) TASK 70-49-18-340-019 1. Thermal Spraying 50 Percent Tungsten Carbide Self-Bonding Blend (Powder) SUBTASK 70-49-18-99G-019 A. General. (1) This form of tungsten carbide self-bonding blend is composed of the tungsten carbide itself in conjunction with cobalt, a nickel-aluminum mixture, and a nickelbase braze alloy containing small amounts of chromium, silicon and boron. In addition to being self-bonding, the coating accepts a high finish by grinding and lapping; therefore, it forms a hard anti-fretting surface that is extremely resistant to rubbing wear.
SUBTASK 70-49-18-340-192 C. Material. (1) Tungsten Carbide Powder Blend C07-010.
THERMAL SPRAYING 50 PERCENT TUNGSTEN CARBIDE SELF-BONDING BLEND (POWDER) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 5,500 psi (37.9 MPa) minimum. (5) Macrohardness. Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape, but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing, and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be 83, based on an average of at least five readings on a Rockwell R15N scale. (6) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Acceptance Criteria Less than or equal to V-1 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed Rating Photograph Figure 1, Page 13 Figure 6 No figure for rating Figure 7, Page 19 No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size
Table 1. Acceptance Limits for Thermal Spray (Cont) Feature Unmelts Transverse Cracks Delaminations Acceptance Criteria Less than or equal to P-2 None allowed None allowed Rating Photograph Figure 8, Page 20 No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments See definition for ratable size See definition for ratable size See definition for ratable size
TUNGSTEN CARBIDE (POWDER) - THERMAL SPRAYING TUNGSTEN CARBIDE (POWDER) TASK 70-49-19-340-020 1. Thermal Spraying Tungsten Carbide (Powder) SUBTASK 70-49-19-99G-020 A. General. (1) Tungsten carbide provides an extremely hard, wear resistant coating for other metals, and is self-bonding. It can also be used for clearance control coatings, since the coating is somewhat abrasive in the as-sprayed condition. The coating will also accept a high finish by grinding and lapping; therefore, it is useful for hard-facing the areas of parts that are subjected to wear. Tungsten carbide is supplied as a powder, with cobalt to form a metallic matrix, for plasma arc disposition. This procedure is similar to TASK 70-49-28-340-029, Thermal Spraying Tungsten Carbide (Powder) with parameters altered for specific applications. This procedure is to be used as called for by individual parts repair procedure. NOTE: This application of the tungsten carbide coating originally required argonhydrogen spray parameters. SUBTASK 70-49-19-340-201 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-19-340-202 C. Material. (1) Tungsten Carbide-Cobalt Powder C07-007.
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THERMAL SPRAYING TUNGSTEN CARBIDE (POWDER) Page 1 Dec 01/03
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STANDARD PRACTICES MANUAL AS907-1-1A (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Phase. Phase shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (h) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (i) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 5,500 psi (37.9 MPa) minimum. (5) Macrohardness. Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape, but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing, and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be 83, based on an average of at least five readings on a Rockwell R15N scale. (6) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual.
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Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations Phase Acceptance Criteria Less than or equal to V-3 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed Less than or equal to P-1 None allowed None allowed Shall be equal or greater than W-1 or equal to or less than W-2 Rating Photograph Figure 1, Page 13 Figure 6, Page 18 No figure for rating Figure 7, Page 19 No figure for rating Figure 8, Page 20 No figure for rating No figure for rating Figure 9, Page 21 Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size See definition for ratable size See definition for ratable size See definition for ratable size None
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CHROMIUM CARBIDE NO. 1 - THERMAL SPRAYING CHROMIUM CARBIDE NO. 1 COMPOSITE (POWDER) TASK 70-49-20-340-021 1. Thermal Spraying Chromium Carbide No. 1 Composite (Powder) SUBTASK 70-49-20-99G-021 A. General. (1) Chromium carbide forms an excellent wear resistant coating in the 12008-16008F (6508-8708C) temperature range. This procedure covers application of the powder form by plasma arc spraying.
SUBTASK 70-49-20-340-212 C. Material. (1) (2) Composite Powder Blend C07-026. The coating material is prepared by thoroughly mixing three parts of chromium carbide powder, by weight, to one part of nickel aluminide powder.
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THERMAL SPRAYING CHROMIUM CARBIDE NO. 1 COMPOSITE (POWDER) Page 1 Dec 01/03
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STANDARD PRACTICES MANUAL AS907-1-1A oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations Acceptance Criteria Uniform Uniform None allowed Less than or equal to I-2 None allowed Uniform None allowed None allowed Rating Photograph No Figure for rating No Figure for rating No figure for rating Figure 7, Page 19 No figure for rating No Figure for rating No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size None See definition for ratable size See definition for ratable size
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NICKEL-CHROMIUM/ALUMINUM - THERMAL SPRAYING NICKEL-CHROMIUM/ALUMINUM COMPOSITE (POWDER) TASK 70-49-21-340-022 1. Thermal Spraying Nickel-Chromium/Aluminum Composite (Powder) SUBTASK 70-49-21-99G-022 A. General. (1) Nickel-Chrome/Aluminum alloy is used to form either a bond coating with various top coat systems or for dimensional restoration. This procedure covers application of the powder form by plasma spraying. NOTE: Nickel-Chrome/Aluminum alloy may also be applied as wire by electric arc spraying per TASK 70-49-39-340-038, Electric Arc Wire Spraying Nickel-Chrome/Aluminum (Wire) as an acceptable alternative. SUBTASK 70-49-21-340-221 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-21-340-222 C. Material. (1) Aluminum-Nickel-Chromium Composite Powder C07-022.
EFFECTIVITY: ALL
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THERMAL SPRAYING NICKEL-CHROMIUM/ALUMINUM COMPOSITE (POWDER) Page 1 Dec 01/03
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. If this coating is applied in a thickness range up to 0.015 inches (0.38 mm), the tensile bond strength for this coating at room temperature shall average 5,000 psi (34.5 MPa), minimum. If this coating is applied in a thickness range greater than 0.015 inches (0.38 mm), the tensile bond strength for this coating at room temperature shall average 4,000 psi (27.6 MPa), minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Acceptance Criteria Less than or equal to V-1 Oxides shall be uniformly distributed. Reject Cluster oxides as shown in Figure 6 view X-3. None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 25 Figure 6 Task TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None
See definition for ratable size None See definition for ratable size See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-21-340-225 F. Recoating Previously Coated Surfaces. CAUTION: THIS PROCEDURE IS NOT APPLICABLE TO PARTS OR COMPONENTS THAT CONTAIN ALUMINUM ALLOYS OR ORGANIC COMPOSITES. DAMAGE MAY BE CAUSED TO PARTS OR COMPONENTS. (1) Surfaces previously coated per TASK 70-49-21-340-022, Thermal Spraying NickelChromium/Aluminum Composite (Powder), may be recoated without removing the original coating, subject to the following conditions: (a) (b) The repair procedure for the part specifies these materials and was applied for the purpose of restoring dimensional integrity. The part to be coated shall be thoroughly cleaned in the following sequence: 1 2 3 4 (c) Alkaline clean per TASK 70-21-09-110-007, Cleaning Method No. 9 Light-Duty Alkaline Cleaning of Titanium Alloys. Steam clean per TASK 70-21-03-160-001, Cleaning Method No. 3 Steam Cleaning. Bake part at 6008 258F (3168 148C) for 30 minutes in air. If surface to be coated exhibits evidence of oil or contamination repeat cleaning and baking operations.
Apply masking and grit blast per TASK 70-49-00-340-001, Thermal Spraying, or applicable manual repair instructions.
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ALUMINA/NICKEL-ALUMINUM - THERMAL SPRAYING ALUMINA/NICKEL-ALUMINUM COMPOSITE (POWDER) TASK 70-49-22-340-023 1. Thermal Spraying Aluminum Oxide/Nickel-Aluminum Composite (Powder) SUBTASK 70-49-22-99G-023 A. General. (1) Aluminum oxide/nickel-aluminum composite is a self-bonding material that provides a hard clearance control surface that is wear resistant and abrasive. The composite is a blend of materials in powder form for plasma arc spraying.
SUBTASK 70-49-22-340-232 C. Material. (1) (2) Aluminum Oxide C07-003. Nickel-Aluminum C07-011. (a) The coating material is prepared by thoroughly blending the powders in the following proportions (percent by weight): 1 2 Aluminum oxide: 55.01.0. Refer to TASK 70-49-02-340-003, Thermal Spraying Aluminum Oxide (Powder). Nickel-Aluminum: 45.01.0. Refer to TASK 70-49-09-340-010, Thermal Spraying Nickel-Aluminide (Powder).
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70-49-22
THERMAL SPRAYING ALUMINA/NICKEL-ALUMINUM COMPOSITE (POWDER) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-22-340-235 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e)
EFFECTIVITY: ALL
70-49-22
STANDARD PRACTICES MANUAL AS907-1-1A Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Phase. Phase shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 2,000 psi (13.8 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Interface Contamination Interface Separations Transverse Cracks Delaminations Phase Acceptance Criteria Less than or equal to V-3 Less than or equal to I-2 None allowed None allowed None allowed Similar to that of C-4 Rating Photograph Figure 1, Page 13 Figure 7 No figure for rating No figure for rating No figure for rating Figure 12, Page 24 Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size See definition for ratable size See definition for ratable size None
EFFECTIVITY: ALL
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EFFECTIVITY: ALL
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PURE ALUMINUM (WIRE) - THERMAL SPRAYING PURE ALUMINUM (WIRE) TASK 70-49-23-340-024 1. Thermal Spraying Pure Aluminum (Wire) SUBTASK 70-49-23-99G-024 A. General. (1) This procedure covers flame spraying of pure aluminum in wire form. For aluminum plasma arc spraying in powder form, refer to TASK 70-49-01-340-002, Thermal Spraying Pure Aluminum (Powder). NOTE: Pure aluminum (wire) may also be applied per TASK 70-49-40-340-039, Electric Arc Spraying Pure Aluminum (Wire) as an acceptable alternative procedure. SUBTASK 70-49-23-340-241 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-23-340-242 C. Material. (1) Pure Aluminum Wire C07-028.
EFFECTIVITY: ALL
70-49-23
THERMAL SPRAYING PURE ALUMINUM (WIRE) Page 1 Dec 01/03
EFFECTIVITY: ALL
70-49-23
STANDARD PRACTICES MANUAL AS907-1-1A oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 1,200 psi (8.3 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-2 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 1, Page 13 Figure 6 No figure for rating Figure 7 No figure for rating No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-23
EFFECTIVITY: ALL
70-49-23
75 PERCENT TUNGSTEN CARBIDE - THERMAL SPRAYING 75 PERCENT TUNGSTEN CARBIDE SELFBONDING BLEND (POWDER) TASK 70-49-24-340-025 1. Thermal Spraying 75 Percent Tungsten Carbide Self-Bonding Blend (Powder) SUBTASK 70-49-24-99G-025 A. General. (1) 75 percent tungsten carbide is a self-bonding coating powder consisting of a mechanical blend of a tungsten carbide-cobalt aggregate, AMS 4775 braze alloy, and a nickel coated aluminum powder suitable for plasma arc spray.
SUBTASK 70-49-24-340-252 C. Material. (1) Tungsten Carbide Blend Powder C07-009.
STANDARD PRACTICES MANUAL AS907-1-1A (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity.
STANDARD PRACTICES MANUAL AS907-1-1A Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Macrohardness. Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape, but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing, and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be 83, based on an average of at least five readings on a Rockwell R15N scale. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-3 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed Less than or equal to P-2 None allowed None allowed Rating Photograph Figure 1, Page 13 Figure 6 No figure for rating Figure 7, Page 19 No figure for rating Figure 8, Page 20 No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size None See definition for ratable size See definition for ratable size
ALUMINUM BRONZE ALLOY (POWDER) - THERMAL SPRAYING ALUMINUM BRONZE ALLOY (POWDER) TASK 70-49-25-340-026 1. Thermal Spraying Aluminum Bronze Alloy (Powder) SUBTASK 70-49-25-99G-026 A. General. (1) Aluminum bronze alloy can be used for building up worn or damaged surfaces, or as a dovetail wear coating. It is available in both powder and wire forms. This procedure covers application of the powder form by plasma arc spraying. NOTE: Aluminum bronze may also be applied by wire for flame spraying per TASK 70-49-26-340-027, Thermal Spraying Aluminum Bronze Alloy (Wire), or by electric arc per TASK 70-49-52-340-051, Electric-Arc Wire Spraying Pure Aluminum Bronze (Wire). Those two procedures are acceptable alternatives. SUBTASK 70-49-25-340-261 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-25-340-262 C. Material. (1) Aluminum Bronze Powder C07-023.
EFFECTIVITY: ALL
70-49-25
THERMAL SPRAYING ALUMINUM BRONZE ALLOY (POWDER) Page 1 Dec 01/03
EFFECTIVITY: ALL
70-49-25
STANDARD PRACTICES MANUAL AS907-1-1A Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 2,000 psi (13.8 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-3 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 1, Page 13 Figure 6, Page 18 No figure for rating Figure 7, Page 19 No figure for rating No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-25
EFFECTIVITY: ALL
70-49-25
ALUMINUM BRONZE ALLOY (WIRE) - THERMAL SPRAYING ALUMINUM BRONZE ALLOY (WIRE) TASK 70-49-26-340-027 1. Thermal Spraying Aluminum Bronze Alloy (Wire) SUBTASK 70-49-26-99G-027 A. General. (1) Aluminum bronze alloy can be used for building up worn or damaged surfaces, or as a dovetail wear coating. It is available in both powder and wire forms. This procedure covers application of the wire form by flame spraying. NOTE: Aluminum bronze may also be applied by powder for plasma arc spraying per TASK 70-49-25-340-026, Thermal Spraying Aluminum Bronze Alloy (Powder), or by electric arc per TASK 70-49-52-340-051, Electric-Arc Wire Spraying Pure Aluminum Bronze (Wire). Those two procedures are acceptable alternatives. SUBTASK 70-49-26-340-271 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-26-340-272 C. Material. (1) Aluminum Bronze Wire C07-024.
EFFECTIVITY: ALL
70-49-26
THERMAL SPRAYING ALUMINUM BRONZE ALLOY (WIRE) Page 1 Dec 01/03
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 2,000 psi (13.8 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-3 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 1, Page 13 Figure 6 No figure for rating Figure 7 No figure for rating No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size See definition for ratable size See definition for ratable size
EFFECTIVITY: ALL
70-49-26
EFFECTIVITY: ALL
70-49-26
COBALT-MOLYBDENUM-CHROMIUM-SILICON - THERMAL SPRAYING COBALT-MOLYBDENUMCHROMIUM-SILICON ALLOY (POWDER) - TRIBALLOY 400 TASK 70-49-27-340-028 1. Thermal Spraying Cobalt-Molybdenum-Chromium-Silicon Alloy (Powder) - Triballoy 400 SUBTASK 70-49-27-99G-028 A. General. (1) Cobalt-molybdenum-chromium-silicon alloy is a powder suitable for thermal spray processes and clearance control applications. It is used for salvage and buildup applications when specified in the applicable repair instructions of the Engine/ Shop Manual.
SUBTASK 70-49-27-340-282 C. Material. (1) Cobalt-Molybdenum-Chrome-Silicon Powder C07-025.
EFFECTIVITY: ALL
70-49-27
THERMAL SPRAYING COBALT-MOLYBDENUM-CHROMIUM-SILICON ALLOY (POWDER) - TRIBALLOY 400 Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity.
EFFECTIVITY: ALL
70-49-27
STANDARD PRACTICES MANUAL AS907-1-1A Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 5,000 psi (34.47 MPa) minimum. (5) Macrohardness Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be 80, based on an average of at least five readings on a Rockwell R15N scale. (6) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks
EFFECTIVITY: ALL
Acceptance Criteria Less than or equal to V-2 Less than or equal to X-2 None allowed Less than or equal to I-1 None allowed Less than or equal to P-2 None allowed
Rating Photograph Figure 1 Figure 6 No figure for rating Figure 7 No figure for rating Figure 8 No figure for rating
Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005
Comments None None See definition for ratable size None See definition for ratable size None See definition for ratable size
70-49-27
Table 1. Acceptance Limits for Thermal Spray (Cont) Feature Delaminations Acceptance Criteria None allowed Rating Photograph No figure for rating Task TASK 70-71-04700-005 Comments See definition for ratable size
EFFECTIVITY: ALL
70-49-27
TUNGSTEN CARBIDE (POWDER) - THERMAL SPRAYING TUNGSTEN CARBIDE (POWDER) TASK 70-49-28-340-029 1. Thermal Spraying Tungsten Carbide (Powder) SUBTASK 70-49-28-99G-029 A. General. (1) Tungsten carbide provides an extremely hard, wear resistant coating for other metals, and is self-bonding. It can also be used for clearance control coatings, since the coating is somewhat abrasive in the as-sprayed condition. The coating will also accept a high finish by grinding and lapping; therefore, it is useful for hard-facing the areas of parts that are subjected to wear. Tungsten carbide is supplied as a powder with cobalt to form a metallic matrix, for plasma arc disposition. This procedure is similar to TASK 70-49-19-340-020, Thermal Spraying Tungsten Carbide (Powder), with parameters altered for specific applications. This procedure is to be used as called for by individual parts Engine/Shop Manual repair procedure. NOTE: This application of the tungsten carbide coating originally required argonhelium spray parameters. SUBTASK 70-49-28-340-291 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-28-340-292 C. Material. (1) Tungsten Carbide-Cobalt Powder C07-007.
EFFECTIVITY: ALL
70-49-28
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Phase. Phase shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (h) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (i) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 5,500 psi (37.9 MPa) minimum. (5) Macrohardness Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be 83, based on an average of at least five readings on a Rockwell R15N scale. (6) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual.
EFFECTIVITY: ALL
70-49-28
Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations Phase Acceptance Criteria Less than or equal to V-3 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed Less than or equal to P-1 None allowed None allowed Equal to or greater than W-1 or equal to or less than W-2 Rating Photograph Figure 1, Page 13 Figure 6, Page 18 No figure for rating Figure 7, Page 19 No figure for rating Figure 8, Page 20 No figure for rating No figure for rating Figure 9 Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size None None See definition for ratable size None
EFFECTIVITY: ALL
70-49-28
75% CHROMIUM CARBIDE - 25% NICKEL CHROMIUM - THERMAL SPRAYING 75 PERCENT CHROMIUM CARBIDE - 25 PERCENT NICKEL CHROMIUM (POWDER) TASK 70-49-29-340-030 1. Thermal Spraying 75 Percent Chromium Carbide - 25 Percent Nickel Chromium (Powder) SUBTASK 70-49-29-99G-030 A. General. (1) 75 percent chromium carbide - 25 percent nickel chromium forms an excellent wear resistant coating in the temperature range of 10008-15008F (5388-8168C). This procedure covers application of the powder form by plasma arc spraying.
SUBTASK 70-49-29-340-302 C. Material. (1) Chromium Carbide-Nickel Chromium Powder C07-027. NOTE: This Standard Practice contains information for both Class A and Class B designations of the as-sprayed coating. This requires the use of Class A powder material for the Class A final coating and Class B powder for the Class B final coating. In situations where the final as sprayed coating class is not designated in the repair document, the more stringent Class A final coating shall be used. SUBTASK 70-49-29-340-303 D. Spraying Parameters. (1) Starting parameter sets will be listed in the spray equipment manuals or are readily available from the spray equipment manufacturers or powder suppliers. Modifications may be necessary for your location and product application. See sprayability testing per TASK 70-49-00-340-001, Thermal Spraying, and TASK 7070-00-700-001, Testing and Quality Analysis. When the final spray parameter settings are developed, all values should be recorded to ensure consistent achievement of high quality coatings.
THERMAL SPRAYING 75 PERCENT CHROMIUM CARBIDE - 25 PERCENT NICKEL CHROMIUM (POWDER) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-005, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 5,000 psi (34.5 MPa) minimum. (5) Macrohardness Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for Class A material coating shall be 83; for Class B material coating the thickness shall be 75, based on an average of at least five readings on a Rockwell R15N scale. (6) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual.
Table 1. Acceptance Limits for Thermal Spray Feature Porosity Acceptance Criteria Less than or equal to V-2 for class A, or V-3 for class B Less than or equal to X-1 for class A, or X-2 for class B None allowed Less than or equal to I-2 None allowed Less than or equal to P-1 None allowed None allowed Rating Photograph Figure 1, Page 13 Task TASK 70-71-04700-005 Comments None
Oxides
Figure 6, Page 18
TASK 70-71-04700-005
None
Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations
No figure for rating Figure 7, Page 19 No figure for rating Figure 8 No figure for rating No figure for rating
TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005
See definition for ratable size None See definition for ratable size None None See definition for ratable size
COBALT-MOLYBDENUM-CHROMIUM-SILICON - THERMAL SPRAYING COBALT-MOLYBDENUMCHROMIUM-SILICON ALLOY (POWDER) - TRIBALLOY 800 TASK 70-49-30-340-031 1. Thermal Spraying Cobalt-Molybdenum-Chromium-Silicon Alloy (Powder) - Triballoy 800 SUBTASK 70-49-30-99G-031 A. General. (1) Cobalt-molybdenum-chromium-silicon alloy is a powder suitable for thermal spray processes. This coating also has clearance control applications and is used, when specified in the applicable repair instructions of the applicable Engine/Shop Manual, for salvage and buildup application.
SUBTASK 70-49-30-340-312 C. Material. (1) Cobalt-Molybdenum-Chrome-Silicon Powder C07-031.
EFFECTIVITY: ALL
70-49-30
STANDARD PRACTICES MANUAL AS907-1-1A (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with T TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity.
EFFECTIVITY: ALL
70-49-30
STANDARD PRACTICES MANUAL AS907-1-1A Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 4,000 psi (27.6 MPa) minimum. (5) Macrohardness Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be 82, based on an average of at least five readings on a Rockwell R15N scale. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-2 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed Less than or equal to P-2 None allowed None allowed Rating Photograph Figure 1, Page 13 Figure 6 No figure for rating Figure 7 No figure for rating Figure 8, Page 20 No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size None None See definition for ratable size
EFFECTIVITY: ALL
70-49-30
EFFECTIVITY: ALL
70-49-30
NICKEL-ALUMINUM-MOLYBDENUM - THERMAL SPRAYING NICKEL-ALUMINUM-MOLYBDENUM (POWDER) TASK 70-49-31-340-032 1. Thermal Spraying Nickel-Aluminum-Molybdenum (Powder) SUBTASK 70-49-31-99G-032 A. General. (1) Nickel-aluminum-molybdenum composite is a self-bonding readily machinable coating for use on titanium and super alloys. This coating is used when specified in the applicable repair instructions of the Engine/Shop Manual for salvage and buildup applications. This procedure covers application of the powder form by plasma arc spraying.
SUBTASK 70-49-31-340-322 C. Material. (1) Nickel-Aluminum-Molybdenum C07-034.
SUBTASK 70-49-31-340-324 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance.
THERMAL SPRAYING NICKEL-ALUMINUM-MOLYBDENUM (POWDER) Page 1 Dec 01/03
EFFECTIVITY: ALL
70-49-31
STANDARD PRACTICES MANUAL AS907-1-1A Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-0055, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed.
EFFECTIVITY: ALL
70-49-31
STANDARD PRACTICES MANUAL AS907-1-1A (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 2,500 psi (17.2 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations Acceptance Criteria Uniform Uniform None allowed Less than or equal to I-2 None allowed Less than or equal to P-2 None allowed None allowed Rating Photograph No figure for rating No figure for rating No figure for rating Figure 7 No figure for rating Figure 8, Page 20 No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size None None See definition for ratable size
EFFECTIVITY: ALL
70-49-31
EFFECTIVITY: ALL
70-49-31
INCONEL 718 (POWDER) - THERMAL SPRAYING INCONEL 718 (POWDER) TASK 70-49-32-340-033 1. Thermal Spraying Inconel 718 (Powder) SUBTASK 70-49-32-99G-033 A. General. (1) Inconel 718 is a self-bonding, readily machinable coating that provides physical and chemical properties of wrought Inconel 718 Alloy. This coating is used, when specified in the applicable repair instructions of the Engine/Shop Manual, for salvage and build-up applications. This procedure covers application of the powder form by plasma arc spraying. NOTE: Inconel 718 may also be applied per TASK 70-49-45-340-044, Electric Arc Spraying Alloy 718 (Wire) as an acceptable alternative. SUBTASK 70-49-32-340-331 B. Equipment. (1) Refer to TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-32-340-332 C. Material. (1) Inconel 718 Alloy Powder C07-038.
EFFECTIVITY: ALL
70-49-32
THERMAL SPRAYING INCONEL 718 (POWDER) Page 1 Dec 01/03
EFFECTIVITY: ALL
70-49-32
STANDARD PRACTICES MANUAL AS907-1-1A oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 7,000 psi (47.6 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Acceptance Criteria Less than or equal to V-1 Oxides shall be uniformly distributed. Reject Cluster oxides as shown in Figure 6 view X-3. None allowed Less than or equal to I-1 None allowed None allowed None allowed Rating Photograph Figure 25 Figure 6 Task TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None
See definition for ratable size None See definition for ratable size None See definition for ratable size
EFFECTIVITY: ALL
70-49-32
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-32-340-335 F. Recoating Previously Coated Surfaces. CAUTION: THIS PROCEDURE IS NOT APPLICABLE TO PARTS OR COMPONENTS THAT CONTAIN ALUMINUM ALLOYS OR ORGANIC COMPOSITES. DAMAGE MAY BE CAUSED TO PARTS OR COMPONENTS. (1) Surfaces previously coated per TASK 70-49-32-340-033, Thermal Spraying Inconel 718 (Powder), may be recoated without removing the original coating, subject to the following conditions: (a) (b) The repair procedure for the part specifies these materials and was applied for the purpose of restoring dimensional integrity. The part to be coated shall be thoroughly cleaned in the following sequence: 1 2 3 4 (c) Alkaline clean per TASK 70-21-09-110-007, Cleaning Method No. 9 Light-Duty Alkaline Cleaning of Titanium Alloys. Steam clean per TASK 70-21-03-160-001, Cleaning Method No. 3 Steam Cleaning. Bake part at 6008 258F (3168 148C) for 30 minutes in air. If surface to be coated exhibits evidence of oil or contamination repeat cleaning and baking operations.
EFFECTIVITY: ALL
70-49-32
ALUMINUM OXIDE - ALUMINA - THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER) SUPERFINE TASK 70-49-33-340-034 1. Thermal Spraying Aluminum Oxide - Superfine (Powder) SUBTASK 70-49-33-99G-034 A. General. (1) Fine mesh aluminum oxide coating provides a hard clearance control surface that is both wear resistant and abrasive This procedure covers application of the powder form by plasma arc spraying.
SUBTASK 70-49-33-340-342 C. Material. (1) Aluminum Oxide Powder C07-039.
EFFECTIVITY: ALL
70-49-33
THERMAL SPRAYING ALUMINUM OXIDE - ALUMINA (POWDER) SUPERFINE Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for ceramic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for ceramic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3.
(f)
Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed.
(g)
EFFECTIVITY: ALL
Unmelts.
70-49-33
STANDARD PRACTICES MANUAL AS907-1-1A Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the manual. (5) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 4,000 psi (27.6 MPa), minimum. (6) Wire Brush. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Interface Contamination Interface Separations Unmelts Acceptance Criteria Less than or equal to V-2 Less than or equal to I-2 None allowed Less than or equal to P-1 Rating Photograph Figure 1, Page 13 Figure 7, Page 19 No figure for rating Figure 8, Page 20, 14, Page 26, and 15, Page 27 No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size Shape of particles is defined in Figure 15, Page 27 None See definition for ratable size
None allowed None allowed
TASK 70-71-04700-005 TASK 70-71-04700-005
EFFECTIVITY: ALL
70-49-33
EFFECTIVITY: ALL
70-49-33
ALUMINUM SILICON POLYESTER - THERMAL SPRAYING ALUMINUM SILICON POLYESTER (POWDER) TASK 70-49-34-340-035 1. Thermal Spraying Aluminum Silicon Polyester (Powder) SUBTASK 70-49-34-99G-035 A. General. (1) The aluminum silicon polyester powder is an effective coating used in low temperature clearance control applications. This procedure covers application of the powder form by plasma arc spraying.
SUBTASK 70-49-34-340-352 C. Materials. (1) Aluminum Silicon Polyester Powder C07-037.
EFFECTIVITY: ALL
70-49-34
THERMAL SPRAYING ALUMINUM SILICON POLYESTER (POWDER) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Phase. Phase shall be identified as defined for metallic coatings in TASK 70-71-04700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 800 psi (5.5 MPa) minimum. The coating shall be tested at approximately 0.080 inch (2.03 mm) top coat thickness. (5) Macrohardness Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the
EFFECTIVITY: ALL
70-49-34
STANDARD PRACTICES MANUAL AS907-1-1A thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be in the range of 65-80, based on an average of at least five readings on a Rockwell R15Y scale. For this hardness scale, the specimen should have a top coat thickness of 0.080 inch (2.03 mm), minimum. (6) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. (7) Wire Brush. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Transverse Cracks Delaminations Phase Acceptance Criteria None allowed None allowed Uniform Rating Photograph No figure for rating No figure for rating N/A Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None See definition for ratable size Figure 16, Page 28
EFFECTIVITY: ALL
70-49-34
EFFECTIVITY: ALL
70-49-34
THERMAL BARRIER COATING SYSTEM - THERMAL BARRIER COATING SYSTEM - YTTRIUM OXIDE STABILIZED ZIRCONIUM OXIDE (8% YTTRIUM OXIDE) OVER NICKEL CHROMIUM ALUMINUM YTTRIUM BONDCOAT TASK 70-49-35-340-037 1. Thermal Barrier Coating System - Yttrium Oxide Stabilized Zirconium Oxide (8% Yttrium Oxide) Over Nickel Chromium Aluminum Yttrium Bondcoat SUBTASK 70-49-35-99G-037 A. General. (1) Thermal Barrier coatings (TBC) provide base metal protection against hot gas streams. They are used to reduce base metal temperatures to prolong part life. The applied TBC is resistant to thermal shock and has good durability. This process describes the deposition of a NiCrAlY powder bond coat and a YZRO3 powder top coat applied with air plasma system.
SUBTASK 70-49-35-340-371 B. Equipment. (1) Refer to equipment requirements in TASK 70-49-00-340-001, Thermal Spraying.
SUBTASK 70-49-35-340-372 C. Materials. (1) (2) Bond Coat: Nickel Chromium Aluminum Yttrium Powder C07-032. Top Coat: Zirconium oxide - Yttrium oxide powder C07-035.
THERMAL BARRIER COATING SYSTEM - YTTRIUM OXIDE STABILIZED ZIRCONIUM 70-49-35 EFFECTIVITY: ALL OXIDE (8% YTTRIUM OXIDE) OVER NICKEL CHROMIUM ALUMINUM YTTRIUM BONDCOAT
Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance of coating. (a) Visual examination of the coating shall be in accordance with the following: 1 2 3 4 (3) The coating shall exhibit no spalling or lifting. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking.
Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic (bond coat) and ceramic coatings (top coat) in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic (bond coat) and ceramic coatings (top coat) in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3.
(f)
Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as
Page 2 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing of the bond coat only and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 4,000 psi (27.6 MPa) minimum. NOTE: This test is only necessary for initial qualification and not required for testing of daily production hardware. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the manual. Table 1. Acceptance Limits for Thermal Spray Feature General Features Bond Coat Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Less than or equal to V-2 Less than or equal to X-1 None allowed Less than or equal to I-2 None allowed Less than or equal to P-1 Figure 1, Page 13 Figure 6, Page 18 No figure for rating Figure 7, Page 19 No figure for rating Figure 8, Page 20 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 None None See definition for ratable size None. See definition for ratable size See definition for ratable size Acceptance Criteria Similar structure Rating Photograph Figure 20, Page 32 Task TASK 70-71-04700-005 Comments None
Page 3 Dec 01/03
Table 1. Acceptance Limits for Thermal Spray (Cont) Feature Transverse Cracks Delaminations Bond Coat/Top Coat Interface Porosity Top Coat Porosity Between 5-25% Figure 17, Page 29, 18, Page 30, 19, Page 31 TASK 70-71-04700-005 None Less than or equal to 15% No figure for rating TASK 70-71-04700-005 None Acceptance Criteria None allowed None allowed Rating Photograph No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 Comments See definition for ratable size See definition for ratable size
Page 4 Dec 01/03
HIGH DENSITY INCONEL 718 - HIGH DENSITY INCONEL 718 COATING APPLIED BY HVOF THERMAL SPRAY TASK 70-49-36-340-038 1. High Density Inconel 718 Coating Applied By HVOF Thermal Spray SUBTASK 70-49-36-99G-038 A. General. (1) Inconel 718 is a self-bonding, readily machinable coating that provides physical and chemical properties of wrought Inconel 718 Alloy. This coating is used for salvage and build-up applications when specified in the repair instructions of the applicable manual. This procedure should be used when Inconel 718 powder is applied with high velocity oxy-fuel (HVOF) equipment.
SUBTASK 70-49-36-340-381 B. Tools, Equipment and Materials. NOTE: The equipment to do high density HVOF spraying consists of the following: (1) Tools and Equipment. (a) (b) An HVOF gun system with a suitable controller. A gas controller that can deliver up to 1000 SCFH oxygen, 1600 SCFH hydrogen, 300 SCFH propylene, and if required, 800 SCFH air. The unit shall provide gun power control and air delivery rate. A pressurized powder feeder that can deliver powder between 4-15 lbs/hr (27 kg/hr). A clean filtered air supply that can deliver up to 800 SCFH.
(c) (d)
SUBTASK 70-49-36-340-382 C. Material. (1) Inconel 718 Powder, HVOF Application C07-041.
SUBTASK 70-49-36-340-383 D. Spray Parameters. (1) Starting parameter sets will be listed in the spray equipment manuals or are readily available from the spray equipment manufacturers or powder suppliers. Modifications may be necessary for your location and product application. See sprayability testing per TASK 70-49-00-340-001, Thermal Spraying, and TASK 7070-00-700-001, Testing and Quality Analysis. When the final spray parameter settings are developed, all values should be recorded to ensure consistent achievement of high quality coatings.
HIGH DENSITY INCONEL 718 COATING APPLIED BY HVOF THERMAL SPRAY Page 1 Dec 01/03
EFFECTIVITY: ALL
70-49-36
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-36-340-384 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e)
EFFECTIVITY: ALL
70-49-36
STANDARD PRACTICES MANUAL AS907-1-1A Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 9,000 psi (64 MPa) minimum. (5) Macrohardness Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be 79, based on an average of at least five readings on a Rockwell R15N scale. (6) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual.
EFFECTIVITY: ALL
70-49-36
Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Acceptance Criteria Less than Figure 21 More than that shown in Figure 21 but no more than that shown in Figure 22, Page 34 None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 21, Page 33 Figures 21 and 22, Page 34 Task TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None
EFFECTIVITY: ALL
70-49-36
TUNGSTEN CARBIDE/17 COBALT WEAR COATING - TUNGSTEN CARBIDE/17% COBALT WEAR COATING APPLIED BY HIGH VELOCITY OXY-FUEL (HVOF) PROCESS TASK 70-49-37-340-036 1. Tungsten Carbide/17% Cobalt Wear Coating Applied By High Velocity Oxy-Fuel (HVOF) Process SUBTASK 70-49-37-99G-036 A. General. (1) This document provides guidelines for the spraying of tungsten carbide -17% cobalt using High Velocity Oxy-Fuel (HVOF). Tungsten carbide - cobalt produces a high-density coating for wear and fretting applications. The tungsten carbide is supplied as a powder with cobalt forming a metallic matrix in the coating. The coating is self-bonding and will accept a high finish by grinding and lapping. This procedure is used when specified for individual parts in the repair procedures of applicable manuals. Substantiation requirements are given in the repair procedures of the applicable manual.
(2)
(3)
SUBTASK 70-49-37-340-361 B. Equipment. (1) The equipment to do high density HVOF spraying consists of the following: (a) (b) An HVOF gun system with a suitable controller. A gas controller that can deliver up to 1,000 SCFH oxygen, 1,600 SCFH hydrogen, 300 SCFH propylene, and if required, 800 SCFH air. The unit shall provide gun power control and air delivery rate. A pressurized powder feeder that can deliver powder between 4-15 lbs/hr (27 kg/hr). A clean filtered air supply that can deliver up to 800 SCFH.
(c) (d) (2) Model Jet Kote 2000
Commercially available equipment consists of the following: Supplier Stellite Coatings Deloro Stellite, Inc. Refer to the List of Suppliers in Step D. of . Sulzer Metco, Inc. Refer to the List of Suppliers in Step D. of . Praxair/TAFA Concord. Refer to the List of Suppliers in Step D. of .
TUNGSTEN CARBIDE/17% COBALT WEAR COATING APPLIED BY HIGH VELOCITY OXY-FUEL (HVOF) PROCESS Page 1 Dec 01/03
Diamond Jet 2600 Hybrid JP-5000
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-37-340-362 C. Materials. (1) Tungsten Carbide C07-040.
SUBTASK 70-49-37-340-365 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance of coating. (a) Visual examination of the coating shall be in accordance with the following: 1 2 3 4 (3) The coating shall exhibit no spalling or lifting. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking.
Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic (bond coat) and ceramic coatings (top coat) in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings.
STANDARD PRACTICES MANUAL AS907-1-1A (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic (bond coat) and ceramic coatings (top coat) in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 4. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. (4) Hardness Tests. (a) Macrohardness. 1 Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be 89, based on an average of at least five readings on a Rockwell R15N scale.
STANDARD PRACTICES MANUAL AS907-1-1A (b) Microhardness. 1 Test specimens will be prepared for microhardness testing. Test specimens shall meet a minimum average hardness DHP (Vickers) 950-1200 using a 300 gram load. The specimen shall be prepared and tested in accordance with TASK 70-34-02-220-008, Vickers Hardness Testing, or ASTM E-384.
(5)
Tensile Bond Strength. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. The tensile bond strength for this coating at room temperature shall be 10,000 psi (64.0 MPa) minimum. Table 1. Acceptance Limits for Thermal Spray
Feature Porosity
Acceptance Criteria <1%
Oxides
<1%
Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations
None allowed Less than or equal to I-2 None allowed Less than or equal to P-2 None allowed None allowed
Rating Photograph Typical photo Figure 27, Page 39 Typical photo Figure 27, Page 39 No figure for rating Figure 7
Task TASK 70-71-04-700005 TASK 70-71-04-700005 70-71-04-70070-71-04-70070-71-04-70070-71-04-70070-71-04-70070-71-04-700-
Comments None
None
TASK 005 TASK 005 No figure for TASK rating 005 Figure 8, Page TASK 20 005 No figure for TASK rating 005 No figure for TASK rating 005
See definition for ratable size None. See definition ratable size See definition ratable size See definition ratable size See definition ratable size for for for for
NICKEL ALUMINUM (WIRE) - ELECTRIC-ARC WIRE SPRAYING NICKEL ALUMINUM (WIRE) TASK 70-49-38-340-037 1. Electric-Arc Wire Spraying Nickel Aluminum (Wire) SUBTASK 70-49-38-99G-037 A. General. (1) Nickel-aluminum alloy is used either to form a bond with various top coat systems, or for dimensional buildup of metal. NOTE: The material is available as powder for plasma arc spraying per TASK 7049-10-340-011, Thermal Spraying Nickel-Aluminum (Powder), and as wire for flame spraying per TASK 70-49-11-340-012, Thermal Spraying NickelAluminum (Wire), or electric arc spraying. Those procedures are acceptable alternatives. (2) Arc wire spraying consists of an electric arc which is struck between two feed wires resulting in complete melting of the wire and subsequent deposition of the molten atomized droplets on the part. The molten droplets are atomized and delivered to the part by a stream of air. The material is self-bonding, has a high bond strength, and can be deposited at high deposition rates in excess of 10-20 lbs/ hr.
SUBTASK 70-49-38-340-371 B. Equipment. (1) The equipment to do electric-arc wire spraying consists of the following. (a) (b) An arc-wire gun utilizing dual wire feed capable of melting, atomizing and depositing the molten droplets on the work piece. An arc-wire gun control unit that is capable of delivering spooled wire to the arc gun unit either manually or automatic with pneumatic or electrically driven motors. The unit shall also provide gun power control and air delivery rate. An electric-arc wire power supply that is capable of 50-350 amps at 20-38 open circuit volts. A clean filtered air supply that is capable of delivering 50 SCFM at 80 psi (552 kPa).
(c) (d) (2)
Commercially available equipment: Model 8830, 8835, 8850, or 9000 Available from Praxair/TAFA Concord
(3)
Refer to the List of Suppliers in Step D. of .
EFFECTIVITY: ALL
70-49-38
ELECTRIC-ARC WIRE SPRAYING NICKEL ALUMINUM (WIRE) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-38-340-372 C. Material. (1) Nickel-Aluminum Wire C07-042.
SUBTASK 70-49-38-340-374 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks.
EFFECTIVITY: ALL
70-49-38
STANDARD PRACTICES MANUAL AS907-1-1A The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. If this coating is applied in a thickness range up to 0.015 inches (0.38 mm), the tensile bond strength for this coating at room temperature shall average 5,000 psi (34.5 MPa), minimum. If this coating is applied in a thickness range greater than 0.015 inches (0.38 mm), the tensile bond strength for this coating at room temperature shall average 4,000 psi (27.6 MPa), minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Acceptance Criteria Less than or equal to V-1 Oxides shall be uniformly distributed. Reject Cluster oxides as shown in Figure 6 view X-3. None allowed Rating Photograph Figure 25, Page 37 Figure 6, Page 18 Task TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None
Oxide Clusters
No figure for rating
TASK 70-71-04700-005
See definition for ratable size
EFFECTIVITY: ALL
70-49-38
Table 1. Acceptance Limits for Thermal Spray (Cont) Feature Interface Contamination Interface Separations Transverse Cracks Delaminations Acceptance Criteria Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 7, Page 19 No figure for rating No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None See definition for ratable size None See definition for ratable size
EFFECTIVITY: ALL
70-49-38
NICKEL-CHROME-ALUMINUM (WIRE) - ELECTRIC-ARC WIRE SPRAYING NICKEL-CHROMEALUMINUM (WIRE) TASK 70-49-39-340-038 1. Electric-Arc Wire Spraying Nickel-Chrome-Aluminum (Wire) SUBTASK 70-49-39-99G-038 A. General. (1) Nickel-chrome-aluminum alloy is used either to form a bond or for dimensional buildup of metal. NOTE: The material is available as a powder for plasma arc spraying per TASK 70-49-21-340-022, Thermal Spraying Nickel-Chromium/Aluminum Composite (Powder). That procedure is an acceptable alternative. (2) Arc wire spraying consists of an electric arc which is struck between two feed wires resulting in complete melting of the wire and subsequent deposition of the molten atomized droplets on the part. The molten droplets are atomized and delivered to the part by a stream of air. The material is self-bonding, has a high bond strength, and can be deposited at high deposition rates in excess of 10-20 lbs/ hr.
(c) (d) (2)
Commercially available equipment: Model 8830, 8835, 8850, or 9000 Available from Praxair/TAFA Concord.
(3)
Refer to the List of Suppliers in Step D. of .
EFFECTIVITY: ALL
70-49-39
ELECTRIC-ARC WIRE SPRAYING NICKEL-CHROME-ALUMINUM (WIRE) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-39-340-382 C. Material. (1) Nickel-Chromium-Aluminum Wire C07-043.
SUBTASK 70-49-39-340-383 D. Spraying Parameters. (1) Starting parameter sets will be listed in the spray equipment manuals or are readily available from the spray equipment manufacturers or powder suppliers. Modifications may be necessary for your location and product application. See sprayability testing per TASK 70-49-00-340-001, Thermal Spraying, and T , Testing and Quality Analysis. When the final spray parameter settings are developed, all values should be recorded to ensure consistent achievement of high quality coatings.
SUBTASK 70-49-39-340-384 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations.
EFFECTIVITY: ALL
70-49-39
STANDARD PRACTICES MANUAL AS907-1-1A The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 4. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. If this coating is applied in a thickness range up to 0.015 inches (0.38 mm), the tensile bond strength for this coating at room temperature shall average 5,000 psi (34.5 MPa), minimum. If this coating is applied in a thickness range greater than 0.015 inches (0.38 mm), the tensile bond strength for this coating at room temperature shall average 4,000 psi (27.6 MPa), minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual.
EFFECTIVITY: ALL
70-49-39
Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Acceptance Criteria Less than or equal to V-1 Oxides shall be uniformly distributed. Reject Cluster oxides as shown in Figure 6 view X-3. None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 25, Page 37 Figure 6, Page 18 Task TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None
SUBTASK 70-49-39-340-385 F. Recoating Previously Coated Surfaces. CAUTION: THIS PROCEDURE IS NOT APPLICABLE TO PARTS OR COMPONENTS THAT CONTAIN ALUMINUM ALLOYS OR ORGANIC COMPOSITES. DAMAGE MAY BE CAUSED TO PARTS OR COMPONENTS. (1) Surfaces previously coated per TASK 70-49-39-340-038, Electric-Arc Wire Spraying Nickel-Chrome-Aluminum (Wire), may be recoated without removing the original coating, subject to the following conditions: (a) (b) The repair procedure for the part specifies these materials and was applied for the purpose of restoring dimensional integrity. The part to be coated shall be thoroughly cleaned in the following sequence: 1 2 3
EFFECTIVITY: ALL
Alkaline clean per TASK 70-21-09-110-007, Cleaning Method No. 9 Light-Duty Alkaline Cleaning of Titanium Alloys. Steam clean per TASK 70-21-03-160-001, Cleaning Method No. 3 Steam Cleaning. Bake part at 6008 258F (3168 148C) for 30 minutes in air.
70-49-39
STANDARD PRACTICES MANUAL AS907-1-1A 4 (c) If surface to be coated exhibits evidence of oil or contamination repeat cleaning and baking operations.
EFFECTIVITY: ALL
70-49-39
EFFECTIVITY: ALL
70-49-39
PURE ALUMINUM (WIRE) - ELECTRIC-ARC WIRE SPRAYING PURE ALUMINUM (WIRE) TASK 70-49-40-340-039 1. Electric-Arc Wire Spraying Pure Aluminum (Wire) SUBTASK 70-49-40-99G-039 A. General. (1) Pure aluminum alloy is used primarily as a flowpath rub coating for compressor stators and spools. NOTE: The material is available as powder for plasma arc spraying per TASK 7049-01-340-002, Thermal Spraying Pure Aluminum (Powder), and as wire for flame spraying per TASK 70-49-23-340-024, Thermal Spraying Pure Aluminum (Wire), or for electric arc wire spraying. Those procedures are acceptable alternatives. (2) Arc wire spraying consists of an electric arc which is struck between two feed wires, resulting in complete melting of the wire and subsequent deposit of the molten atomized droplets on the part. The molten droplets are atomized and delivered to the part by a stream of air. The material is usually not self-bonding but it has a high bond strength and can be deposited at rates in excess of 6-12 lbs/hr.
(c) (d) (2)
Commercially available equipment: Model 8830, 8835, 8850, or 9000 Available from Praxair/TAFA Concord. Refer to the List of Suppliers in Step D. of SUBTASK 70-80-00-800-003.
EFFECTIVITY: ALL
70-49-40
ELECTRIC-ARC WIRE SPRAYING PURE ALUMINUM (WIRE) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-40-340-392 C. Material. (1) (2) Pure Aluminum Wire (99.0% Minimum) C07-044. Aluminum Wire AMS 4180 C07-028.
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STANDARD PRACTICES MANUAL AS907-1-1A The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 1,200 psi (8.27 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual
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Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-2 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 1, Page 13 Figure 6, Page 18 No figure for rating Figure 7, Page 19 No figure for rating No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size None See definition for ratable size
EFFECTIVITY: ALL
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HIGH DENSITY HVOF T-800 - HIGH DENSITY HVOF T-800 (TRIBALOY) COATING TASK 70-49-43-340-042 1. High Density HVOF T-800 (Tribaloy) Coating SUBTASK 70-49-43-99G-042 A. General. (1) Tribaloy T-800 material is usually applied by air plasma spray (APS) per TASK 7049-30-340-031, Thermal Spraying Cobalt-Molybdenum-Chromium-Silicon Alloy (Powder) - Triballoy 800, on surfaces in the HPT and LPT sections of the engine that are prone to fretting wear. The coating is normally used for operating temperatures greater than 10008F (5388C). This procedure describes the application of prealloyed Tribaloy T-800 powder by the high velocity oxy fuel (HVOF) process. HVOF spraying is a combustion process using a suitable fuel gas such as oxygen/ hydrogen, oxygen/propylene or kerosene which is ignited under a pressure of 35125 psi (242-863 kPa). Powder is introduced axially or radially into the flame, melted, and accelerated onto the substrate at a velocity of 2000-5000 ft/sec (60690152400 cps). The deposits that are produced have a bond strength greater than 9,000 psi (62100 kPa), a density of almost 100 percent, and can be deposited much thicker than conventional combustion or plasma processes. The material is selfbonding and is deposited at a rate of 4 to 8 lbs/hr (1.8 and 3.6 kg/hr). A higher rate of deposit is possible.
(2)
SUBTASK 70-49-43-340-421 B. Equipment. (1) The equipment to do high density HVOF spraying consists of the following: (a) (b) An HVOF gun system with a suitable controller. A gas controller that can deliver up to 1000 SCFH oxygen, 1600 SCFH hydrogen, 300 SCFH propylene, and if required, 800 SCFH air. The unit shall provide gun power control and air delivery rate. A pressurized powder feeder that can deliver powder between 4-15 lbs/hr (27 kg/hr). A clean filtered air supply that can deliver up to 800 SCFH.
(c) (d) (2)
Commercially available equipment consists of the following:
EFFECTIVITY: ALL
70-49-43
HIGH DENSITY HVOF T-800 (TRIBALOY) COATING Page 1 Dec 01/03
Model Model Jet Kote 2000 Address Address Stellite Coatings Deloro Stellite, Inc. Refer to the List of Suppliers in Step D. of SUBTASK 7080-00-800-003. Sulzer Metco, Inc. Refer to the List of Suppliers in Step D. of SUBTASK 70-80-00-800-003. Praxair/TAFA Concord. Refer to the List of Suppliers in Step D. of SUBTASK 70-80-00-800003.
SUBTASK 70-49-43-340-422 C. Material. NOTE: Powders may be sieved to meet spray requirements for the equipment used. (1) Co-Mo-Cr-Si Powder, HVOF Application C07-047.
SUBTASK 70-49-43-340-423 D. Spraying Parameters. (1) Starting parameter sets will be listed in the spray equipment manuals or are readily available from the spray equipment manufacturers or powder suppliers. Modifications may be necessary for your location and product application. See sprayability testing per TASK 70-49-00-340-001, Thermal Spraying, and TASK 7070-00-700-001, Testing and Quality Analysis. When the final spray parameter settings are developed, all values should be recorded to ensure consistent achievement of high quality coatings. For initial recommendations, see Table 1, Page 2. Table 1. Oxide Rating Gases Primary: Oxygen Fuel: Hydrogen Carrier: Argon Manifold Pressure 1205 psi (82834 kPa) 1205 psi (82834 kPa) 1005 psi (69034 kPa) Flow Rate (SCFH) 550100 1230100 25-35
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Powder Rate: Standoff Distance: Traverse Rate: Part Rotation: Thickness per Pass: Part Temperature: Water Cooling: Water Inlet: Water Outlet: Line Pressure: Maximum Substrate Temperature: Steel: Titanium: Aluminum:
224 grams/min 6.01.0 in. (15225 mm) 3.0 - 4.0 in./sec (76 - 102 mm/sec) 200 - 400 fpm (6 - 12 mps) 0.0002 - 0.0010 in. (0.005 - 0.025 mm) 150 - 3008F (66 - 1488C) 95 - 1058F (35 - 418C) 125 - 1358F (52 - 578C) 180+10 psi (124269 kPa) 4008F (2048C) 3008F (1488C) 3008F (1488C)
Recommended Thickness: 0.0030-0.0300 in. (0.076-0.762 mm). SUBTASK 70-49-43-340-424 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 3, Page 5. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 3, Page 5. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 3, Page 5. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 3, Page 5. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal
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STANDARD PRACTICES MANUAL AS907-1-1A Spray Coatings. Tensile bond strength for this coating at room temperature shall be 8,500 psi (58.65 MPa) minimum. (5) Macrohardness Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be 89, based on an average of at least five readings on a Rockwell R15N scale. No individual specimen shall have a reading of less than 87. (6) Microhardness. Test specimens will be prepared for microhardness testing. Test specimens shall meet a minimum average hardness DPH (Vickers) 675 using a 300 gram load. The specimen shall be prepared and tested in accordance with TASK 70-34-02-220-008, Vickers Hardness Testing, or ASTM specification E384. No individual specimen shall have a reading of less than 575. (7) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 3. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations Acceptance Criteria Shall not exceed Figure 21 Shall not exceed Figure 21 None allowed Less than or equal to I-2 None allowed Less than or equal to P-1 None allowed None allowed Rating Photograph Figure 21, Page 33 Figure 21 No figure for rating Figure 7, Page 19 No figure for rating Figure 8, Page 20 No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 T Comments None None See definition for ratable size None See definition for ratable size None None See definition for ratable size
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COPPER-ZINC-SILVER (WIRE) - ELECTRIC-ARC WIRE SPRAYING COPPER-ZINC-SILVER (WIRE) TASK 70-49-44-340-043 1. Electric-Arc Wire Spraying Copper-Zinc-Silver (Wire) SUBTASK 70-49-44-99G-043 A. General. (1) The Copper-Zinc-Silver alloy has good rubbing characteristics and can easily be machined to close tolerances. The coating is frequently used as an abradable coating for stationary cooling and vent seals. NOTE: The material is available as wire for flame spraying per TASK 70-49-17340-018, Thermal Spraying Copper-Zinc-Silver Alloy (Wire), and for electric-arc spraying. That procedure is an acceptable alternative. (2) Electric-arc wire spraying consists of an electric arc which is struck between two feed wires, resulting in complete melting of the wire and subsequent deposit of the molten atomized droplets on the part. The molten droplets are atomized and delivered to the part by a stream of air.
SUBTASK 70-49-44-340-431 B. Equipment. (1) The equipment to do electric-arc wire spraying consists of the following: (a) (b) An arc-wire gun utilizing dual wire feed capable of melting, atomizing, and depositing the molten droplets on the work piece. An arc-wire gun control unit that is capable of delivering spooled wire to the arc gun unit either manually or automatic with pneumatic or electrically driven motors. The unit shall also provide gun power control and air delivery rate. An electric-arc wire power supply that is capable of 50-350 amps at 20-38 open circuit volts. A clean filtered air supply that is capable of delivering 50 SCFM at 80 psi (552 kPa).
(c) (d) (2)
Commercially available equipment. Model 8830, 8835, 8850, or 9000 Available from Praxair/TAFA Concord. Refer to the List of Suppliers in Step D. of SUBTASK 70-80-00-800-003.
EFFECTIVITY: ALL
70-49-44
ELECTRIC-ARC WIRE SPRAYING COPPER-ZINC-SILVER (WIRE) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-44-340-432 C. Material. NOTE: Copper-Zinc-Silver wire material should have a chemical composition to GE Specification B20A4 with a wire diameter of 0.0625 in. (1.588 mm) nominal and spools up to 25 lb (11.34 kg) permitted. (1) Copper-Zinc-Silver Pre-alloyed Wire C07-051.
SUBTASK 70-49-44-340-434 E. Homogenization Heat Treatment. (1) Unless otherwise specified, the Copper-Zinc-Silver alloy coated parts shall be heat treated at 850-9008F (454-4828C) air for two hours. The heat treatment shall be done before the final machining or any other processing that might be impaired by the heat treatment.
SUBTASK 70-49-44-340-435 F. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition.
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STANDARD PRACTICES MANUAL AS907-1-1A The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 4. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 3,000 psi (20.7 MPa) minimum.
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STANDARD PRACTICES MANUAL AS907-1-1A (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Acceptance Criteria Uniformly distributed in proportions less than G-1 Uniformly distributed in proportions less than G-1 None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 10, Page 22 Task TASK 70-71-04700-005 Comments None
Oxides
Figure 10, Page 22
TASK 70-71-04700-005
None
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ALLOY 718 (WIRE) - ELECTRIC-ARC WIRE SPRAYING ALLOY 718 (WIRE) TASK 70-49-45-340-044 1. Electric-Arc Wire Spraying Alloy 718 (Wire) SUBTASK 70-49-45-99G-044 A. General. (1) The Alloy 718 coating is self-bonding, easily machinable, and has the same physical and chemical properties as the plasma-sprayed Alloy 718. This coating is normally used for buildup and salvage applications as specified in repair instructions of the applicable manual. NOTE: Alloy 718 is also available in a powder form for electric-arc spraying per TASK 70-49-32-340-033, Thermal Spraying Inconel 718 (Powder). That procedure is an acceptable alternative. (2) Electric-arc wire spraying consists of an electric arc which is struck between two feed wires, resulting in complete melting of the wire and subsequent deposit of the molten atomized droplets on the part. The molten droplets are atomized and delivered to the part by a stream of air. The material is self-bonding, has a high bond strength, and can be deposited at rates in excess of 10-15 lbs/hr.
(c) (d) (2)
(3)
Refer to the List of Suppliers in Step D. of SUBTASK 70-80-00-800-003.
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ELECTRIC-ARC WIRE SPRAYING ALLOY 718 (WIRE) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-45-340-442 C. Material. (1) Alloy 718 Wire C07-049.
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STANDARD PRACTICES MANUAL AS907-1-1A The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 3. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 3. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 7,000 psi (47.6 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual.
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Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Acceptance Criteria Less than or equal to V-1 Oxides shall be uniformly distributed. Reject Cluster oxides as shown in Figure 6 view X-3. None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 25, Page 37 Figure 6, Page 18 Task TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None
SUBTASK 70-49-45-340-445 F. Recoating Previously Coated Surfaces. CAUTION: THIS PROCEDURE IS NOT APPLICABLE TO PARTS OR COMPONENTS THAT CONTAIN ALUMINUM ALLOYS OR ORGANIC COMPOSITES. DAMAGE MAY BE CAUSED TO PARTS OR COMPONENTS. (1) Surfaces previously coated per TASK 70-49-21-340-022, Thermal Spraying NickelChromium/Aluminide Composite (Powder), may be recoated without removing the original coating, subject to the following conditions: (a) (b) The repair procedure for the part specifies these materials and was applied for the purpose of restoring dimensional integrity. The part to be coated shall be thoroughly cleaned in the following sequence: 1 2 3 Alkaline clean per TASK 70-21-09-110-007, Cleaning Method No. 9 Light-Duty Alkaline Cleaning of Titanium Alloys. Steam clean per TASK 70-21-03-160-001, Cleaning Method No. 3 Steam Cleaning. Bake part at 6008 258F (3168 148C) for 30 minutes in air.
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STANDARD PRACTICES MANUAL AS907-1-1A 4 (c) If surface to be coated exhibits evidence of oil or contamination repeat cleaning and baking operations.
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NICKEL-CHROMIUM-SILICON-IRON - NICKEL-CHROMIUM-SILICON-IRON COATING APPLIED BY HIGH DENSITY HIGH VELOCITY OXY-FUEL (HVOF) TASK 70-49-46-340-045 1. Nickel-Chromium-Silicon-Iron Coating Applied by High Density High Velocity Oxy-Fuel (HVOF) SUBTASK 70-49-46-99G-045 A. General. (1) Nickel-Chromium-Silicon-Iron coating is high temperature coating applied to compressor blade dovetails of advanced commercial engines for wear and fretting applications. The material, which is similar in composition to Metcolloy 33 C07-006 except it is a pre-alloyed powder and not a cast wire, is applied by the HVOF process. The coating is normally used over an operating temperature range of 70011008F (370-5908C). This procedure describes the application of pre-alloyed NickelChromium-Silicon-Iron powder by the HVOF process. HVOF spraying is a combustion process using a suitable fuel gas such as oxygen/ hydrogen, oxygen/propylene, or kerosene which is ignited under pressure, typically 35 to 125 psi (241 to 862 kPa). Powder is then introduced axially or radially into the flame, melted and accelerated onto the substrate at a high velocity, typically 2,000 to 5000 ft/sec. (610 to 1524 m/sec.). The deposits produced, typically have a bond strength greater than 9,000 psi (62053 kPa) are close to 100 percent dense and can be deposited much thicker than conventional combustion or plasma processes. The material is self bonding, and is deposited at a rate between 5 and 6 lbs/hr (2.3 and 2.7 kg/hr), although much higher rates are possible.
(2)
SUBTASK 70-49-46-340-451 B. Equipment. (1) The equipment to do high density HVOF spraying consists of the following: (a) (b) An HVOF gun system with a suitable controller. A gas controller that can deliver up to 1000 SCFH oxygen, 1600 SCFH hydrogen, 300 SCFH propylene, and if required, 800 SCFH air. The unit shall provide gun power control and air delivery rate. A pressurized powder feeder that can deliver powder between 4-15 lbs/hr (27 kg/hr). A clean filtered air supply that can deliver up to 800 SCFH.
(c) (d) (2)
NICKEL-CHROMIUM-SILICON-IRON COATING APPLIED BY HIGH DENSITY HIGH VELOCITY OXY-FUEL (HVOF) Page 1 Dec 01/03
Model Jet Kote 2000
Address Stellite Coatings Deloro Stellite, Inc. Refer to the List of Suppliers in Step D. of SUBTASK 7080-00-800-003. Sulzer Metco, Inc. Refer to the List of Suppliers in D. of SUBTASK 70-80-00-800-003. Praxair/TAFA Concord. Refer to the List of Suppliers in D. of SUBTASK 70-80-00-800-003.
SUBTASK 70-49-46-340-452 C. Material. NOTE: Powders may be sieved to meet spray requirements for the equipment used. (1) Nickel-Chromium-Silicon-Iron Powder C07-050.
SUBTASK 70-49-46-340-454 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage.
STANDARD PRACTICES MANUAL AS907-1-1A The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 4. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. Porosity shall be uniformly distributed.
STANDARD PRACTICES MANUAL AS907-1-1A (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 10,000 psi (68.9 MPa) minimum. (5) Macrohardness Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be 70, based on an average of at least five readings on a Rockwell R15N scale. (6) Microhardness. Test specimens will be prepared for microhardness testing. Test specimens shall meet a minimum average hardness DPH (Vickers) 675 using a 300 gram load. The specimen shall be prepared and tested in accordance with TASK 70-34-02-220-008, Vickers Hardness Testing, or ASTM specification E384. (7) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Acceptance Criteria Uniform Less than or equal to X-2 None allowed Less than or equal to I-1 None allowed No more than 3 unmelts in the FOV at 200x Rating Photograph No figure for rating Figure 6, Page 18 No figure for rating Figure 7, Page 19 No figure for rating Figure 8, Page 20 Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size None
Table 1. Acceptance Limits for Thermal Spray (Cont) Feature Transverse Cracks Delaminations Acceptance Criteria None allowed None allowed Rating Photograph No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None See definition for ratable size
ALUMINUM SILICON POLYESTER - THERMAL SPRAYING ALUMINUM SILICON POLYESTER (POWDER) COLD PROCESS TASK 70-49-47-340-046 1. Thermal Spraying Aluminum Silicon Polyester (Powder) Cold Process SUBTASK 70-49-47-99G-046 A. General. (1) The Aluminum Silicon Polyester powder is an effective coating used in low temperature clearance control applications. This procedure covers application of the powder form by plasma-arc spraying.
SUBTASK 70-49-47-340-462 C. Materials. (1) Top Coat: Aluminum Silicon Polyester Powder C07-037.
SUBTASK 70-49-47-340-463 D. Spraying Parameters. (1) Starting parameter sets will be listed in the spray equipment manuals or are readily available from the spray equipment manufacturers or powder suppliers. Modifications may be necessary for your location and product application. See sprayability testing per TASK 70-49-00-340-001, Thermal Spraying, and TASK 7070-00-700-001, Testing and Quality Analysis. When the final spray parameter settings are developed, all values should be recorded to ensure consistent achievement of high quality coatings. See Table 1, Page 1 for spraying parameters to be used as a starting point. 0.218 in. (5.54 mm) (Metco GP) 0.0625 in. (1.588 mm) inside diameter, 208 forward Argon, 200 SCFH Helium, 25 SCFH 500 amperes 8 lbs/hr 50 flow meter reading None close to flame, cooling away from flame is acceptable
THERMAL SPRAYING ALUMINUM SILICON POLYESTER (POWDER) COLD PROCESS Page 1 Dec 01/03
Nozzle Diameter: Powder Injector: Primary Gas: Secondary Gas: Amperage: Powder Feed Rate: Carrier Flow: Cooling Air:
STANDARD PRACTICES MANUAL AS907-1-1A Powder Injection Geometry: Diametrically opposite direction of part i.e., Part rotating CW, inject CCW.
SUBTASK 70-49-47-340-464 E. Quality Assurance. (1) Perform the following tests to confirm satisfactory quality of the coating and the coating-to-substrate bond. (a) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (b) Appearance. Visual examination of the coating shall be in accordance with the following: 1 Adhesion. The coating shall exhibit no spalling or lifting. 2 Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. 3 Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (c) Wire brush adherence test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. (d) Coating Microstructure. The test specimens shall be prepared and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: 1 Delaminations. The coating shall be free of delaminations as defined for metallic or ceramic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. 2 Integrity.
STANDARD PRACTICES MANUAL AS907-1-1A The coating shall show acceptable integrity as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. 3 Phase. The phase content in the coating shall be reviewed as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 2, Page 3. (e) Coating Tensile Bond Strength. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating (over bond coat) shall be 800 psi (8.3 MPa) minimum. Coating shall be tested at an approximate 0.080 inch (2.03 mm) top coat thickness. (f) Rockwell Hardness Testing. Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03220-009, Rockwell Hardness Testing and ASTM E-18 (whichever results in the maximum thickness requirement). The hardness range for this coating shall be 55-80 minimum, based on an average of at least five readings on a Rockwell 15Y scale. For this hardness scale, the specimens should have a minimum top coat thickness of 0.080 inch (2.03 mm). Table 2. Acceptance Limits for Thermal Spray Feature Transverse Cracks Delaminations General Features Acceptance Criteria None allowed None allowed Uniform distribution of phases and no layering Rating Photograph No figure for rating No figure for rating Figure 16, Page 28 Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments See definition for ratable size See definition for ratable size None
HIGH DENSITY HVOF T-400 - HIGH DENSITY HVOF T-400 (TRIBALOY) COATING TASK 70-49-48-340-047 1. High Density HVOF T-400 (Tribaloy) Coating SUBTASK 70-49-48-99G-047 A. General. (1) Tribaloy T-400 material is normally applied by Air Plasma Spray (APS) per TASK 70-49-27-340-028, Thermal Spraying Cobalt-Molybdenum-Chromium-Silicon Alloy (Powder) - Triballoy 400, on surfaces in the HPT and LPT sections of the engine that are prone to fretting wear. The coating is normally used at operating temperatures greater than 10008F (5388C). This procedure describes the application of prealloyed Tribaloy T-400 powder by the high velocity oxy fuel (HVOF) process. HVOF spraying is a combustion process using a suitable fuel gas such as oxygen/ hydrogen, oxygen/propylene or kerosene which is ignited under a pressure of 35125 psi (242-863 kPa). Powder is introduced axially or radially into the flame, melted, and accelerated onto the substrate at a high velocity, 2000-5000 ft/sec (60690-152400 cps). The deposits produced have a bond strength greater than 9,000 psi (62190 kPa), a density of almost 100 percent, and can be deposited much thicker than conventional combustion or plasma processes. The material is self-bonding and is deposited at a rate of 4 to 8 lbs/hr (1.8 and 3.6 kg/hr). A higher rate of deposit is possible.
(2)
SUBTASK 70-49-48-340-471 B. Equipment. (1) The equipment to do high density HVOF spraying consists of the following: (a) (b) An HVOF gun system with a suitable controller. A gas controller that can deliver up to 1,000 SCFH oxygen, 1600 SCFH hydrogen, 300 SCFH propylene, and if required, 800 SCFH air. The unit shall provide gun power control and air delivery rate. A pressurized powder feeder that can deliver powder between 4-15 lbs/hr (27 kg/hr). A clean filtered air supply that can deliver up to 800 SCFH.
(c) (d) (2)
EFFECTIVITY: ALL
70-49-48
Model Model Jet Kote 2000 Address Address Stellite Coatings Deloro Stellite, Inc. Refer to the List of Suppliers in Step D. of SUBTASK 7080-00-800-003. Sulzer Metco, Inc. Refer to the List of Suppliers in Step D. of SUBTASK 70-80-00-800-003. Praxair/TAFA Concord. Refer to the List of Suppliers in Step D. of SUBTASK 70-80-00-800003.
SUBTASK 70-49-48-340-472 C. Material. NOTE: Powders may be sieved to meet spray requirements for the equipment used. (1) Co-Mo-Cr-Si Powder C07-025.
SUBTASK 70-49-48-340-473 D. Spraying Parameters. (1) Starting parameter sets will be listed in the spray equipment manuals or are readily available from the spray equipment manufacturers or powder suppliers. Modifications may be necessary for your location and product application. See sprayability testing per TASK 70-49-00-340-001, Thermal Spraying, and TASK 7070-00-700-001, Testing and Quality Analysis. When the final spray parameter settings are developed, all values should be recorded to ensure consistent achievement of high quality coatings. For initial recommendations see Table 1, Page 2. Table 1. Spray Parameters Gases Primary: Oxygen Fuel: Hydrogen Carrier: Helium Manifold Pressure 1052 psi (72514 kPa) 1152 psi (79414 kPa) 902 psi (62114 kPa) Flow Rate (SCFH) 5607 124015 102
EFFECTIVITY: ALL
70-49-48
Powder Rate: Standoff Distance: Traverse Rate: Part Rotation: Thickness per Pass: Part Temperature: Water Cooling: Water Inlet: Water Outlet: Line Pressure: Maximum Substrate Temperature: Steel: Titanium: Aluminum:
224 grams/min 6.01.0 in. (15225 mm) 3.0 - 4.0 in./sec (76 - 102 mm/sec) 200 - 400 fpm (6 - 12 mps) 0.0002 - 0.0010 in. (0.005 - 0.025 mm) 150 - 3008F (66 - 1488C) 95 - 1058F (35 - 418C) 125 - 1358F (52 - 578C) 180+10 psi (124269 kPa) 4008F (2048C) 3008F (1488C) 3008F (1488C)
Recommended Thickness: 0.0030-0.0300 in. (0.076-0.762 mm). SUBTASK 70-49-48-340-474 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure.
EFFECTIVITY: ALL
70-49-48
STANDARD PRACTICES MANUAL AS907-1-1A Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 3, Page 5. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 3, Page 5. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 3, Page 5. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 3, Page 5. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal
EFFECTIVITY: ALL
70-49-48
STANDARD PRACTICES MANUAL AS907-1-1A Spray Coatings. Tensile bond strength for this coating at room temperature shall be 8,500 psi (58.65 MPa) minimum. (5) Macrohardness Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be 83, based on an average of at least five readings on a Rockwell R15N scale. No individual specimen shall have a reading of less than 81. (6) Microhardness. Test specimens shall be prepared for microhardness testing. Test specimens shall meet a minimum average hardness DPH (Vickers) 500 using a 300 gram load. The specimen shall be prepared and tested in accordance with TASK 70-34-02-220-008, Vickers Hardness Testing, or ASTM specification E384. No individual specimen shall have a reading of less than 400. (7) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 3. Acceptance Limits for Thermal Spray Feature Porosity Acceptance Criteria Less than or equal to that shown in Figure 21, Page 33 Less than or equal to that shown in Figure 21, Page 33 None allowed Less than or equal to I-2 None allowed Less than or equal to P-2 None allowed Rating Photograph Figure 21, Page 33 Task TASK 70-71-04700-005 Comments None
Oxides
Figure 21, Page 33
TASK 70-71-04700-005
None
Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks
No figure for rating Figure 7, Page 19 No figure for rating Figure 8, Page 20 No figure for rating
None None See definition for ratable size None None
EFFECTIVITY: ALL
70-49-48
Table 3. Acceptance Limits for Thermal Spray (Cont) Feature Delaminations Acceptance Criteria None allowed Rating Photograph No figure for rating Task TASK 70-71-04700-005 Comments See definition for ratable size
EFFECTIVITY: ALL
70-49-48
COPPER-NICKEL-INDIUM (WIRE) - ELECTRIC-ARC WIRE SPRAYING COPPER-NICKEL-INDIUM (WIRE) TASK 70-49-49-340-048 1. Electric-Arc Wire Spraying Copper-Nickel-Indium (Wire) SUBTASK 70-49-49-99G-048 A. General. (1) The Copper-Nickel-Indium forms an effective anti-fretting surface on rubbing areas of parts. NOTE: The material is available as powder for plasma spraying per TASK 70-4905-340-006, Thermal Spraying Copper-Nickel Indium (Powder). That procedure is an acceptable alternative. (2) Electric-arc wire spraying consists of an electric arc which is struck between two feed wires, resulting in complete melting of the wire and subsequent deposit of the molten atomized droplets on the part. The molten droplets are atomized and delivered to the part by a stream of air.
SUBTASK 70-49-49-340-051 B. Equipment. (1) The equipment to do electric-arc wire spraying consists of the following: (a) (b) An arc-wire gun utilizing dual wire feed capable of melting, atomizing, and depositing the molten droplets on the work piece. An arc-wire gun control unit that is capable of delivering spooled wire to the arc gun unit either manually or automatic with pneumatic or electrically driven motors. The unit shall also provide gun power control and air delivery rate. An electric-arc wire power supply that is capable of 50-350 amps at 20-38 open circuit volts. A clean filtered air supply that is capable of delivering 50 SCFM at 80 psi (552 kPa).
(c) (d) (2)
(3)
EFFECTIVITY: ALL
70-49-49
ELECTRIC-ARC WIRE SPRAYING COPPER-NICKEL-INDIUM (WIRE) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-49-340-052 C. Material. NOTE: Copper-nickel-indium wire material should have a chemical composition to GE Specification B50TF72, Class A, with a wire diameter of 0.0625 in. (1.588 mm) nominal and spools up to 25 lb (11.34 kg) permitted. (1) Copper-Nickel-Indium Wire C07-054.
SUBTASK 70-49-49-340-055 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions:
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 4. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. (4) Lap Shear. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. (5) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Spray Coatings. Tensile bond strength for this coating at room temperature shall be 2,000 psi (13.8 MPa) minimum. (6) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. (7) Wire Brush. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Unmelts Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-3 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed Less than or equal to P-1 None allowed None allowed Rating Photograph Figure 1, Page 13 Figure 6, Page 18 No figure for rating Figure 7, Page 19 No figure for rating Figure 8, Page 20 No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size None None See definition for ratable size
EFFECTIVITY: ALL
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HIGH DENSITY HVOF RENE 80 - HIGH DENSITY HVOF RENE 80 COATING TASK 70-49-50-340-042 1. High Density HVOF Rene 80 Coating SUBTASK 70-49-50-99G-042 A. General. (1) Rene 80 material is usually applied by air plasma spray (APS) similar to TASK 7049-30-340-031, Thermal Spraying Cobalt-Molybdenum-Chromium-Silicon Alloy (Powder) - Triballoy 800. This material is applied to various surfaces in the HPT and LPT sections of the engine that are prone to fretting wear. The coating is normally used at operating temperatures greater than 10008F (5388C). This procedure describes the application of pre-alloyed Rene 80 powder by the high velocity oxy fuel (HVOF) process. HVOF spraying is a combustion process using a suitable fuel gas such as oxygen/ hydrogen, oxygen/propylene, or kerosene which is usually ignited under a pressure of 35-125 psi (242-863 kPa). Powder is introduced axially or radially into the flame, melted, and accelerated onto the substrate at a high velocity - usually 2,000-5,000 ft/sec (607-1,524 meters/sec). The deposits produced have a bond strength greater than 8,000 psi (55,200 kPa), a density of almost 100 percent, and can be deposited much thicker than conventional combustion or plasma processes. The material is self-bonding and is usually deposited at a rate of 4 to 8 lbs/hr (1.8 and 3.6 kg/hr). A higher rate of deposit is possible.
(2)
SUBTASK 70-49-50-340-001 B. Equipment. (1) The equipment to do high density HVOF spraying is: (a) (b) An HVOF gun system with a suitable controller. A gas controller that can deliver up to 1,000 SCFH oxygen, 1,600 SCFH hydrogen, 300 SCFH propylene, and if required, 800 SCFH air. The unit must give gun power control and air delivery rate. A pressurized powder feeder that can deliver powder between 4-15 lbs/hr (27 kg/hr). A clean filtered air supply that can deliver up to 800 SCFH.
(c) (d) (2)
Commercially available equipment consists of: NOTE: This list does not include all possible suppliers.
EFFECTIVITY: ALL
70-49-50
HIGH DENSITY HVOF RENe 80 COATING Page 1 Dec 01/03
Model Jet Kote 2000
Address Stellite Coatings Deloro Stellite, Inc. Refer to the List of Suppliers in Step D. of SUBTASK 7080-00-800-003. Sulzer Metco, Inc. Refer to the List of Suppliers in Step D. of SUBTASK 70-80-00-800-003. Available from Praxair/TAFA Concord. Refer to the List of Suppliers in Step D. of SUBTASK 7080-00-800-003. (3) Materials: (a) Rene 80 Allow Powder C07-053.
Diamond Jet 2600/2700 JP-5000
SUBTASK 70-49-50-340-002 C. Spraying Parameters. (1) Starting parameter sets will be listed in the spray equipment manuals or are readily available from the spray equipment manufacturers or powder suppliers. Modifications may be necessary for your location and product application. See sprayability testing per TASK 70-49-00-340-001, Thermal Spraying, and TASK 7070-00-700-001, Testing and Quality Analysis. When the final spray parameter settings are developed, all values should be recorded to ensure consistent achievement of high quality coatings.
SUBTASK 70-49-50-340-003 D. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c)
EFFECTIVITY: ALL
Surface condition.
70-49-50
STANDARD PRACTICES MANUAL AS907-1-1A The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 4. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. Porosity shall be uniformly distributed. (h) Unmelts. Unmelts in the coating shall be classified for size, shape, and bonding as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 9,000 psi (64 MPa) minimum. (5) Macrohardness Test specimens will be prepared for Rockwell hardness testing. The specimen material may be of a convenient size or shape but it should be at least 0.060 inch (1.52 mm) thick and of the same material as the coated part. The specimen must be coated with sufficient material to meet the thickness values of the part, the thickness values that are specified in TASK 70-49-00-340-001, Thermal Spraying, or the thickness requirements in TASK 70-34-03-220-009, Rockwell Hardness Testing and ASTM E-18 (whichever results in the maximum thickness). The Rockwell hardness for this coating shall be 75, based on an average of at least five readings on a Rockwell R15N scale. No individual specimen shall have a reading of less than 70. (6) Microhardness. Test specimens will be prepared for microhardness testing. Test specimens shall meet a minimum average hardness DPH (Vickers) 400 using a 300 gram load. The specimen shall be prepared and tested in accordance with TASK 70-34-02-220-008, Vickers Hardness Testing, or ASTM specification E384. (7) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Acceptance Criteria Less than or equal to that shown in Figure 21, Page 33 Less than or equal to that shown in Figure 21, Page 33 None allowed Less than or equal to I-2 None allowed No more than 5 unmelts per FOV Rating Photograph Figure 21, Page 33 Task TASK 70-71-04700-005 Comments None
Oxides
Figure 21, Page 33
TASK 70-71-04700-005
None
Oxide Clusters Interface Contamination Interface Separations Unmelts
No figure for rating Figure 7, Page 19 No figure for rating Figure 8, Page 20
TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005
None None See definition for ratable size None
EFFECTIVITY: ALL
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Table 1. Acceptance Limits for Thermal Spray (Cont) Feature Transverse Cracks Delaminations Acceptance Criteria None allowed None allowed Rating Photograph Figure 22, Page 34 Figure 22, Page 34 Task TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None See definition for ratable size
EFFECTIVITY: ALL
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EFFECTIVITY: ALL
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PURE MOLYBDENUM (WIRE) - ELECTRIC-ARC WIRE SPRAYING PURE MOLYBDENUM (WIRE) TASK 70-49-51-340-050 1. Electric-Arc Wire Spraying Pure Molybdenum (Wire) SUBTASK 70-49-51-99G-050 A. General. (1) Because molybdenum forms a surface that is self-bonding, self-lubricating, wearresistant, it is often used as a bond coat. NOTE: The material is available as powder for plasma arc spraying per TASK 7049-07-340-008, Thermal Spraying Alloy (Powder), and as wire for plasma spraying per TASK 70-49-08-340-009, Thermal Spraying Molybdenum (Wire), and for electric arc spraying. Those procedures are acceptable alternatives. (2) Arc wire spraying consists of an electric arc which is struck between two feed wires, resulting in complete melting of the wire and subsequent deposit of the molten atomized droplets on the part. The molten droplets are atomized and delivered to the part by a stream of air. The material is usually not self-bonding but it has a high bond strength and can be deposited at rates in excess of 6-12 lbs/hr (2.7-5.4 kg/hr).
SUBTASK 70-49-51-340-051 B. Equipment. (1) The equipment to do electric-arc wire spraying consists of the following: (a) (b) An arc-wire gun utilizing dual wire feed capable of melting, atomizing, and depositing the molten droplets on the work piece. An arc-wire gun control unit that is capable of delivering spooled wire to the arc gun unit either manually or automatic with pneumatic or electrically driven motors. The unit shall also provide gun power control and air delivery rate. An electric-arc wire power supply that is capable of 50-450 amps at 20-38 open circuit volts. A clean filtered air supply that is capable of delivering 60 SCFM (1.7 cms) at 80 psi (552 kPa).
(c) (d) (2)
(3)
EFFECTIVITY: ALL
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ELECTRIC-ARC WIRE SPRAYING PURE MOLYBDENUM (WIRE) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-51-340-052 C. Material. NOTE: Molybdenum wire material should have a chemical composition to GE Specification P50T30, except the wire diameter shall be 0.0625 in. (1.588 mm) nominal with spools up to 30 lb (13.62 kg) permitted. (1) Molybdenum Wire C07-055.
SUBTASK 70-49-51-340-055 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) (3) Appearance. Visual examination of the coating shall be in accordance with the following: (a) (b) (c) (d) Adhesion. The coating shall exhibit no spalling or lifting. Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking.
(e) (f) (4)
Coating Microstructure.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (5) Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) (b) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 4. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. Porosity shall be uniformly distributed.
(c) (d) (e) (f) (g) (h)
(i) (j)
(k) (l)
(m) (n)
(6) (7)
Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 2,500 psi (17.2 MPa) minimum.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (8) (9) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual. Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Transverse Cracks Delaminations Acceptance Criteria Uniform Uniform None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph No figure for rating No figure for rating No figure for rating Figure 7 No figure for rating No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size None See definition for ratable size
EFFECTIVITY: ALL
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PURE ALUMINUM BRONZE (WIRE) - ELECTRIC-ARC WIRE SPRAYING ALUMINUM BRONZE (WIRE) TASK 70-49-52-340-051 1. Electric-Arc Spraying Aluminum Bronze (Wire) SUBTASK 70-49-52-99G-051 A. General. (1) Because molybdenum forms a surface that is self-bonding, self-lubricating, wearresistant, it is often used as a bond coat. NOTE: The material is available as powder for plasma arc spraying per TASK 7049-07-340-008, Thermal Spraying Alloy (Powder), and as wire for plasma spraying per TASK 70-49-08-340-009, Thermal Spraying Molybdenum (Wire), and for electric arc spraying. Those procedures are acceptable alternatives. (2) Arc wire spraying consists of an electric arc which is struck between two feed wires, resulting in complete melting of the wire and subsequent deposit of the molten atomized droplets on the part. The molten droplets are atomized and delivered to the part by a stream of air. The material is usually not self-bonding but it has a high bond strength and can be deposited at rates in excess of 6-12 lbs/hr (2.7-5.4 kg/hr).
SUBTASK 70-49-52-340-051 B. Equipment. (1) The equipment to do electric-arc wire spraying consists of the following: (a) (b) An arc-wire gun utilizing dual wire feed capable of melting, atomizing, and depositing the molten droplets on the work piece. An arc-wire gun control unit that is capable of delivering spooled wire to the arc gun unit either manually or automatic with pneumatic or electrically driven motors. The unit shall also provide gun power control and air delivery rate. An electric-arc wire power supply that is capable of 50-450 amps at 20-38 open circuit volts. A clean, filtered air supply that is capable of delivering 60 SCFM (1.70 CMS) at 80 psi (552 kPa).
(c) (d) (2)
Commercially available equipment. Model 8830, 8835, 8850, or 9000 Available from Praxair/TAFA Concord. Refer to the List of Suppliers in Step D of Subtask 70-80-00-800-003.
EFFECTIVITY: ALL
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ELECTRIC-ARC WIRE SPRAYING ALUMINUM BRONZE (WIRE) Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-49-52-340-052 C. Material. NOTE: Aluminum bronze alloy wire C07-056 wire diameter shall be 0.0625 in. (1.588 mm) nominal with spools up to 30 lb (13.62 kg) permitted. You can use the other aluminum bronze alloy wire C07-024 as an alternative. (1) (2) Aluminum Bronze Alloy Wire C07-056. Aluminum Bronze Alloy Wire (MIL-W-6712 Type II) C07-024.
SUBTASK 70-49-52-340-055 E. Quality Assurance. (1) Thickness. Measure the coating thickness using a standard flat-anvil-and-spindle micrometer. The measurement may be made on either a coated production part or on a flat test specimen having a thickness of at least 0.060 inch (1.52 mm). Determine coating thickness to the nearest 0.0001 inch (0.003 mm) at three different locations. (2) Appearance. Visual examination of the coating shall be in accordance with the following: (a) Adhesion. The coating shall exhibit no spalling or lifting. (b) Coverage. The coating shall exhibit complete, uniform coverage in those areas specified for coating in the applicable manual. Coating is not permissible in areas other than those specified. (c) Surface condition. The coating shall be uniform and free from cracks, blisters, spatter, chipping, and flaking. (3) Coating Microstructure. Test specimens shall be prepared for microscopic examination, and evaluated in accordance with TASK 70-71-04-700-005, Metallographic Evaluation of Thermal
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Spray Coatings. Metallographic examination of the prepared specimen shall be made for uniformity of coating, as well as for the following other conditions: (a) Delaminations. The coating shall be free of delaminations as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (b) Integrity. The coating shall show acceptable integrity as defined in TASK 70-71-04-700005, Metallographic Evaluation of Thermal Spray Coatings. (c) Interface Separation. The coating shall be free of interface separations as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings. (d) Transverse Cracks. The coating shall be free of transverse cracks as defined for metallic coatings in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. (e) Interface Contamination. Interface contamination in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. (f) Oxides and Oxide Clusters. Oxides in the coating shall be identified as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated as described in the guidelines of Table 1, Page 4. The coating shall be free of oxide clusters as defined in TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings. Oxides shall be uniformly distributed. (g) Porosity. Porosity in the coating shall be classified for size as defined in TASK 70-7104-700-005, Metallographic Evaluation of Thermal Spray Coatings, and then rated per the guidelines of Table 1, Page 4. Porosity shall be uniformly distributed. (4) Tensile. Tensile specimens shall be prepared for tensile bond testing and evaluated in accordance with TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. Tensile bond strength for this coating at room temperature shall be 2,000 psi (13.8 MPa) minimum. (5) Bend Test. The technical requirement for this test has been deleted and no longer needs to be performed when specified in the applicable manual.
EFFECTIVITY: ALL
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Table 1. Acceptance Limits for Thermal Spray Feature Porosity Oxides Oxide Clusters Interface Contamination Interface Separations Transverse Cracks Delaminations Acceptance Criteria Less than or equal to V-3 Less than or equal to X-2 None allowed Less than or equal to I-2 None allowed None allowed None allowed Rating Photograph Figure 1, Page 13 Figure 6, Page 18 No figure for rating Figure 7, Page 19 No figure for rating No figure for rating No figure for rating Task TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 TASK 70-71-04700-005 Comments None None See definition for ratable size None See definition for ratable size None See definition for ratable size
EFFECTIVITY: ALL
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TIGHTENING PRACTICES AND TORQUE VALUES - TIGHTENING PRACTICES AND TORQUE VALUES TASK 70-51-00-400-004 1. Tightening Practices and Torque Values SUBTASK 70-51-00-99G-004 A. General. (1) This standard practice details the methods, terms, and procedures used in tightening and applying torque to threaded fasteners such as, bolts, nuts, and fittings. Torque in pound-inches (lb in.) or newton-meters (Nm), is the specific twisting force applied to threaded fasteners to obtain optimum security of the part, within the tensile limits of the material, or the shear limits of the threads of the fastener. One lb in. (Nm) is the twisting force of one pound (0.45 kg) applied to a lever one inch (25.4 mm) long. Higher torque values are equal to the product of the pounds (kilograms) times the length of the lever in inches (millimeters). NOTE: Torque (twisting force) is expressed in lb in. (Nm) to distinguish it from force applied in a straight line (work), which is expressed as inch-pounds (in. lb), foot-pounds (ft lb), or joules (J). One ft lb (J) of work is defined as the amount of energy required to lift an object having one pound (0.45 kg) of mass through a distance of one foot (0.305 m). SUBTASK 70-51-00-400-041 B. Definition of Terms. (1) Bolt. For purposes of these definitions, any male-threaded part. (2) Breakaway Torque. The torque required to just start an installed nut moving off the bolt, with no axial load on the bolt. (Nut is not seated, but is stationary at initiation of torque.) (3) Gross Torque. The actual indicated torque applied by the torque wrench, including run-on torque and seating torque. (4) Installed Nut. A nut is defined as installed on a bolt when not less than chamfer plus one and a half threads of the bolt extend beyond the nut. Nuts that have midlength nylon inserts or other centralized locking devices do not require the bolt to protrude from the nut, as long as the bolt passes through the locking device by the chamfer plus one and a half threads. (5) Maximum Installation Torque.
(2)
EFFECTIVITY: ALL
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TIGHTENING PRACTICES AND TORQUE VALUES Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A The highest value obtained as the nut is initially installed, and is being sized (opened up or worn in) by the bolt. (6) Minimum Prevailing Torque. The minimum value obtained while the nut or bolt is in motion from the end of the first revolution to the end of the second revolution during the removal of the nut from the bolt, or the bolt from a threaded hole. (7) Removed Nut. A self-locking nut is defined as removed when the locking section is disengaged from the bolt. (The nut need not be physically removed from the bolt.) (8) Run-On Torque. The torque required to turn a nut or bolt before it is completely seated to perform an axial tightening action on the bolt or spacing elements. (9) Seated Nut/Bolt. The torque that applies a specified compressive force to the spacing elements, or an axial loading or elongating force to a bolt, after the bearing surfaces of the bolt and/or nut are in contact with the spacing elements. (10) Spacer, Spacing Elements. For purposes of these definitions, any parts, regardless of function, size, shape, or material that are held together by one or more threaded fasteners. (11) Unseated Nut/Bolt. A nut or bolt is defined as unseated when it is removed a minimum of one turn from the seated position, removing any axial load from the bolt. (12) Unseated Torque. The torque required to unseat the bearing surface of a nut or bolt from a spacer, removing all axial load from the bolt. SUBTASK 70-51-00-400-042 C. Tightening Procedure. CAUTION: WHEN ASSEMBLY REQUIRES HEATING OR CHILLING PARTS, DO NOT TIGHTEN RETAINING NUTS OR BOLTS TO FINAL TORQUE VALUES UNTIL THE PARTS HAVE RETURNED TO ROOM TEMPERATURE. IF THE PART HAS BEEN HEATED, THE FASTENER MAY LOOSEN AS THE PART COOLS. IF THE PART HAS BEEN CHILLED, THE FASTENER MAY BE OVERSTRESSED AS THE PART EXPANDS. PARTS MAY BE SEATED BY TIGHTENING NUTS OR BOLTS PROVIDING FASTENERS ARE LOOSENED UNTIL PARTS HAVE RETURNED TO ROOM TEMPERATURE. (1) Tighten at a uniform rate until the specified torque is obtained. In some cases, where gaskets or other parts cause a slow permanent set, be sure to check the torque at the desired value after the material is seated.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A (2) Do not tighten to the final torque value during the first drawdown; uneven tension can cause distortion or overstressing of parts. Seat mating parts by drawing down the bolts in gradual increments, following a staggered or diametrically opposite sequence, until the parts are firmly seated. Complete the tightening procedure by loosening each fastener separately, then tighten to the specified torque value. Do not exceed the maximum torque values specified by the engine manual.
SUBTASK 70-51-00-400-043 D. Torque Wrench Sizes. (1) This standard practice does not cover the use of torque multipliers to obtain higher torque values. Information regarding the operation of such equipment can be found in the manufacturers literature. The torque wrenches listed below are recommended for use within the indicated ranges. Larger wrenches have a wider tolerance, and their use can result in serious inaccuracies. Torque Limits 0-25 lb in. (0.000-2.82 Nm) 26-140 lb in. (2.93-15.82 Nm) 141-550 lb in. (15.83-62.14 Nm) 360-1680 lb in. (40.87-189.81 Nm) 1692-2880 lb in. (189.82-325.39 Nm) 2892-12000 lb in. (325.40-1355.00 Nm) Tolerance 1 lb in. (0.11 Nm) 5 lb in. (0.56 Nm) 20 lb in. (2.26 Nm) 60 lb in. (6.78 Nm) 120 lb in. (13.56 Nm) 240 lb in. (27.12 Nm)
(2)
Torque Wrench Size 30 lb in. (3.39 Nm) 150 lb in. (16.94 Nm) 600 lb in. (67.79 Nm) 1800 lb in. (203.37 Nm) 3000 lb in. (338.95 Nm) 12000 lb in. (1355.81 Nm) SUBTASK 70-51-00-400-044 E.
Use of Offset Extension Wrench. (1) When an offset extension wrench, such as a crowfoot extension, is used with a torque wrench, the effective length of the torque wrench is changed. The torque wrench is so calibrated that when an extension wrench is used, the indicated torque, the value that appears on the scale or dial of the torque wrench, may be different from the actual torque that is applied to the nut or bolt. See Figure 1, Page 5. The Method of Computing the Adjustment is as follows: (a) The addition or subtraction of the effective length of the crowfoot extension (E) is determined by its position on the torque wrench (L). When the extension wrench is pointed in the same direction as the torque wrench, add the effective length of the extension to the effective length of the torque
(2)
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STANDARD PRACTICES MANUAL AS907-1-1A wrench (L + E). When the extension is pointed back toward the handle of the torque wrench, subtract the effective length of the torque wrench (L - E). When the extension is pointed at right angles to the torque wrench, the effective length does not change. The effective length (L) of the torque wrench is predetermined by the torque wrench manufacturer. Refer to manufacturers specification for the particular torque wrench being used. The effective length (E) of the crowfoot extension is determined by measuring from the center of the drive opening to the center of the wrench opening. (b) Multiply the required torque (T) by the effective length of the torque wrench (L). Divide this product by (L + E) or (L - E) as determined from Figure 1, Page 5. The quotient is the gage or scale reading required to obtain the desired torque. For example: Required torque = 265 lb in. (29.94 Nm) Effective length of torque wrench = 8.4 inches (213.36 mm) Effective length of crowfoot = 1.5 inches (38.1 mm) Then: (Required torque) X (L) = 265 X 8.4 = 2226.0 (29.94 Nm X 213.36 mm = 6388.00) (L + E) = 9.9 inches (251.46 mm) 2226.0 divided by 9.9 = 224.85 lb in. 6388.00 divided by 251.46 = 25.404 Nm Thus: A gage reading of 225 lb in. indicates a required torque of 265 lb in. (A gage reading of 25.42 Nm indicates a required torque of 29.94 Nm)
EFFECTIVITY: ALL
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Use of Offset Extension Wrench Figure 1
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-51-00-400-045 F. Standard Torque Values. Table 1. Steel Nuts and Bolts UNC and -8 Series Nominal Size No. 4 No. 6 No. 8 No. 10 No. 12 (1/4 in.) 5/16 Threads per Inch 40 32 32 24 20 18 Torque (see notes) 3-5 lb in. 0.339-0.565 Nm 8-10 lb in. 0.904-1.130 Nm 13-16 lb in. 1.469-1.808 Nm 20-25 lb in. 2.3-2.8 Nm 40-60 lb in. 4.520-6.780 Nm 70-110 lb in. 7.910-12.430 Nm 160-210 lb in. 18.080-23.730 Nm 250-320 lb in. 28.250-36.160 Nm 420-510 lb in. 47.460-57.630 Nm 575-720 lb in. 48-60 lb ft 65.0-81.3 Nm 840-960 lb in. 70-80 lb ft 94.920-108.480 Nm 1620-1860 lb in. 135-155 lb ft 183.1-210.1 Nm 2460-2820 lb in. 205-235 lb ft 278.0-318.6 Nm UNF and -12 Series Threads per Inch 40 36 32 28 24 Torque (see notes) 10-12 lb in. 1.130-1.356 Nm 16-19 lb in. 1.808-2.147 Nm 33-37 lb in. 3.728-4.180 Nm 55-70 lb in. 6.215-7.910 Nm 100-130 lb in. 11.300-14.690 Nm 190-230 lb in. 21.470-25.990 Nm 300-360 lb in. 33.900-40.680 Nm 480-570 lb in. 54.240-64.410 Nm 660-780 lb in. 55-65 lb ft 74.580-88.140 Nm 985-1140 lb in. 82-95 lb ft 111.300-128.820 Nm 1800-2040 lb in. 150-170 lb ft 203.4-230.4 Nm 2820-3180 lb in. 235-265 lb ft 318.660-359.340 Nm
3/8
16
24
7/16
14
20
1/2
13
20
9/16
12
18
5/8
11
18
3/4
10
16
7/8
14
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Table 1. Steel Nuts and Bolts (Cont) UNC and -8 Series Nominal Size 1.000 Threads per Inch 8 Torque (see notes) 3600-4080 lb in. 300-340 lb ft 406.800-461.040 Nm 5000-5720 lb in. 415-480 lb ft 565.000-646.360 Nm 7200-8400 lb in. 600-700 lb ft 813.600-949.200 Nm 9600-11100 lb in. 800-930 lb ft 1084.8001254.300 Nm 12000-14400 lb in. 1000-1200 lb ft 1356.0001627.200 Nm 5280-6120 lb in. 440-510 lb ft 596.640-691.560 Nm 7500-8700 lb in. 625-725 lb ft 847.500-983.100 Nm 10100-12000 lb in. 840-1000 lb ft 1138.8721356.000 Nm 13800-16200 lb in. 1150-1350 lb ft 1559.4001830.600 Nm UNF and -12 Series Threads per Inch 14 Torque (see notes) 4200-4800 lb in. 350-400 lb ft 474.600-542.400 Nm 5820-6780 lb in. 485-565 lb ft 657.660-766.140 Nm 8280-9600 lb in. 690-800 lb ft 935.640-1084.800 Nm 10800-12720 lb in. 900-1060 lb ft 1220.4001437.360 Nm 14400-16800 lb in. 1200-1400 lb ft 1627.2001898.400 Nm -
1-1/8
12
1-1/4
12
1-3/8
12
1-1/2
12
1-1/8
1-1/4
1-3/8
1-1/2
NOTE: POUND INCHES X 0.113 = Nm NOTE: POUND FEET X 1.356 = Nm
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Table 1. Steel Nuts and Bolts (Cont) UNC and -8 Series Nominal Size Threads per Inch Torque (see notes) UNF and -12 Series Threads per Inch Torque (see notes)
NOTE: EXCEPTION: Use one-half the values given in the above for thin steel hex nuts. These are nuts having a height of less than 0.6 the pitch-diameter for plain nuts, and less than 0.8 the pitch-diameter for self-locking nuts. NOTE: EXCEPTION: Use one-half the values given in the above for nuts and bolts of nonferrous alloys.
Table 2. Studs and Stepped Studs - Aluminum/Magnesium Bolt or Stud Size 3/16 - 24 1/4 - 20 5/16 - 18 3/8 - 16 7/16 - 14 1/2 - 13 Pound-inches 35 - 40 75 - 80 135 - 145 240 - 250 370 - 380 580 - 600 Newton meters (3.955 - 4.520) (8.475 - 9.040) (15.255 - 16.385) (27.120 - 28.250) (41.810 - 42.940) (65.540 - 67.800)
NOTE: Studs that have different threads on opposite ends shall be tightened to the torque applicable to the small size.
Table 3. Tubing and Hose Fittings Thread Size (inch)-(number) 15/16-24 3/8-24 7/16-20 1/2-20 9/16-18 3/4-16 All Aluminum Parts (Note1) 35-45 3.955-5.085 50-60 5.650-6.780 65-75 7.345-8.475 95-105 10.735-11.865 165-185 18.645-20.905 Steel Tube Aluminum or Steel Nuts(Note2) 40-50 4.520-5.650 90-100 10.170-11.300 135-155 15.255-17.515 175-205 19.775-23.165 265-305 29.945-34.465 460-540 51.980-61.020
Tube OD (inch) 1/8 3/16 1/4 5/16 3/8 1/2
Torque Units lb in. Nm lb in. Nm lb in. Nm lb in. Nm lb in. Nm lb in. Nm
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Table 3. Tubing and Hose Fittings (Cont) Thread Size (inch)-(number) 7/8-14 1-1/16-12 All Aluminum Parts (Note1) 230-270 25.990-30.510 330-385 28-32 37.290-43.505 555-645 46-54 62.715-72.885 720-840 60-70 81.360-94.920 720-840 60-70 81.360-94.920 Steel Tube Aluminum or Steel Nuts(Note2) 665-775 75.145-87.575 940-1100 78-92 106.220-124.300 1325-1555 110-130 149.725- 175.715 1550-1800 130-150 175.150- 203.400 1900-2200 158-183 214.700-248.600
Tube OD (inch) 5/8 3/4
Torque Units lb in. Nm lb in. lb ft Nm lb in. lb ft Nm lb in. lb ft Nm lb in. lb ft Nm
1.000
1-5/16-12
1-1/4
1-5/8-12
1-1/2
1-7/8-12
NOTE:
These values apply when female sealing surface is aluminum. Male connector and nut may be steel or aluminum. These values apply when tube, brazed ferrule and connector are steel. Male end fitting and nut may be steel or aluminum.
NOTE:
Table 4. Unions, Plugs, and Bulkhead Fittings Fitting Size -2 -3 -4 Thread Size - inchpitch 5/16-24 3/8-24 7/16-20 Torque Value 40-50 4.514-5.643 90-100 10.158-11.387 135-155 11.25-12.92 15.3-17.5 155-175 12.91-14.66 17.474-19.751 175-205 14.58-17.08 19.775-23.165 Torque Unit lb in. Nm lb in. Nm lb in. lb ft Nm lb in. lb ft Nm lb in. lb ft Nm
-5
1/2-20
-6
9/16-18
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Table 4. Unions, Plugs, and Bulkhead Fittings (Cont) Fitting Size -8 Thread Size - inchpitch 3/4-16 Torque Value 265-305 22.08-25.42 29.945-34.465 350-410 29.17-34.17 39.550-46.330 555-645 46.00-54.00 62.715-72.885 720-840 60.00-70.00 81.360-94.920 885-1035 73.75-86.25 100.005-116.955 995-1165 82.92-97.08 112.435-131.645 Torque Unit lb in. lb ft Nm lb in. lb ft Nm lb in. lb ft Nm lb in. lb ft Nm lb in. lb ft Nm lb in. lb ft Nm
-10
7/8-14
-12
1-1/16-12
-16
1-5/16-12
-20
1-5/8-12
-24
1-7/8-12
SUBTASK 70-51-00-400-046 G. Tightening of Plugs and Tube Fittings (1) Assembly techniques vary, depending upon the specific type of plug or tube fitting being used. The types normally encountered include nonpositioning plugs and unions, using packings preformed (O-rings) or other compressible packing for seals; positioning fittings, with or without backup washers; and universal bulkhead fittings, held in position by locknuts. See Figure 2, Page 13 All tube fittings should be tightened to their proper torque using two wrenches. The secondary wrench is used to apply counter-torque to prevent distortion of the tubing assembly. Correct Assembly Techniques. (a) Installation of Packings Preformed (O-Rings) on Fittings. 1 When ratio of packing preformed (O-ring) diameter to cross-section is greater than 20, use a conic sleeve screwed onto fitting so that packing preformed (O-ring) may be rolled into groove of fitting without danger of being damaged. For diameter ratios less than 20, a conic sleeve is not needed, except when the packing preformed (O-ring) must be rolled over threads or splines.
(2)
(3)
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STANDARD PRACTICES MANUAL AS907-1-1A 3 (b) Lubricate packing preformed (O-ring) with petrolatum and roll it into groove of fitting.
Lubrication. Use no lubricant on threads or friction surfaces unless specified by the engine manual.
(c)
Nonpositioning Fittings. Lubricate the packing lightly to prevent cutting by sharp threads, then install packing on fitting so that packing lies evenly in groove of fitting. Screw fitting into boss. Tighten to the specified torque value.
(d)
Positioning Fittings (No Backup Washers). Screw the locknut completely over the first section of threads on the fitting, past the packing groove, and onto the second section of threads. Lubricate packing to prevent cutting by sharp threads, and install it carefully over first section of threads and into the packing groove so that it lies evenly against the second section of threads. Turn locknut until it just bears against the packing. Install fitting in boss so that packing touches the countersunk surface. Turn fitting to desired position by backing out not more than one turn. Hold fitting in position and tighten locknut to the specified torque value.
(e)
Positioning Fittings (With Backup Washers). Screw the locknut completely over the first section of threads on the fitting, and onto the second section of threads with the washer recess facing the packing groove. Grip the backup washer firmly by its outside edge, and screw the fitting into the cupped washer. Do not use any lubricant. Continue screwing the washer onto the fitting until the washer is free on the packing groove. Pick out any slivers of plastic material cut from the washer, then press the edges of the washer into the recess in the locknut until evenly seated. Ensure that threads of fitting do not interfere with seating of washer. Lubricate and install packing as directed in step (3). Hold the locknut in position with a wrench, and turn the fitting into the boss 1.5 turns. Position the fitting as desired by turning into the boss up one additional turn (total 1.5-2.5 turns). Hold fitting in position, and tighten locknut to the specified torque value.
(f)
Universal Bulkhead Fittings. Attach bulkhead fitting to bulkhead with locknut as shown in Figure 2, Page 13. After the connecting tube or hose nut has been properly tightened, hold fitting with wrench and tighten locknut to the specified torque value.
(g)
Tube, Manifold, and Hose (0.75 in.[19 mm] and smaller in diameter coupling nuts triple tightening procedure. 1 2 Tighten the coupling nut to applicable torque identified in Subtask 7051-00-400-045, Standard Torque Values. Break the torque on the coupling nut and then tighten to the torque value identified above.
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STANDARD PRACTICES MANUAL AS907-1-1A 3 Break the torque on the coupling nut and then tighten to the torque value identified above.
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Installation and Torque of Unions, Plugs, and Bulkhead Fittings Figure 2
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-51-00-400-047 H. Net Torque. (1) In certain applications, engine manuals may specify a net torque value when the tightening force applied by the fastener is critical, and must be controlled within precise limits to obtain a specific amount of stretch to a bolt or to provide an exact amount of hold-down pressure. Net torque equals gross torque minus run-on torque. The method of determining net torque is shown in the following example. (a) (b) Requirement to tighten a nut on a bolt to a net torque of 20-40 lb in. (2.46-4.52 Nm). Screw the nut on the bolt, and determine the torque required to turn the nut before any tightening action takes place. Record this value as run-on torque. Assume the value to be 15 lb in. (1.69 Nm). Add the run-on torque value determined in step (2) to the minimum and maximum specified torque values. Then: 20 lb in. (2.26 Nm) plus 15 lb in. (+1.69 Nm) equals 35 lb in. (3.95 Nm), and 40 lb in. (4.52 Nm) plus 15 lb in. (+1.69 Nm) equals 55 lb in. (6.21 Nm). Therefore: to obtain a net torque of 20-40 lb in. (2.26-4.52 Nm), a gross torque of 35-55 lb in. (3.95-6.21 Nm) must be applied to the nut. SUBTASK 70-51-00-400-048 I. Torque Check for Re-Use of Self-Locking Nuts. NOTE: The information presented here does not apply to nuts specified in engine manual for one time use only. (1) (2) Self-locking nuts must meet the minimum breakaway torque requirements to be considered reusable. The requirements for this torque check are as follows. (a) Refer to following list for minimum breakaway torque on self-locking nuts. This list applies to silver plated, dry-film coated, and lubricated self-locking nuts. Values given are for nuts with no axial load. To check minimum breakaway torque, install the nut onto a bolt until 2 to 5 threads are exposed beyond the nut. Measure the amount of torque required to turn the nut on or off the bolt.
(2)
(c)
(b)
CAUTION: DO NOT PINCH, SQUEEZE OR OTHERWISE DEFORM ANY SELFLOCKING NUT TO OBTAIN OR REGAIN SELF-LOCKING TORQUE. (c) (d)
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All nuts that do not meet these minimum frictional requirements should be replaced. Minimum Breakaway Torque for Self-Locking Nuts
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Thread Size 0.136 (6) 0.164 (8) 0.190 (10) 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1.0 1 1/8 1 1/4 SUBTASK 70-51-00-400-049 J.
Threads/Inch 32/40 32/36 32 28 24 24 20 20 18 18 16 14 14 12 12
Minimum Breakaway Torque 1.0 lb in. (0.11 Nm) 1.5 lb in. (0.17 Nm) 2.0 lb in. (0.22 Nm) 3.5 lb in. (0.40 Nm) 6.5 lb in. (0.73 Nm) 9.5 lb in. (1.07 Nm) 14.0 lb in. (1.58 Nm) 18.0 lb in. (2.03 Nm) 24.0 lb in. (2.71 Nm) 32.0 lb in. (3.62 Nm) 50.0 lb in. (5.65 Nm) 70.0 lb in. (7.91 Nm) 92.0 lb in. (10.39 Nm) 117.0 lb in. (13.22 Nm) 143.0 lb in. (16.16 Nm)
Torque Procedure for V-Band Type Clamps. (1) Tighten the V-band nut to 50 percent of the required torque. Check to be sure that the coupling is seated over the flanges equally around the periphery and the seal is properly seated, if applicable. With plastic or nonmetallic mallet tap the coupling lightly around its circumference to distribute the V-band tension. While increasing the torque toward 100 percent of the specified value, lightly tap the outer periphery as necessary to prevent unequal loading. After 100 percent of the specified torque is reached, tap around the band again and retighten once more to the specified value.
(2) (3) (4)
SUBTASK 70-51-00-400-050 K. Torque Procedure for Misalignment Joint Couplings. (1) (2) Lubricate threads with antiseize compound C02-058. Tighten the misalignment joint coupling nut to 50 percent of the required torque. Make certain that the female fitting is seated and centered over the male fitting equally around the periphery, and make certain the metal gasket seal is properly seated.
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STANDARD PRACTICES MANUAL AS907-1-1A (3) (4) (5) (6) (7) (8) With plastic or non-metallic mallet, tap the coupling nut lightly around its circumference to distribute the misalignment joint loading. While increasing the torque toward 100 percent of the specified value, lightly tap the outer periphery, as necessary, to prevent unequal loading. After 100 percent of the specified torque is reached, tap around the coupling nut outer periphery again. Break torque and loosen coupling nut of the misalignment fitting one-half turn. Tighten once more to the specified torque value. Assemble shields to joints, as applicable.
SUBTASK 70-51-00-400-051 L. Acceptability Limits, Acceptance Torques. (1) (2) This procedure describes the verification that torque values specified on a drawing or in a specification have been met. For the purposes of this specification, the following definitions apply: (a) Acceptance Torque - The torque applicable after final assembly. It shall include the net effect of the torque required to overcome friction between mating bearing faces and between mating threads, to overcome the selflocking feature (if any) and, to apply the desired axial load to the fastener assembly. It also includes the effect of joint/fastener relaxation. The acceptance torque shall be measured only in the tightening direction with the mating fastener component restrained. Seating Torque - The torque required by drawing or specification to bring the bearing faces into the seated position and measured only in the tightening direction.
(b)
(3)
Requirements. (a) Application - The conditions described herein shall be applied only to parts which have been assembled into a sub-assembly or an engine prior to engine test. Acceptance Torque Requirements - The acceptance torque requirements for self locking nuts shall be in accordance with the following table. The acceptance torques shall be measured in the tightening direction. These values shall be used in the process of inspecting or auditing to insure that the proper seating torque has been applied. Seating Torque lb in (Nm) 24-27 (2.71-3.05) 33-37 (3.73-4.18) 40-60 (4.52-6.78) Acceptance Torque lb in (Nm) 21-39 (2.37-4.41) 30-46 (3.39-5.20) 36-78 (4.07-8.81)
(b)
Thread Size 0.190-32 0.190-32 0.190-32

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Thread Size 0.250-28 0.250-28 0.250-28 0.3125-24 0.375-24 0.375-24 0.375-24
Seating Torque lb in (Nm) 28-35 (3.16-3.95) 55-70 (6.21-7.91) 110-120 (12.43-13.56) 100-130 (11.30-14.69) 190-230 (21.47-25.99) 380-420 (42.93-47.45) 540-560 (61.01-63.27)
Acceptance Torque lb in (Nm) 24-46 (2.71-5.20) 50-91 (5.65-10.28) 100-156 (11.30-17.63) 91-169 (10.28-19.09) 172-299 (19.43-33.78) 344-546 (38.87-61.69) 489-728 (55.25-82.25)
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WRENCH-ARC METHOD - WRENCH-ARC METHOD FOR TIGHTENING BALL-NOSE FITTINGS TASK 70-51-01-400-001 1. Wrench-Arc Method for Tightening Ball-Nose Fittings SUBTASK 70-51-01-99G-001 A. General. (1) This procedure gives the instructions to secure ball-nose fittings. The wrench arc method is done by a visual measurement of the angular displacement instead of a torque measurement. The wrench arc method is limited to the two methods. (a) The turn of the B-nut method uses a regular open end wrench, crowfoot, tubing wrench. NOTE: The turn of the B-nut method for wrench arc tightening is the same as the line of sight method except for the degree of arc to be applied to the B-nut before you turn over (invert) the 15 degree off-set open end wrench. (b) The line of sight method uses a 15 degree off-set open end wrench.
SUBTASK 70-51-01-400-011 B. Equipment. Description Wrenches (Box, Open End, and Combination)
Federal Specification GGG-W-636 SUBTASK 70-51-01-400-012 C. Materials (1) None.
SUBTASK 70-51-01-400-013 D. Procedure. (1) Preliminary Instructions. (a) Before you tighten the nuts, make sure that all threads and all sealing/mating surfaces are clean and free of nicks, burrs, and scratches. NOTE: No lubricant is required with the ball-nose fittings. NOTE: The presence of residual system fluids is acceptable.
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WRENCH-ARC METHOD FOR TIGHTENING BALL-NOSE FITTINGS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (b) (c) (d) Use open-end wrenches with 15 degree offset angled heads when you tighten the nut and for wrench-arc tightening. Refer to Figure 1, Page 4. Use an open end wrench on all wrench-arc tasks to seat the nut tight (no torque). The nut is snug when: 1 2 3 (2) A sharp rise in resistance is felt (greater than run-on torque). Parts appear to be properly seated. No looseness between the mating parts is noted.
Turn of the B-nut method. Refer to Figure 1, Page 4. NOTE: New hardware will require you to wrench arc tighten the new B-nut and then loosen. You must then tighten the B-nut again through a complete arc of 30 degrees. (a) Snug the B-nut with an open-end wrench. NOTE: Do not remove the wrench from the B-Nut until this process is completed. (b) (c) Look at the position of the open end wrench handle. Pick out a point of reference on the B-nut in line with the handle. NOTE: The reference point is always between the B-nut flats and the wrench handle. When you turn the B-nut 1/2 flat you have moved the B-nut through an arc of 30 degrees. (d) Tighten the B-nut with an open end wrench through an arc of 30 degrees.
(3)
Line of sight method. Refer to Figure 1, Page 4. NOTE: New hardware will require you to wrench arc tighten the new B-nut and then loosen. You must then tighten the B-nut again through a complete arc of 30 degrees. (a) (b) (c) Snug the nut with an open-end wrench. Look at the position of the wrench handle. Pick out a point of reference on the B-nut in line with the handle. NOTE: The reference point is always between the B-nut flats and the wrench handle. When you turn the B-nut 1/2 flat you have moved the B-nut through an arc of 30 degrees. (d) (e) Tighten the B-nut 15 degrees. Turn the 15 degree off set wrench over.
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STANDARD PRACTICES MANUAL AS907-1-1A (f) (g) Place the wrench on the same B-nut flats. Tighten the B-nut an additional 15 degrees back to the point of reference on the wrench, before you turned it over.
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Arc Wrench Methods Figure 1
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WRENCH-ARC METHOD - WRENCH-ARC METHOD FOR TIGHTENING FLARELESS FITTINGS TASK 70-51-02-400-001 1. Wrench-Arc Method for Tightening Flareless Fittings SUBTASK 70-51-02-99G-001 A. General. (1) This procedure gives the instructions to secure flareless fittings, shown in Figure 1, Page 2. This is done by visual measurement of angular displacement instead of torque measurement. Wrenching is limited to the technique described in this procedure.
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WRENCH-ARC METHOD FOR TIGHTENING FLARELESS FITTINGS Page 1 Dec 01/03
Typical Flareless Fitting Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-51-02-400-011 B. Equipment. Description Wrenches (Box, Open End, and Combination)
Federal Specification GGG-W-636 SUBTASK 70-51-02-400-012 C. Materials. (1) None.
SUBTASK 70-51-02-400-013 D. Procedure. (1) Preliminary Instructions. (a) (b) Before tightening nuts, make sure that all threads and all sealing/mating surfaces are clean and free of nicks, burrs, and scratches. No lubricant is required with the flareless fittings. NOTE: The presence of residual system fluids is acceptable. (c) (d) (e) Open-end wrenches, with 158 offset angled heads, will normally be used for tightening the nut and for wrench-arc tightening. All wrench-arc tasks require the nut to be seated tight (no torque), using an open-end wrench. The nut is tight when: 1 2 3 (2) A sharp rise in resistance is felt (greater than run-on torque). Parts appear to be properly seated. No looseness between the mating parts is noted.
Tightening Method for 158 Wrench-Arc (preferred method). Refer to Figure 2 (Sheet 1 of 4), Page 6. (a) (b) (c) (d) Use an open-end wrench and tighten the nut. With the open-end wrench still on the nut, establish a line of sight using the wrench handle. Use the angular difference between the handle and the wrench flats (158) to visually measure the amount that the nut will have to be turned. Turn the wrench until the flats on the nut (engaged by wrench) are aligned with the line of sight established by the handle in step (2).
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STANDARD PRACTICES MANUAL AS907-1-1A (3) Tightening Method for 158 Wrench-Arc (Alternate Method). (a) (b) (c) (4) Use an open-end wrench and tighten the nut. With the open-end wrench still on the nut, use the engaged nut flats to establish a line of sight. Turn the wrench until the handle is aligned with the line of sight.
Tightening Method for 308 Wrench Arc. Refer to Figure 2 (Sheet 1 of 4), Page 6. (a) (b) (c) (d) Tighten the nut with an open-end wrench. Refer to Figure 2 (Sheet 1 of 4), Page 6, sheet 2, view C. Look at the position of the wrench handle. Pick out a point of reference on the engine in line with the handle. Invert the wrench using the same nut flats. The angular difference between the center lines of the wrenches in the two positions is 308. Turn the wrench to the position established in step (2). NOTE: If new fittings are being used, tighten the nut to a 308 wrench-arc, loosen the nut, and repeat steps (1)-(4).
(5)
Tightening Method for 608 or 1208 Wrench Arc. Refer to Figure 2 (Sheet 1 of 4), Page 6. NOTE: In this method of tightening, primarily used for flareless fittings, flats on the union are used as a reference. Wrenches other than open-end wrenches (crowfeet or tubing wrenches) may be used. (a) (b) (c) (d) Use an open-end wrench and tighten nut. Use the corners on the coupling nut between the flats on the mating union to determine the amount that the coupling nut will have to move. Turn the coupling nut one flat for 608 wrench arc. Turn the coupling nut two flats for 1208 wrench arc.
(6)
Tightening Method for 908 or 1808 Wrench Arc. Refer to Figure 2 (Sheet 1 of 4), Page 6. NOTE: In this procedure, wrenches other than open-end (box, tubing, crowfoot) may be used. Any local reference, such as the engine or component centerline may be used to estimate wrench travel. (a) (b) Use a wrench and tighten the nut. For a 908 arc, turn the wrench until the handle is perpendicular (at a right angle) to its starting position.
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STANDARD PRACTICES MANUAL AS907-1-1A (c) For a 1808 arc, turn the wrench until the handle points in the opposite direction.
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Wrench-Arc Tightening Techniques Figure 2 (Sheet 1 of 4)
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Wrench-Arc Tightening Techniques Figure 2 (Sheet 4)
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ENGINE PARTS - PRESERVATION OF ENGINE PARTS TASK 70-60-00-620-001 1. Preservation of Engine Parts SUBTASK 70-60-00-99G-001 A. General. (1) Engine parts made of noncorrosion-resistant materials should be protected if they are permitted to stand for more than a few minutes. Examples of noncorrosionresistant materials include chromoloy, alloys of aluminum, magnesium and copper, and corrosion-resistant alloys that have been nitrided or malcolmized. Parts containing dissimilar metals are also subject to corrosion. This practice does not apply to assembled engines, bearings, electrical parts or accessories.
SUBTASK 70-60-00-620-011 B. Protection of Parts in Process. (1) Noncorrosion-resistant materials should be preserved during the overhaul process of inspection and repair by one of the following procedures. If a preserved part is handled before expiration of the preservation period, or if the preservation period expires, the part must be reprocessed at once. NOTE: Bearings require special handling. (Refer to TASK 70-60-01-620-002, Preservation of Antifriction Bearings). (2) For preservation up to five days, use the following process. (a) (b) (c) (d) (3) Clean parts to be sure that they are free from oil, grease, dust, or shop soil. Make a solution of one part inhibitor C02-056 to ten parts water, or use solution S1156. Dip or coat the parts with solution, and air-dry. Cover to protect from dust.
For preservation up to ten days, use the following procedure. (a) (b) Clean parts to be sure that they are free from oil, grease, dust, or shop soil. Dip or coat the parts with preservative conforming to specification AMS 3065 or MIL-C-15074 C02-054. NOTE: Effective preservation time can be doubled if parts are wrapped (not merely covered) in 4-mil polyethylene sheet. (c) Cover to prevent dust contamination.
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PRESERVATION OF ENGINE PARTS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (4) For preservation up to 20 days, use the following procedure. (a) (b) Clean parts to be sure that they are free from oil, grease, dust, or shop soil. Dip or coat the parts with preservative conforming to specification MIL-L-6085 C02-050. NOTE: Effective preservation time can be doubled if parts are wrapped (not merely covered) in 4-mil polyethylene sheet. (c) (5) Cover to prevent dust contamination.
For preservation up to 30 days, use the following procedure. (a) (b) Clean parts to be sure that they are free from oil, grease, water, dust, or shop soil. Blow dry with clean shop air. Submerge parts in storage preservative C02-055 or equivalent. If parts are moist, or contain water in crevices or blind areas, leave them in the preservative for at least 30 minutes. NOTE: Effective preservation time can be doubled if parts are wrapped (not merely covered) in 4-mil polyethylene sheet. (c) Drain off excess preservative, and cover to prevent dust contamination.
SUBTASK 70-60-00-620-012 C. Protection of Parts for Storage. (1) The following instructions apply to the protection of parts that are to be stored for extended periods. (a) Painted Surfaces. In general, painted surfaces do not require protection beyond a simple dust cover. If the paint is chipped or missing in spots, it should be touched-up before the part is stored. (b) Plated Surfaces. In general, plated surfaces require no protection other than a dust cover. Silver-plated parts must be wrapped in anti-tarnish paper and stored in sulfide-free containers. (c) Uncoated Surfaces. Metallic surfaces that are not normally coated or plated are most susceptible to corrosion. Iron and steel alloys are usually considered the most vulnerable. Stainless steels such as 321 and A286 do not require protection; however, the 400-series of stainless steels does require it. Brass and bronze should be protected. Process parts as follows. 1 Apply a coat of preservative C02-054 to the part by dipping, brushing, or spraying.
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STANDARD PRACTICES MANUAL AS907-1-1A 2 (d) Place the part in a plastic bag or other vapor-proof container to protect it from dust, dirt, and moisture, or wrap in paper if size requires it.
Parts with Cavities. Parts that have cavities subject to corrosion or rusting should be filled with engine oil C02-019, then drained thoroughly, to protect the internal surfaces. Plug or cover all openings and ports to prepare for storage.
SUBTASK 70-60-00-620-013 D. Protection of Fuel and Lube Components. (1) Fuel and lube components must be handled individually, as follows. (a) Lube Components. Preserve with engine oil C02-019, and seal if possible. Partially assembled components may be wrapped in 4-mil polyethylene wrap. (b) Fuel Components. Totally displace fuel with jet engine lubricating oil, specification MIL-L-6081, grade 1010 C02-021. Seal all ports and openings. Partially assembled components may be handled as in Subtask 70-60-00-620-012, Protection of Parts for Storage.
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ANTIFRICTION BEARINGS - PRESERVATION OF ANTIFRICTION BEARINGS TASK 70-60-01-620-002 1. Preservation of Antifriction Bearings SUBTASK 70-60-01-99G-002 A. General. (1) Antifriction bearings are precision assemblies, and must be protected against both atmospheric and mechanical damage at all times. Special handling techniques for bearings are described in TASK 70-14-00-620-003, Handling of Bearings, cleaning methods are described in TASK 70-22-01-110-046, Special Cleaning Procedure No. 1 - Cleaning of Bearings Using a Water Based Cleaning Solution, and inspection criteria are described in TASK 70-33-01-220-004, Antifriction Bearing Inspection. The duration of the storage period after cleaning and inspection determines the type of preservation to be used.
SUBTASK 70-60-01-620-021 B. In-Process Preservation. CAUTION: DO NOT USE COMPRESSED AIR TO BLOW EXCESS SOLVENTS OR LUBRICANTS FROM ASSEMBLED BEARINGS AS SPINNING CAN DAMAGE THE BEARING. (1) During the disassembly of the engine, and throughout all subsequent operations, preserve bearings in accordance with the following recommendations. (a) (b) Apply preservation oil MIL-L-6085 C02-050 to bearings within 15 minutes of the time that they become accessible at disassembly. Protect bearings in assemblies from dirt and moisture by covering or sealing sumps and tube openings with a moisture barrier material such as grade A grease proof paper or polyethylene sheet. Apply preservation oil MIL-L-6085 C02-050 to bearings as soon as they are removed from assemblies, and place bearing in a clear plastic bag or wrap in grade A grease proof paper C02-009. Send to bearing processing area at once. After cleaning, and during and after inspection, immerse bearing in fingerprint neutralizer C02-054. Make sure that neutralizer contacts all surfaces. Remove neutralizer by rinsing in Stoddard solvent C04-002 or equivalent, and coat bearing with preservation oil MIL-L-6085 C02-050. Coat bearing with preservation oil MIL-L-6085 C02-050 after installation on a shaft or in a housing. When preservation oil is applied to a bearing installed in a sump, let any excess oil drain from the scavenge port before sealing the sump openings.
(c)
(d)
(e)
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PRESERVATION OF ANTIFRICTION BEARINGS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (f) Wear clean white nylon gloves or plastic gloves, or apply protective hand cream C10-064 when handling bearings. Heated rings may be handled with clean asbestos gloves.
SUBTASK 70-60-01-620-022 C. Preservation After Processing. (1) If bearing is to be returned to engine assembly within 7 days, immerse it in preservation oil MIL-L-6085 C02-050, drain, and place in a clean plastic bag or wrap in grade A grease proof paper C10-009. Place in a protective container until installation. If bearing is to be placed in storage for an extended period of time, it should be preserved with preservative C02-024, then wrapped in grade A grease-proof paper C10-009, glossy side toward the bearing. Store bearings in covered individual containers until used. NOTE: An alternative method of extended period storage may be used with preservation oil C02-050 provided bearings are packed in shrink-wrap or plastic bags to minimize exposure to moisture.
(2)
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PRESERVATION OF ANTIFRICTION BEARINGS Page 2 Dec 01/03
TESTING AND QUALITY ANALYSIS - TESTING AND QUALITY ANALYSIS TASK 70-70-00-700-001 1. Testing and Quality Analysis SUBTASK 70-70-00-99G-001 A. General. (1) This procedure consists of a series of operations. Test specimens and special tools or fixtures required in the performance of specific tasks are described in the procedures that make use of them.
SUBTASK 70-70-00-700-011 B. Thermal Spray Coating Quality Tests. (1) Types of Tests. All thermal spray deposits shall be visually checked for complete coverage, uniform structure, freedom from cracks, voids, spalling, chipping, flaking, or other indications of poor adhesion. The quality of the thermal spray deposit shall be tested, as shown in Table 1, Page 2, by the following methods: (a) Tensile bond test. Refer to TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. The tensile bond test is performed using pull test buttons or adapters in a tensile testing machine to check adherence of the thermal spray coating. At least three tests shall be performed for each part. Refer to Table 2, Page 7 for a cross reference of materials used for test buttons/adapters based on the alloy of the part being repaired. (b) Lap shear bond test. Refer to TASK 70-71-02-700-003, Bond Strength LapShear Testing of Thermal Spray Coatings. The lap shear bond test is performed using a three-piece set of test panels in a tensile testing machine to check the adherence of the thermal spray coating. Refer to Table 2, Page 7 for a cross reference of materials used for test buttons based on the alloy of the part being repaired. Two pieces of each three-piece set are sprayed for a length of 0.50 inch (12.7 mm) along with the production part, and at least three sets must be sprayed in conjunction with each part. (c) Scratch hardness test. Refer to TASK 70-71-03-700-004, Scratch-Hardness Testing of Thermal Spray Coatings. The scratch hardness test is performed using a test panel sprayed in conjunction with the production part. (d) Metallographic examination. Refer to TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings.
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TESTING AND QUALITY ANALYSIS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (e) (f) A test panel or scrap part, sprayed in conjunction with the production part, is sectioned, polished, and examined microscopically. Rockwell hardness test. This test is usually performed on a small coupon sprayed with the part and sometimes on the same coupon used for metallography. The hardness of the coating is determined in accordance with TASK 70-34-03-220-009, Rockwell Hardness Testing. (g) Vickers (microhardness) test. This test is performed on a mounted cross-section and the same sample prepared for the metallographic evaluation can be used. The hardness of the coating is determined in accordance with TASK 70-34-02-220-008, Vickers Hardness Testing. (2) Frequency of Testing. (a) After the initial coating qualification, part quality testing should begin with evaluation of all test coupons (at 100% frequency) as required by: The specific manual repair, The specific thermal spray procedure [for example, TASK 70-49-10-340-011, Thermal Spraying Nickel-Aluminum (Powder)], The general thermal spray requirements in TASK 70-49-00-340-001, Thermal Spraying, The specific testing procedures (for example, TASK 70-71-04-700-005, Metallographic Evaluation of Thermal Spray Coatings), and the general testing requirements in TASK 70-70-00-700-001, Testing and Quality Analysis. (b) As spraying continues, passing data should be gathered and analyzed by an acceptable statistical process control (SPC) system. The frequency of testing may then be reduced (or the time intervals between quality control testing increased) based on the statistical analysis if consistent results are obtained. The frequency intervals should all be based on requirements documented in the repair shops internal Quality Assurance System.
SUBTASK 70-70-00-700-012 C. Metal-To-Metal, Film Adhesive Bonding Quality Tests. NOTE: Test procedure adhesive evaluations can now be found in TASK 70-70-01700-001, Testing and Quality Analysis of Metal-to-Metal Bonding.
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Table 1. Test Requirements for Thermal Spray Coating Coating Procedure 70-49-01 (powder) (also see 70-4923 and 70-49-40) 70-49-02 (powder) 70-49-03 (powder) 70-49-04 (powder) 70-49-05 (powder) (also see 70-4949) 70-49-06 (powder) 70-49-07 (powder) (also see 70-4908 and 70-49-51) 70-49-08 (wire) (also see 70-4907 and 70-49-51) 70-49-09 (powder) 70-49-10 (powder) (also see 70-4911 and 70-49-38) 70-49-11 (wire) (also see 70-4910 and 70-49-38) 70-49-12 (powder) 70-49-13 (wire) 70-49-14 (powder) 70-49-15 (powder) 70-49-16 (powder) 750 (5.17) 1200-3000 (8.2720.68) 5500 (37.92) 2500 (17.24) Tensile Bond per 70-71-01 psi (MPa) 1200 (8.27) Metallographic Exam per 70-7104 X
Coatings Aluminum, Pure
Hardness
Alumina Chromium Carbide Copper-Nickel Copper-NickelIndium
1000 (6.89) 3000 (20.68) 2900 (20.00) 2000 (13.79)
X X X X Note 1
Magnesium Molybdenum
X X
Molybdenum
2500 (17.24)
Nickel-Aluminide Nickel-Aluminum
2500 (17.24) 4000/5000 (27.6/ 34.47)
X X
Nickel-Aluminum
4000/5000 (27.6/ 34.47)
Nickel-Chromium Nickel-Chromium Nickel-Graphite (75:25) Nickel-Graphite (85:15) Nickel-SiliconBoron

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X X X X X
Note 2 Note 3
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Table 1. Test Requirements for Thermal Spray Coating (Cont) Coating Procedure 70-49-17 (wire) (also see 70-4944) 70-49-18 (powder) 70-49-19 (powder) (also see 70-4928) 70-49-20 (powder) 70-49-21 (powder) (also see 70-4939) 70-49-22 (powder) 70-49-23 (wire) (also see 70-4901 and 70-49-40) 70-49-24 (powder) 70-49-25 (powder) (also see 70-4926 and 70-49-52) 70-49-26 (wire) (also see 70-4925 and 70-49-52) 70-49-27 (powder) 70-49-28 (powder) (also see 70-4919) 70-49-29A (powder) 70-49-29B (powder) 2000 (13.79) 4000-5000 (27.634.47) Tensile Bond per 70-71-01 psi (MPa) 3000 (20.68) Metallographic Exam per 70-7104 X
Coatings Silver Alloy (CuZn-Ag) 50% Tungsten Carbide Tungsten Carbide-Cobalt
Hardness
5500 (37.92) 5500 (37.92)
X X
Note 1 Note 1
Chromium Carbide No. 1 Composite NickelChromium/ Aluminum Composite Alumina/NickelAluminum (55:45) Aluminum, Pure
2000 (13.79) 1200 (8.27)
X X
75% Tungsten Carbide AluminumBronze
X X
Note 1
AluminumBronze Triballoy 400 (CoMoCrSi) Tungsten Carbide-Cobalt
2000 (13.79)
5000 (17.24) 5500 (37.92)
X X
Note 4 Note 1
Chromium Carbide-Nickel Chromium
5000 (34.47)
Note 1
5000 (34.47)
Note 5
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Table 1. Test Requirements for Thermal Spray Coating (Cont) Coating Procedure 70-49-30 (powder) 70-49-31 (powder) Tensile Bond per 70-71-01 psi (MPa) 4000 (27.58) 2500 (17.24) Metallographic Exam per 70-7104 X X
Coatings Triballoy 800 (CoMoCrSi) Nickel AluminumMolybdenum Composite Inconel 718
Hardness Note 6
70-49-32 (powder) (also see 70-4945) 70-49-33 (powder) 70-49-34 (powder) 70-49-35 (powder) 70-49-35 (powder) 70-49-36 (powder) 70-49-37 (powder) 70-49-38 (wire) (also see 70-4910 and 70-49-11) 70-49-39 (wire) (also see 70-4921) 70-49-40 (wire) (also see 70-4901 and 70-49-23) 70-49-43 (powder) 70-49-44 (wire) (also see 70-4917) 70-49-45 (wire) (also see 70-4932)
7000 (48.26)
Alumina, fine AluminumSilicon-Polyester NiCrAlY TBC Inconel 718 (HVOF) Tungsten Carbide-Cobalt (HVOF) Nickel Aluminum, Electric Arc Nickel Chrome Aluminum, Electric Arc Pure Aluminum, Electric Arc Triballoy 800 (CoMoCrSi Powder) HVOF Copper Zinc Silver, Electric Arc Inco 718 Wire, Electric Arc
4000 (27.58) 800 (5.52) 4000 (27.58)
X X X X Note 7
9000 (62.05) 10,000 (62.05)
X X
Note 13 Note 8
4000/5000 (27.6/ 34.47) 4000/5000 (27.6/ 34.47) 1200 (8.27)
8500 (58.61)
Note 9
3000 (20.68)
7000 (48.26)
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Table 1. Test Requirements for Thermal Spray Coating (Cont) Coating Procedure 70-49-46 (powder) 70-49-47 (powder) 70-49-48 (powder) 70-49-49 (wire) (also see 70-4905) 70-49-50 (powder) 70-49-51 (wire) (also see 70-4907 and 70-49-08) 70-49-52 (wire) (also see 70-4925 and 70-49-26) Tensile Bond per 70-71-01 psi (MPa) 10,000 (68.95) Metallographic Exam per 70-7104 X
Coatings Nickel Chrome Silicon Iron, HVOF Aluminum Silicon Poly (Cold Process) Triballoy 800 (CoMoCrSi Powder) HVOF Cu-Ni-In Electric Arc Rene 80 (HVOF) Molybdenum Electric Arc Al-Bronze Electric Arc
Hardness Note 10
800 (5.52)
Note 14
8500 (58.61)
Note 11
2000 (13.79)
9000 (62.05) 2500 (17.24)
X X
Note 12
2000 (13.79)
1. Rockwell hardness test with Rockwell 15-N superficial hardness of 83 (ASTM E18) NOTE: 2. Rockwell hardness test with Rockwell 15-Y hardness of 30-50 (ASME E18) NOTE: 3. Rockwell hardness test with Rockwell 15-Y hardness of 50-70 (ASME E18) NOTE: 4. Rockwell hardness test with Rockwell 15-N superficial hardness of 80 (ASTM E18) NOTE: 5. Rockwell hardness test with Rockwell 15-N superficial hardness of 75 (ASTM E18) NOTE: 6. Rockwell hardness test with Rockwell 15-N superficial hardness of 82 (ASTM 18) NOTE: 7. Rockwell hardness test with Rockwell 15-Y hardness of 65-80 (ASTM E18) NOTE: 8. Rockwell hardness test with Rockwell 15-N superficial hardness of 89 (ASTM E18) and a Vickers 300 gram load of 950-1200 (ASTM E384) NOTE: 9. Rockwell hardness test with Rockwell 15-N superficial hardness of 89 (ASTM E18) and a Vickers 300 gram load hardness of 675 (ASTM E384)
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Table 1. Test Requirements for Thermal Spray Coating (Cont) Coating Procedure Tensile Bond per 70-71-01 psi (MPa) Metallographic Exam per 70-7104
Coatings
Hardness
NOTE: 10. Rockwell hardness test with Rockwell 15-N superficial hardness of 70 (ASTM E18) and a Vickers 300 gram load hardness of 675 (ASTM E384) NOTE: 11. Rockwell hardness test with Rockwell 15-N superficial hardness of 83 (ASTM E18) and a Vickers 300 gram load hardness of 500 (ASTM E384) NOTE: 12. Rockwell hardness test with Rockwell 15-N superficial hardness of 75 (ASTM E18) and a Vickers 300 gram load hardness of 400 (ASTM E384) NOTE: 13. Rockwell hardness test with Rockwell 15-N superficial hardness of 79 (ASTM E18) NOTE: 14. Rockwell hardness test with Rockwell 15-Y hardness of 55-80 (ASTM E18)
Table 2. Test Specimen Material Commercial Name of Test Part Material Specimen Austenitic Steel, Martensitic Steel, AISI 3212 or Hastelloy X Nickel Alloy, or Cobalt Alloy Titanium Alloy A 40, A 110 AT, or Y1 6-4 Aluminum Alloy 5052 or 6061 Specification Reference AMS 5510 (Z10CNT18), or AMS 5536 (NC22FeD) T40 (AMS 4902), TA5E (AMS 4910), or TA6V (AMS 4911) AG3 (AMS 4015) or AG1 (AMS 4025)
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METAL TO METAL BONDING - TESTING AND QUALITY ANALYSIS FOR METAL-TO-METAL BONDING TASK 70-70-01-700-001 1. Testing and Quality Analysis for Metal-to-Metal Bonding SUBTASK 70-70-01-99G-001 A. General. (1) This procedure consists of a series of operations, as contrasted with simple tests such as the cellophane tape pull-test for paint adherence or "feel" tests for bearing end-play. Test specimens and special tools or fixtures required in the performance of specific tasks are described in the procedures that make use of them.
SUBTASK 70-70-01-700-001 B. Metal-To-Metal, Film Adhesive Bonding Quality Tests. (1) All metal-to-metal bondments made with a thermal setting film adhesive must have certain mechanical properties demonstrated in the bonded joints. Process control specimens should be processed identically to and cured concurrently with all repair bondments. The process control (test) specimens must meet the strength requirements detailed in Table 1, Page 1 for the following specimens. (a) Tensile Lap Shear Test. 1 This test is conducted on five specimens at normal and elevated temperatures. Refer to TASK 70-71-05-700-006, Adhesive Bond Strength Lap Shear Testing.
(b)
Climbing Drum Peel Test. 1 This test is conducted on four specimens at room temperature. Specimens are panel assemblies and one face sheet is stripped off. Refer to TASK 70-71-06-700-007, Adhesive Bond Strength Climbing Drum Peel Test.
(c)
Flatwise Tensile Test. 1 This test is conducted on six specimen panel assemblies, three at normal temperature and three at elevated temperatures. Refer to TASK 70-71-07-700-008, Adhesive Bond Strength Flatwise Tensile Testing.
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TESTING AND QUALITY ANALYSIS FOR METAL-TO-METAL BONDING Page 1 Dec 01/03
Table 1. Process Control Specimen Strength Requirements Number of Specimens
Test
Unsupported Film Minimum Average in psi (MPa)
Unsupported Film Minimum Individual in psi (MPa) -
Supported Film Minimum Average in psi (MPa) 2500 psi (17.24)
Supported Film Minimum Individual in psi (MPa) 2250 psi (15.51)
Tensile Lap Shear, *room temperature Tensile Lap Shear, 2953058F (1461528C) for 10 minutes Climbing Drum Peel, *room temperature Flatwise Tensile, *room temperature
1200 psi (8.27)
1100 psi (7.58)
11 pounds inch/ inch (0.49 Nm/cm)
9 pounds inch/inch (0.40 Nm/ cm)
1000 psi (6.89)
900 psi (6.21)
1000 psi (6.89)
900 psi (6.21)
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Table 1. Process Control Specimen Strength Requirements (Cont) Number of Specimens 3
Test Flatwise Tensile, 2953058F (1461528C) for 10 minutes
Unsupported Film 550 psi (3.79)
Unsupported Film 500 psi (3.45)
Supported Film 450 psi (3.10)
Supported Film 400 psi (2.76)
NOTE: * 70-808F (21-278C)
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BOND STRENGTH TENSILE TESTING - BOND STRENGTH TENSILE TESTING OF THERMAL SPRAY COATINGS TASK 70-71-01-700-002 1. Bond Strength Tensile Testing of Thermal Spray Coatings SUBTASK 70-71-01-99G-002 A. General. (1) This procedure describes the method, test specimens and special fixtures required for determining the bond tensile strength of thermal spray coatings when specified in the repair or in TASK 70-70-00-700-001, Testing and Quality Analysis. Use this test procedure when specified in the applicable thermal spray coating procedure. For testing, either a coated tensile button or a coated tensile loading fixture is permitted for tensile evaluation.
SUBTASK 70-71-01-700-021 B. Equipment (1) (2) (3) Tensile testing machine. Tensile bond test assembly fixture per Figure 1 (Sheet 1 of 4), Page 2 or Figure 3, Page 7. Tensile bond test specimen per Figure 2, Page 6.
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BOND STRENGTH TENSILE TESTING OF THERMAL SPRAY COATINGS Page 1 Dec 01/03
Tensile Bond Test Assembly Fixture Figure 1 (Sheet 1 of 4)
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Tensile Bond Test Assembly Fixture Figure 1 (Sheet 4)
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Tensile Bond Test Specimen Figure 2
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Gravity Bond Fixture Figure 3
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-71-01-700-022 C. Material Epoxy Adhesive Adhesive Film or Liquid Materials. Consumable Number C01-100 C01-103 C01-105 C01-146 C10-013 C10-010 C10-117
Release Agent Compound Abrasive Pad
SUBTASK 70-71-01-700-023 D. Tensile Bond Test Assembly Fixture. (1) Use the assembly fixture to align and assemble each test specimen. The test specimen can be either a coated loading fixture/uncoated loading fixture pair or a coated test button between two loading fixtures. The assembly fixture may be made of AISI 300-series stainless steel or an equivalent dent-resistant material. A suitable release agent, such as C10-013, or equivalent, should be applied to the fixture to prevent adherence of the adhesive. See Figure 1 (Sheet 1 of 4), Page 2 or Figure 3, Page 7.
SUBTASK 70-71-01-700-024 E. Tensile Bond Test Specimen. (1) Either test buttons or loading fixtures of the same alloy and heat treatment as the production part that they represent are used to test the bond strength of thermal spray coatings. If buttons are chosen for spraying, the tensile loading fixtures shown in Figure 2, Page 6 can be made from a material other than the production parts. A suggested material is AISI 300 series stainless steel. Alternative materials can be chosen but differences in thermal expansion must be verified. The test specimen should be prepared as follows. See Figure 2, Page 6. (a) Machine the test specimen (button or loading fixture) of the same alloy type as the production part to the dimensions shown (see Figure 2, Page 6). Use at least three specimens per production part. Process the specimens along with, or in identical treatments with the production part. Use the same heat treating, cleaning, and surface preparation for the specimens as for the production parts. Mask circumference of the test specimens, being careful to avoid masking or touching any of the prepared surface. Mount the test specimens (minimum of three) with the production part in such a way they will receive the same application of thermal spray without
(2)
(b)
(c) (d)
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STANDARD PRACTICES MANUAL AS907-1-1A obscuring the part. The coating must be at least 0.005 inch (0.13 mm) thick, and must not vary across the surface more than 0.003 inch (0.08 mm). (e) If you use test buttons, grit blast both faces of each button with 150-mesh grit. Use very low pressure - 20 to 40 psi (0.138 to 0.276 MPa).
SUBTASK 70-71-01-700-025 F. Assembly of Test Specimen. (1) Prepare the test specimen as directed in the following paragraphs. Two loading fixtures are required for each test specimen. (a) Grit blast the face of each loading fixture using 150-mesh grit. Use a very low pressure - 20 to 40 psi (0.138 to 0.276 MPa). Degrease each fixture. This step should be performed even if one of the loading fixtures has been coated. NOTE: It is recommended to use gloves or some other means of covering your hands to prevent transfer of hand oils to the adhesive/bonding surfaces. (b) The tensile specimens can be prepared using the following adhesives listed in Table 1, Page 9 with recommended/suggested curing cycles. 1 2 For materials with a tensile minimum below 2500 psi (17.2 MPa), only film adhesive C01-103 may be used. If using a liquid adhesive C01-100, C01-105, or C01-146, apply a uniform layer of adhesive to the necessary surfaces. If using the coated loading fixture/uncoated loading fixture pair, apply the adhesive to both faces of the loading fixtures. If using the test button, apply the adhesive to both faces of the test button and the mating faces of the loading fixtures. If using the film adhesive C01-103, cut or punch discs from the film sheet that are the same diameter as the tensile specimen. Place a disc between the coated loading fixture/uncoated loading fixture pair or on each side of the button between the uncoated loading fixtures. NOTE: A suitable releasing agent may be applied to the test assemblies and curing fixtures to prevent adherence of adhesive to those surfaces. (c) Either a pressure ( Figure 1 (Sheet 1 of 4), Page 2) or gravity ( Figure 3, Page 7) curing fixture may be used for curing of the assemblies at temperature.
EFFECTIVITY: ALL
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Table 1. Curing Cycle Requirements Consumable C01-100 C01-105 Type Liquid Liquid Suggested* Curing Cycle** 200-2258F (93-1078C) for 1-2 hours 350-3758F (177-1908C) for 1-3 hours 350-3758F (177-1908C) for 1-3 hours 350-4008F (177-2048C) for 1-3 hours Notes None Store in freezer between use to prolong shelf life. Store in freezer between use to prolong shelf life. Store in freezer between use to prolong shelf life.
C01-146
Liquid
C01-103
Film
*This is a recommended starting point and can be changed due to manufacturer recommendations or low results in the adhesive-only pull test. **Choose a cure temperature within the range specified, and control that temperature 108F ( 68C). A higher cure temperature usually results in a higher tensile strength (for a given adhesive). 1 An adhesive-only specimen should also be included in the fixture. This will consist of a specimen with only adhesive between the two loading fixtures. This should pull at 8000-10000 psi (55.2-68.9 MPa). NOTE: When using the adhesive-only test specimen, it is not necessary to apply the shelf life control to the adhesive used for testing in TASK 70-71-01-700-002, Bond Strength Tensile Testing of Thermal Spray Coatings. The data gathered on this test specimen can be used to monitor the cured strength of the adhesive. The adhesive must be discarded as its cured strength approaches the minimum limit. 2 For the gravity fixture ( Figure 3, Page 7) alignment is critical. Inspect the surface of the grooves in the loading fixtures to insure there are no dents or raised areas that could prevent proper alignment of the assemblies. Place the loading fixture threads down into the fixture followed by either adhesive-button-adhesive-loading fixture or adhesive-loading fixture depending on the choice of specimens for spraying. For the pressure fixture, position the test specimen with the loading fixtures and adhesive as described earlier and place the assemblies in the fixture of Figure 1 (Sheet 1 of 4), Page 2 Tighten the clamping screws to a suggested value of 35-40 lb in. (4.0 - 4.5 N.m) of torque. This will apply approximately 900-1000 psi (6.2-6.8 MPa) pressure on specimen. Check for proper alignment before curing. The pressure settings are recommended as a starting point. If the adhesive is continually pulled out between the button/loading fixture, a reduction in
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STANDARD PRACTICES MANUAL AS907-1-1A torque may be necessary. If adhesive only specimens fall below 8000 psi (55.2 MPa), a change in pressure may also be required. (d) Cure the assemblies in the fixture at the suggested time/temperatures listed in Table 1, Page 9 or as recommended by the manufacturer directions. Cure time is dependent upon the cure temperature. Other factors affecting curing are size/material of your curing fixture and tensile fixtures, power/capacity of your oven, etc. Using a thermocouple attached to the curing fixture or a dummy tensile assembly is highly recommended. The curing fixture should cool to a temperature that allows handling of the material without gloves before removing the tensile assemblies from the fixture. (e) After curing, carefully remove any residual adhesive from surfaces adjacent to the bond area by sanding with 180-grit abrasive paper or cloth or abrasive pads C10-117 and C10-010. Mount the test specimen between centers, and check concentricity and alignment with a dial indicator or comparator. Check at each loading fixture, 0.125 inch (3.18 mm) from the adhesive bond. Runout must be within 0.015 inch (0.38 mm) FIR. NOTE: Care must be taken with the abrasive pads to prevent removal of adhesive from between the loading fixtures. SUBTASK 70-71-01-700-026 G. Test Procedure. (1) The tension testing machine shall be capable of applying an increasing tensile load at a constant rate of 940 to 1100 pounds (4.18 to 4.89 kN) per minute or at a constant rate of cross-head travel of 0.030 to 0.050 inch (0.76 to 1.27 mm) per minute. The test specimen shall be at room temperature when tested. Perform the test as follows: (a) (b) Mount and align the test specimen in the tensile test machine so that no bending or twisting strain will be exerted on the specimen. Apply a tensile stress to each test specimen at a constant rate between 1200 and 1400 psi (8.27 and 9.65 Mpa) per minute or at a constant rate of crosshead travel of 0.030 to 0.050 inch (0.76 to 1.27 mm) per minute until rupture occurs. ASTM C-633 is an acceptable test method. Record rupture points for each of the 3 (or more) test specimens. Calculate bond strength by taking ratio of maximum applied load to specimen contact area. Examine the rupture-surface of each test button under 20-30 power magnification to determine if the failure is on epoxy or coating break. If a
(c)
(d)
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STANDARD PRACTICES MANUAL AS907-1-1A substantial epoxy failure is present due to a cause such as insufficient curing, retesting may occur if additional buttons are available. NOTE: Generally, you should discard a batch of adhesive when tensile tests show that the cured strength approaches the minimum limit. But low strength values could be the result of incorrect parameters (such as cure time or temperature). Do not discard a batch of adhesive only because of one bad test. The use of statistical process control (SPC) procedures is recommended to help you decide if tensile test results are false.
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BOND STRENGTH LAP-SHEAR TESTING - BOND STRENGTH LAP-SHEAR TESTING OF THERMAL SPRAY COATINGS TASK 70-71-02-700-003 1. Bond Strength Lap-Shear Testing of Thermal Spray Coatings SUBTASK 70-71-02-99G-003 A. General. (1) This procedure describes the method, test specimens and materials required for determining the bond lap-shear strength of thermal spray coatings. Use this testing procedure when specified in the applicable thermal spray coating procedure.
SUBTASK 70-71-02-700-031 B. Equipment. (1) (2) Testing machine per requirements of ASTM Specification E4. Test specimen per Figure 1, Page 2.
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BOND STRENGTH LAP-SHEAR TESTING OF THERMAL SPRAY COATINGS Page 1 Dec 01/03
Lap-Shear Test Specimen Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-71-02-700-032 C. Material A. Adhesive Film or Liquid (1) FM-1000 (2) EC2186 or EC2086 (3) 2214 SUBTASK 70-71-02-700-033 D. Preparation of Test Specimen. (1) Make test panels of the same type of material and hardness as production parts. The test panels must be prepared for coating in the same manner as the production part and must be coated identically with the part which they represent. See Figure 1, Page 2. (a) Specimen Blanks. 1 Edges of panels adjacent to the bonded joint shall be machined at right angles to the faces, and shall be without bevels or burrs. Dimensions are shown in Figure 1, Page 2. C01-103 C01-105 C01-146 Materials. Solution/Product Number
(b)
Surface Preparation. 1 Before applying the thermal spray coating, mask the specimen so that the coating is applied only to the region shown in Figure 1, Page 2. a After application of the thermal spray coating, the thickness of the coating must be uniform within 0.0005 inch (0.013 mm), and burrs at the coating-mask interface must be removed before bonding. Degrease the center panel, and roughen both surfaces to 100-150 microinches (rms), minimum, by grit blasting. The roughened area must be larger than the area required for bonding.
Bonding the Specimen. a b All surfaces to be bonded must be degreased before bonding. Adhesive for bonding should be C01-103, C01-105 or C01-146. Cut the adhesive film to the size and shape of the bonding area before bonding. Assemble the test panels and adhesive film strip as shown in Figure 1, Page 2; then apply contact pressure of 25 psi (172.4 kPa) for one hour at a temperature of 3008F (1498C) or as recommended by the adhesive manufacturer to bond the panels
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STANDARD PRACTICES MANUAL AS907-1-1A together. When shims are required, use C01-105 adhesive and bond at 3758F (1918C). d When the assembled test specimen has cooled to room temperature after bonding, remove all excess adhesive from the sides by carefully scraping and sanding.
SUBTASK 70-71-02-700-034 E. Testing. (1) Mount the test specimen in a testing machine that conforms to the requirements of ASTM Specification E4. Clamp as follows: (a) Use shims of sufficient thickness to fill the space between the ends of the outer panels so that they will not be bent or sprung by the clamps of the machine when tightened for testing. Align the test specimen in the testing machine so that the jaws and the centerline of the specimen are in a straight line, jaws directly opposite each other, with the imaginary extension of the centerline passing through the points of suspension. The jaws should be no closer than 2 inches (51 mm) to the edge of the lap joint, and must grip tightly and uniformly. The test specimen shall be at room temperature when the test is made. Apply load at a constant rate between 940-1100 lbs/min (4.18-4.89 KN/min) or a headspeed travel rate of 0.05 inch/min (1.3 mm/min) until the test specimen shears. ASTM C-633 is an acceptable test method.
(b)
(c) (d)
SUBTASK 70-71-02-700-035 F. Test Results. (1) Record the following information derived from the test. (a) (b) (c) Maximum applied load at failure. Length and width of shear area(s), measured to nearest 0.010 inch (0.25 mm) to calculate surface area of bonded joint. Shear strength is expressed by the following formula: Shear strength, psi (MPa) = Applied Load, lb (N) divided by Surface area of bonded joint, sq. in. (sq mm) (d) Nature or location of failure, such as: 1 2 3 Cohesive failure of thermal spray coating. Cohesive failure of adhesive. Failure of adhesion between thermal spray coating and substrate metal.
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STANDARD PRACTICES MANUAL AS907-1-1A 4 5 Failure of bond between adhesive and thermal spray coating. Failure of bond between adhesive and center panel. NOTE: If the test fails in the adhesive below specified values, it indicates a bad test specimen and the test should be repeated.
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SCRATCH-HARDNESS TESTING - SCRATCH-HARDNESS TESTING OF THERMAL SPRAY COATINGS TASK 70-71-03-700-004 1. Scratch-Hardness Testing of Thermal Spray Coatings SUBTASK 70-71-03-99G-004 A. General. (1) Abradable coatings applied by thermal spraying can be evaluated satisfactorily by the scratch-hardness test. This procedure describes the technique and equipment used for the test, and the method of evaluating it.
SUBTASK 70-71-03-700-041 B. Equipment. (1) The following items are required for performing the scratch-hardness test: (a) (b) Hoffman scratch-hardness tester, Model SG-1610 (modified), obtainable from BYK-Gardner. Refer to the List of Suppliers in SUBTASK 70-80-00-800-003. Pocket optical comparator C05-112, having 10 power magnification, with a reticle having 0.005 inch (0.13 mm) scale divisions. (Fine-scale reticle No. 121, or equivalent.)
SUBTASK 70-71-03-700-042 C. Procedure. (1) Conduct the scratch-hardness test as directed in the following steps: (a) Preparation of Test Specimen. The test specimen is a flat plate which has been processed with the production part that it represents, and which is made of the same material. Minimum coating thickness should be 0.035 inch (0.90 mm). Size of the test specimen is not critical; however, the sprayed area should be at least 1 x 3 inches (25 x 76 mm) to permit satisfactory testing. Prepare the specimen for testing as follows: 1 2 3 Test is to be conducted on the as-sprayed surface. Do not file or smooth the coating surface. Dust surface of thermal sprayed area with fine white talc. Using a cardboard straightedge, scrape off excess talc to a thin, uniform coating which will provide contrast between the surface and the scratch path. Place on a flat supporting surface, with the test surface up.
SCRATCH-HARDNESS TESTING OF THERMAL SPRAY COATINGS Page 1 Dec 01/03
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STANDARD PRACTICES MANUAL AS907-1-1A (b) Test Setup. 1 Prepare the equipment for making the test, as follows: a Insert the carbide scratching point as deeply as possible into the carriage of the Hoffman scratch-hardness tester, and secure in place. Place the beam in the carriage by inserting the 2 notches at the pointed end of the beam into the pivoted stirrup above the scratching tool so that the notches interlock firmly with the pins. Set the left edge of the rider weight at number 20 on the beam. This setting places a 2000 gram load on the scratching tool.
c (c)
Performing the Test. 1 Make the scratch test in accordance with the following steps: a Position the carriage of the tester on the prepared surface of the test specimen so that a 2 inch (51 mm) long scratch can be made. Hold the carriage with the right hand so that all 4 wheels are in contact with the coated surface of the test specimen. Simultaneously, raise the beam of the tester with the left hand. With the beam still raised, grasp the carriage directly over the pair of wheels nearest the scratching tool with the thumb and first 2 fingers of the right hand. See Figure 1, Page 3. Hold the carriage so that the wheels are firmly in contact with the test surface during the test. Lower the beam gently with the left hand until the scratching tool rests unsupported on the test surface. Draw the carriage across the test surface in a straight line for approximately 2 inches (51 mm), making sure that all 4 wheels of the carriage and the scratching tool maintain contact with the test surface. Make a total of 3 scratches, employing the technique described in steps (2) through (4) above. The scratches should be approximately parallel, and about 0.250 inch (6.35 mm) apart.
c d
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Hoffman Scratch-Hardness Tester Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-71-03-700-043 D. Evaluating the Test. (1) Using the pocket-sized optical comparator, measure the width of the scratches as follows: (a) (b) (c) Measure 3 places on each of the 3 scratches. The values should be read at mid-point and about 0.50 inch (12.7 mm) from each end of each scratch. Determine the widths by counting the number of scale divisions across the scratch. Record. Average the 9 readings obtained and report this value as the Hoffman Scratch Hardness Number.
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METALLOGRAPHIC EVALUATION - METALLOGRAPHIC EVALUATION OF THERMAL SPRAY COATINGS TASK 70-71-04-700-005 1. Metallographic Evaluation Of Thermal Spray Coatings SUBTASK 70-71-04-99G-005 A. General. (1) This procedure describes the method of preparation and the evaluation criteria used to determine the integrity of thermal spray coatings as required per the shop manual or TASK 70-70-00-700-001, Testing and Quality Analysis. The most expedient method of detecting voids, oxide inclusions, unmelted particles, phase separation, and other metallurgical deficiencies in thermal spray coatings is by the microscopic comparison of the test specimen with the photomicrograph of a standard of known quality. The preparation of test specimens and the interpretation of photomicrographs requires considerable experience and practice, as well as complete familiarity with the particular equipment available in a given laboratory. Recognizing this inherent diversity, the following text presents only those practices for the guidance of the metallographer that have proven generally satisfactory in the preparation of coated specimens. For example, training is available from Metcut Research. Refer to the List of Suppliers in SUBTASK 70-80-00-800-003. This training will assist the metallographer in developing effective, equivalent procedures to evaluate thermal spray coatings.
(2)
(3)
SUBTASK 70-71-04-700-051 B. Equipment. (1) (2) (3) (4) (5) Sectioning equipment. Refer to SUBTASK 70-71-04-700-053, Preparation of Specimens. Grinding/polishing equipment. Refer to SUBTASK 70-71-04-700-053, Preparation of Specimens. Consumables. Refer to SUBTASK 70-71-04-700-053, Preparation of Specimens. Microscope and associated tools. Photostandards. See Table 3, Page 12.
SUBTASK 70-71-04-700-053 C. Preparation of Specimens. (1) General
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METALLOGRAPHIC EVALUATION OF THERMAL SPRAY COATINGS Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A (a) Metallographic preparation of thermal spray samples involves the preparation of a composite specimen composed of the coating and substrate material. Coating types can vary from soft porous abradables to dimensional restoration metal build-ups to hard face materials. Many coatings with similar properties can be prepared using a universal standard method. However, materials at the soft or hard end of the spectrum may necessitate special considerations. Methods developed for metallic-only samples can be used for coating samples with two important considerations: 1 2 (c) Coatings are usually more heterogeneous in nature than (for example) wrought or cast metals. Coatings can be more sensitive to damage (such as smearing and pullout) during preparation.
(b)
These considerations substantiate the recommendation of semi-automated or automated grinding/polishing machines for thermal spray materials in lieu of manual polishing for consistent reproducibility and control of process parameters.
(2)
Sectioning (a) Many spray shops eliminate the need for sectioning by spraying a small sample that can be mounted and then ground/polished to an appropriate plane for review/interpretation. If sectioning is required, two common methods are abrasive wheel cutting or diamond wire cutting. The following considerations should be made: 1 2 Always section with the cut force from coating to substrate. Use minimal clamping pressure and, if possible, a soft cushion such as wood to secure the specimen for sectioning. This will minimize possible cracking of the coating and alteration of the structure. When sectioning, the usage of a thin sectioning wheel will minimize damage which must be removed in subsequent steps. Apply minimum pressure during actual cutting to minimize possible overheating of the specimen and alteration of the structure. Wheels which are comprised of a binder that breaks down readily exposing fresh cutting surfaces are usually best for a wide range of coatings. For the choice of sectioning method, it is critical to maintain written procedures and identify the critical parameters requiring control for consistent techniques.
(b)
3 4 5
(3)
Cleaning
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STANDARD PRACTICES MANUAL AS907-1-1A (a) Cleaning is an important step after sectioning; cleaning removes all contaminates from the surface of the specimen and removes any fluids that may have penetrated into the coating of the material, especially porous materials. Recommended methods of cleaning may include the following or any combination thereof: 1 2 Washing with soap and water. Brushing or soaking of sample in solvent-like materials such as acetone/alcohol followed by application of heat with a heat gun or hotplate to drive off any internal absorption. Cleaning of sample by performing an initial/extra vacuum step (if using vacuum impregnation in mounting) to volatilize any entrapped materials.
(4)
Mounting (a) Mounting is a very critical step for metallography of coatings because this procedure serves to hold the sample together during grinding/polishing. This is especially true for porous materials. Methods for mounting of coating materials are suggested below and sometimes used together. 1 2 (c) Hot Mounting (in a press). Cold Mounting (can be assisted by heat, vacuum impregnation, or pressure impregnation).
(b)
Suggested mounting materials for coatings are: 1 2 Hot mount epoxies. Cold mount epoxies.
(d)
Choice of mounting procedure/material should be driven by: 1 2 3 4 Time available for mounting. Size/level of porosity in coating and degree of interconnected porosity. Required viscosity of epoxy for impregnation of porosity, if important. Hardness of coating vs. mounting material.
(e)
For porous coatings like abradables, thermal barrier coatings (TBC), and other materials, cold mounting with vacuum impregnation and/or pressure impregnation is recommended. The viscosity of the cold mount epoxy will be important if porosity in the coating is small and difficult to impregnate. A well impregnated sample will also show less tendency towards pullout of phases and microstructure damage.
(f)
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STANDARD PRACTICES MANUAL AS907-1-1A (g) For the choice of mounting method/material, it is critical to maintain written procedures and identify the critical parameters requiring control for consistent techniques.
(5)
Grinding/Polishing (a) There are many methods/formats available for preparation of coating samples primarily encompassing traditional grinding papers and the relatively new disc systems. Critical parameters that must be considered/controlled in preparation are: Description Applied/specified per mount Both the table and specimen holder Relative rotation of the head with respect to the table Grinding: disc vs. grinding papers Polishing: no-nap vs. high-nap clothes Diamond, SiC, colloidal silica, Al2O3 How samples are placed in the holder with respect to wheel rotation How often is lubricant/abrasive applied Oil, water, alcohol Define general amount with either manual or automatic application. Duration for the individual steps (c) When choosing a preparation method for a coating type, the following items must be considered: 1 2 3 4 5 6 (d) Aggressiveness of grinding/cutting action. Hardness of coating vs. abrasive type. Tendency of coating phases to be pulled out. Composition of coating phases to prevent chemical attack. Degree of impregnation from mounting. Tendency of smearing (closing porosity).
(b) Parameter Pressure Speed Rotation direction Format Abrasive Orientation Frequency Type of lubricant Quantity of lubricant Time
When initial grinding is performed, care must be taken to remove cut-off damage if the sectioning step was used. If an as-sprayed coupon was mounted, remove sufficient material to eliminate any coating edge effects. Many laboratories use aluminum oxide grinding stones for removal of this initial material.
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STANDARD PRACTICES MANUAL AS907-1-1A (e) Polishing formats for coatings usually involve moderate to extended times on no-nap clothes followed by short finishing steps on higher-nap clothes. Care must be taken to avoid over polishing with colloidal silica in the final polishing steps. Typical procedures involving both grinding paper and disc formats are shown in Table 1, Page 6 and Table 2, Page 7. These procedures may require modification for different coatings and equipment available in specific laboratories. Equipment is available that will control some or all of the critical parameters. These semi-automatic/automatic machines, in conjunction with written procedures that monitor/control critical parameters, will result in consistent and reproducible results. Periodic calibration and maintenance of the equipment will assure reliability and repeatability.
(f)
(g)
(h) (6)
Consumables (a) Consumables used in the metallographic process are obviously very critical to the final result. It is important to obtain high quality materials to insure reproducibility and consistent results. Although consistency from a reliable manufacturer is usually good, products from company to company can vary due to lack of standards within the industry. Changes in consumable suppliers should be considered carefully. It is suggested that if changes are made to an already established procedure with new consumables, some trial samples should be run to insure similar performance and results. Some issues that can occur are: 1 2 3 4 The amount of grit deposited on a grinding paper can vary resulting in removal differences during grinding. The amount of diamond in a suspension can vary resulting in removal differences during polishing. The distribution of particle size in a suspension can vary resulting differences in materials removal and possibly scratch retention. Changes in the type of carrier in a suspension can affect material removal rate and performance. This may also affect the corrosive potential of the solution. Over-polishing can result with the excessive time/usage of colloidal silica.
5 (7)
Use of Physical Metallographic Standards (a) A relatively new concept is the use of metallographic standards similar to hardness blocks for Rockwell machines. For daily calibration of the hardness tester, a hardness block is tested to insure the machine is reading within the range of the block. A similar principle can be used with known metallographic mounts or standards.
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STANDARD PRACTICES MANUAL AS907-1-1A (b) Changes can occur in preparation machines and consumables without the metallographer detecting the variance. Preparation with semi-automatic/ automatic machines usually involves grinding/polishing of more than one mount. If the metallographer has a known sample from either a good spray run in the past or possibly a Round Robin in the thermal spray industry, the metallographer can place that specimen in the rack before being run. If the results on the known sample are similar to previous values, it can be assumed that the procedure is under control. If results are different, something has changed in preparation and an investigation of the metallographic technique is in order. This procedure is not suggested for every rack of mounts that is prepared. Some recommended situations may be: 1 2 3 4 Periodic sampling such as once every two weeks, or more frequent if the use of the machine is not on a daily basis. Results indicate a failing spray run and the production group cannot identify a reason for the unacceptable values. Introduction of new consumables of grinding/polishing methods. Sources of these metallographic standards can be: a b c Internal company Round Robins between sites. Participation in industry Round Robins. Passing samples from previous spray runs that may have been reviewed and accepted by a company representative. Table 1. Grinding Paper Format Surface Grinding Papers Grit Size 180 Pressure per Mount 5 lbs. Speed (rpm) Time 300 Abrasive Lubricant Usually water
(c)
SiC 30 sec (enough papers to flatten specimen and remove damage/ edge effects) 30 sec (usually 2 papers per grit size) SiC
Grinding Papers
240 thorough 800/1200
5 lbs.
300
Usually water
No-nap Cloth
5 lbs. Can be in the range of 1 to 6 micron diamond
300
Poly or Can be in the range of monocrystal-line 1 to 4 diamond minutes
Usually water or alcohol
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Table 1. Grinding Paper Format (Cont) Surface Higher-nap Cloth Grit Size Usually 0.05 micron Pressure per Mount 5 lbs. Speed (rpm) Time 300 Abrasive Lubricant
Usually 15 to Col-loidal Usually 30 sec silica, Al2O3 water or alcohol
NOTE: All Rotations are Complimentary.
Surface Fixed Diamond or Comp-osite Disc
Grit Size 40 to 60 micron
Pressure per Mount 5 lbs.
Speed (rpm) Time 300 2 to 4 min (enough papers to flatten specimen and remove damage/ edge effects) 3 to 5 min. (usually 2 papers per grit size) Can be in the range of 1 to 4 minutes
Abrasive Poly- or Monocrystal-line diamond
Lubricant Usually water
Fixed Diamond or Comp-osite Disc No-nap Cloth
6 to 9 micron 5 lbs.
300
Poly- or Monocrystal-line diamond Poly or monocrystal-line diamond
Usually water
5 lbs. Can be in the range of 1 to 6 micron diamond Usually 0.05 micron 5 lbs.
300
Usually water or alcohol
Higher-nap Cloth
300
Usually 15 to Col-loidal Usually 30 sec silica, Al2O3 water or alcohol
NOTE: All Rotations are Complimentary.
SUBTASK 70-71-04-700-054 D. Metallographic Evaluation. (1) Definitions (a) The following definitions should be used for evaluation: 1 Interface Contamination Embedded foreign particles or contamination between the base metal and the coating. This contamination may be in the form of base metal oxides, grit, or residual coating remaining from previous stripping operations.
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STANDARD PRACTICES MANUAL AS907-1-1A 2 Coating Contamination Foreign material present in the coating. This contamination may be in the form of metallic or ceramic particles. These particles may come from nozzle hardware, contaminated powder feed systems, etc. 3 Transverse Crack A linear or branched separation with random direction within the coating that must be greater than 0.001 inch (25 micrometers or 1 mil) to be ratable. 4 Delamination A separation or horizontal defect that follows, or is associated with, contour of the linear build-up or coating layers that must be greater than 0.005 inch (125 micrometers or 5 mil) to be ratable. For linear interface defects, see Separation. 5 Field of View (FOV) A unit area as viewed or photographed using normal light microscopy. A unit of measure to aid in evaluation to determine the percentage of occurrence for a particular condition. 6 Grit Blast Inclusion Embedded abrasive particle associated with the substrate surface preparation. 7 Hardness Resistance to deformation. 8 Integrity Overall coating quality primarily associated with oxides porosity and unmelted particles. 9 Layering Stratification of coating components or features. 10 Oxide Oxidized coating constituent. 11 Oxide Clusters Concentration of oxides that must be greater than 0.003 inches (75 micrometers) to be ratable. 12 Oxide Stringers Linear oxides. 13 Porosity Typical holes within a coating.
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STANDARD PRACTICES MANUAL AS907-1-1A 14 Pull-out Mechanically induced damage associated with metallographic preparation 15 Separation A defect that follows, or is associated with, the contour of the interface. It must be longer than 0.005 inches (125 micrometers) to be ratable. For linear intracoating defects, see Delamination. 16 Straight-line Interface A condition associated with insufficient roughening of the surface prior to spraying. 17 Unmelted Particles Unreacted powder particles contained within the coating matrix. These particles have a round or globular appearance (3:2 ratio), are not adhered to the surrounding coating matrix by any more than 25%, and are greater than 0.002 inch (50 micrometers) in any direction. 18 Uniformity Homogenous distribution of coating constituents (e.g. phases, porosity, oxides, etc.). (2) Rules for Metallographic Evaluation of Coated Test Samples (a) Bondcoat Systems (Two areas): 1 2 Must review bond between bond and top coatings. Must review bond between bond coat and substrate. NOTE: A single preparation method may not be suitable to review both bond and top coatings. (b) Transverse Coating Cracks: 1 2 3 (c) Review for cracking. All indications of less than 0.001 inch (25 micrometers) shall not be considered a defect. Defects shall be repolished and re-evaluated.
Delamination 1 2 3 Review for delaminations. All indications of less than 0.005 inch (125 micrometers) in length shall not be considered a defect. Defects shall be repolished and re-evaluated.
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STANDARD PRACTICES MANUAL AS907-1-1A (d) Edge Effects 1 (e) Do not evaluate coating areas less than 0.010 inch (250 micrometers) from the test piece edge of coating runout.
FOV (Field of View) 1 2 3 Shall be representative of a particular or predominate condition. A periodic sampling across the coating sample. When addressing specific rejectable conditions, they are to be characterized by measuring the affected fields of view.
(f)
Microhardness 1 2 3 Do not measure hardness within 3 measured indication diagonals of coating edges, substrates, surfaces, or areas of coating runout. Indentations shall be made on the transverse cross section, in representative areas and traversing the thickness. Microhardness testing shall be performed on metallographically prepared surfaces and comprise the average of at least 5 impressions.
(g)
Illumination 1 Bright field shall be used for comparison with photographic standards.
(h)
Magnification 1 Same as the Photomicrographic standards.
(i)
Mount Material 1 Cold mounting is preferable. NOTE: Vacuum impregnation is recommended for porous coatings like TBCs and abradables.
(j)
Repolishing/Regrinding 1 Repolishing is limited to two (2) times. This means a maximum total of three (3) preparation cycles is permitted, comprising the initial preparation and two (2) repolish cycles. Repolishing is only permitted for metallurgically induced defects such as cracks, delamination, separation, pull-out, phase contrast, and spalling.
(k)
Sample Size 1 Suggested panel size shall be 0.060 inch (1.5 mm) thick x 0.75 inch (19 mm) width x 1.5 inch (38.1 mm) length.
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STANDARD PRACTICES MANUAL AS907-1-1A 2 If minimal panel size is not practical, coated panels used for metallographic evaluation shall be large enough to avoid edge defects and cutting defects. Minimum separation between cuts shall be 0.5 inch (12.8 mm). Specimen shall be cut through the width. NOTE: The spray direction can influence the metallographic result. (l) Thickness 1 Coating thickness for metallographic investigation shall be 0.008-0.012 inch (200-300 micrometers) for a single coating. For a duplex coating, the bond coat shall be 0.003-0.008 inch (75-200 micrometers) and the top coat shall be 0.008-0.012 inch (200-300 micrometers).
3 4
(m)
In-between Condition 1 If the visual interpretation is in-between the rejectable and the acceptable photomicrographic standards, it must be rated to the lower (worst) condition.
(3)
General Microstructure Evaluation (a) When specified by the applicable manual, metallographic examination of the prepared specimen shall be made for the following other conditions: 1 Porosity. Examine at 200-500X. Estimate visually, quantify by image analysis, quantify by grid count, or compare to appropriate photostandards. Porosity shall be uniformly distributed. 2 Interface Contamination and Separation. Examine at 200-500X for the presence of contamination. This may be in the form of oxides, grit, or residual coating from previous stripping operations. Estimate the percent of contamination for comparison to acceptance values in either number or photostandard format. The coating shall be free of interface separations as defined in TASK 70-7104-700-005. 3 Unmelts Examine at 200-500X for the total percent of unmelts for comparison to acceptance values in either number or photostandard format. Unmelts can be associated with porosity and oxides. Ratable unmelts shall be determined by examination of size, shape, and bonding for each particle. 4 Oxides and Oxide Clusters Examine at 200-500X, noting the presence of oxides that may appear in either stringer or globular form. Care must be taken not to include porosity as part of the oxide content. The coating shall be free of oxide
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STANDARD PRACTICES MANUAL AS907-1-1A clusters as defined in TASK 70-71-04-700-005. Oxides shall be uniformly distributed. 5 Transverse Cracks Examine at 500X. When evaluating for cracks, it is most important to differentiate between cracks caused by mechanical damage and those which are intrinsic to the structure. Cracks that are perpendicular to the base metal may sometimes be caused by flexion of the substrate or by thermal stresses. The later types of cracks are to be noted. The coating shall be free of delaminations as defined in TASK 70-71-04-700-005. 6 Delaminations Examine at 200X. When evaluating for delaminations, it is most important to differentiate between delaminations caused by mechanical damage and those which are intrinsic to the structure. Delaminations which propagate along or parallel to the base metal interface are commonly (but not always) a result of mechanical damage. The coating shall be free of delaminations as defined in TASK 70-71-04-700-005. 7 Integrity Examine at 200-500X. This is a measure of the overall coating quality and soundness. This characteristic applies to metallurgical abnormalities such as areas of loosely bonded coating, pieces of the gun nozzle in the structure, and other rejectable conditions. The coating shall show acceptable integrity as defined in TASK 70-71-04700-005. Table 3. Photo Cross Reference Figure No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Photo No. 8603003 317961 321659* 321660* C72031014 9008005 9008006 9008007 9008008 317966 325698 325699 325700 8907003 Figure No. 15 16 17 18 19 20 21 22 23 24 25 26 27 Photo No. 8907002 8710001 9010008 8807028 8807029 8007221 8704002 9011003 8806001* 9308001 S8873 9209001 S26217
*The requirement for these photos has been deleted. Copies will no longer be supplied.
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Void Content in Thermal Sprayed Coatings (200X) Figure 1
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Void Content in Thermal Sprayed Coatings (500X) Figure 2
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Total Void Content in Nickel-Graphite Sprayed Coatings (50X) Figure 3
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Oxide Content in Thermal Sprayed Coatings (200X) Figure 6
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Void and Oxide Inclusions in Coating-Substrate Interface of Thermal Sprayed Coatings (200X) Figure 7
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Unmelted Particle Content in Thermal Sprayed Coatings (200X) Figure 8
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Cobalt-Rich Phase Content in Tungsten Carbide Thermal Sprayed Coatings (500X) Figure 9
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Total Void and Inclusion Content in Thermal Sprayed Coatings (100X) (Note: Inclusions outlined in G3.) Figure 10
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Metallic-Ceramic Phase Distribution in Cermet Thermal Sprayed Coatings (250X) Figure 11
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C-4 Figure 12
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Metallic-Ceramic Phase Distribution in Cermet Thermal Sprayed Coatings (250X) Figure 13
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Aluminum Oxide Coating Microstructures Figure 14
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Typical Features - Aluminum Oxide Coating Figure 15
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Typical Micro Structure of Aluminum Silicon Polyester Abadable Coating Figure 16
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Apparent Porosity of Ceramic Thermal Barrier Coating Figure 17
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Microstructure Typical of Ceramic Thermal Barrier Coating Figure 20
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Voids Porosity and Oxides in HVOF Coating Figure 21
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Inconel 718 HVOF Spray, Preferred Microstructure Figure 22
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Voids Porosity and Oxides in as Sprayed Coating Figure 23
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Oxide Content in as Sprayed Figure 24
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Voids and Porosity in as Sprayed Coating Figure 25
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Apparent Total Nickel-Graphite Thermal Sprayed Coating at 50X Figure 26
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Voids, Porosity, and Oxides in As-Sprayed Coating (Diamond Polished) at 200X and 500X Figure 27
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ADHESIVE BOND STRENGTH - ADHESIVE BOND STRENGTH TENSILE LAP SHEAR TESTING TASK 70-71-05-700-006 1. Adhesive Bond Strength Tensile Lap Shear Testing SUBTASK 70-71-05-99G-006 A. General. (1) This procedure describes the method and test specimens required for determining the tensile lap shear strength of film adhesive bondments. Use this test procedure when specified in Standard Practice film adhesive bonding procedure or applicable manual repair.
SUBTASK 70-71-05-700-061 B. Equipment. (1) (2) (3) Tooling to prepare specimens. Testing machine. Specimens per Figure 1, Page 2.
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ADHESIVE BOND STRENGTH TENSILE LAP SHEAR TESTING Page 1 Dec 01/03
Lap Shear Specimen Figure 1
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-71-05-700-062 C. Materials. (1) Material to be tested is specified in each applicable manual repair.
SUBTASK 70-71-05-700-063 D. Preparation of Specimen. (1) One panel assembly is required to make a total of five 1.00 inch (25.4 mm) wide lap shear specimens with a 0.50 inch (12.7 mm) lap. See Figure 1, Page 2. (a) Unless otherwise specified by the applicable manual repair, the panel assembly is to consist of 2 details 2024-T3 bare aluminum 4 x 6 x 0.63 inches (102 x 152 x 1.60 mm). Both details are to be cleaned, prepared and primed in an identical manner and concurrently with the detail parts of the repair being performed. NOTE: All edges of the metal panels and specimens which will be within (or which will bound) the joints shall be machined true (without burrs or bevels and at right angles to faces) and smooth (16 AA maximum) before the panels are surface treated and bonded. (b) The 2 details of the panel assembly are to be bonded, in a 0.50 inch (12.7 mm) lap along the 6 inch (152 mm) side. They are to be bonded with 0.095 lb/sq. ft. supported adhesive identical to and concurrently with the detail parts of the repair being performed. NOTE: Process control specimens may be bagged on a separate tool provided that the vent line from this tool is interconnected with at least one of the vent lines from the assembly being bonded. Interconnection of the vent lines shall be accomplished in such a manner that any pressure variation on one assembly will be accurately reflected on the other. (c) Prepared panels are cut into 1 inch (25 mm) wide specimens as in Figure 1, Page 2. Panels should not be cut into specimens until at least 24 hours after bonding. Aluminum-alloy panels may be sawed with a bandsaw, with the setting and spacing of the teeth and operational speed adjusted to hold frictional heating of the bond to a minimum. Two specimens are prepared with a thermocouple for elevated temperature tests. See Figure 1, Page 2.
SUBTASK 70-71-05-700-064 E. Testing. (1) For the normal temperature tensile shear test 3 specimens are used. The test specimen is gripped tightly and uniformly across the ends in the jaws of the testing machine with the jaws and specimen so aligned that the jaws are directly opposite each other, and in such a position that an imaginary straight line will pass through the center of the bonded area and through the points of suspension. The specimen is gripped 2 0.25 inches (51 6.4 mm) from each edge of the lap joint. The load shall then be applied at a rate of 940-1100 pounds per minute or at an equivalent head speed travel of 0.030-0.050 inch/minute (0.76-1.27 mm/minute).
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STANDARD PRACTICES MANUAL AS907-1-1A (2) For analytical purposes, the following should be recorded: (a) (b) The load at failure. (The testing machine accuracy should be within 1 percent.) Length and width of shear area measured to the nearest 0.01 inch (0.3 mm). [All failing loads are expressed in pounds per square inch of actual shear area, calculated to the nearest 0.01 sq. in. (6.4 sq. mm)]. Nature and percent of failure, such as: 1 2 3 (d) Cohesive failure (failure within adhesive). Adhesion failure (adhesive peeling from the metal). Contact failure (lack of complete adhesive-to metal contact during bonding).
(c)
Adhesive (micrometer) thickness (measured to the nearest 0.001 inch (0.03 mm) of the overall thickness of lap joint) less the combined micrometer thickness of the individual pieces of surface treated metal or the adhesive thickness can be measured with a traveling comparator microscope or an equivalent measuring apparatus.
(3)
The average and minimum strengths of the 3 specimens should equal or exceed that listed in Table 1, Page 2 in TASK 70-70-00-700-001, Testing and Quality Analysis. For the elevated temperature tensile shear tests, 2 specimens are used. These tests are performed as in paragraph 1.E.(1) with the added requirement that a suitable oven or furnace be provided to maintain the specimens at 3008F (1498C). The tests are made 10 minutes after the specimen has reached equilibrium at temperature. The specimen is brought to temperature within 3 minutes to 10 minutes maximum. The average and minimum strengths of the 2 specimens should equal or exceed that listed in Table 1, Page 2 in TASK 70-70-00-700-001, Testing and Quality Analysis.
(4)
(5)
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ADHESIVE BOND STRENGTH - ADHESIVE BOND STRENGTH CLIMBING DRUM PEEL TASK 70-71-06-700-007 1. Adhesive Bond Strength Climbing Drum Peel SUBTASK 70-71-06-99G-007 A. General. (1) This procedure describes the method and test specimens required for a climbing drum peel test to determine the strength of a face sheet-to-honeycomb bondment. Use this test procedure when specified in Standard Practice film adhesive bonding procedure or applicable manual repair.
SUBTASK 70-71-06-700-071 B. Equipment. (1) (2) (3) Tooling to prepare specimens. Specimens per Figure 1, Page 2 and Figure 2, Page 3. Peel test apparatus per Figure 3, Page 4.
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ADHESIVE BOND STRENGTH CLIMBING DRUM PEEL Page 1 Dec 01/03
Test Specimen Bondment Figure 1
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Sandwich Peel Specimen Figure 2
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Climbing Drum Sandwich Peel Test Figure 3
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-71-06-700-072 C. Materials. (1) Material to be tested is specified in each Engine/Shop Manual repair.
SUBTASK 70-71-06-700-073 D. Preparation of Specimen. (1) Panel assemblies are fabricated sufficiently large to cut into 4 each 3 x 12 inch (76 x 305 mm) specimens. When repair also calls for flatwise tensile tests (TASK 70-7107-700-008, Adhesive Bond Strength Flatwise Tensile Testing), the panel should be constructed large enough to contain specimens for both tests. See Figure 1, Page 2. (a) The panel assembly consists of 2 face sheets and a honeycomb core. These pieces are to be cleaned, prepared and primed in an identical manner and concurrently with the detail parts of the repair being performed. NOTE: All edges of the metal panels and specimens which will be within (or which will bound) the joints shall be machined true (without burrs or bevels and at right angles to faces) and smooth (16 AA maximum) before the panels are surface treated and bonded. (b) Unless otherwise specified by Engine/Shop Manual repair, both face sheets are made 10 x 28 x 0.020 inches (254 x 711 x 0.51 mm) 2024-T3 aluminum alclad. The face sheets are to be etched and primed identically to the detail parts in the repair process. Unless otherwise specified by the Engine/Shop Manual repair, the honeycomb core is made 10 x 28 x 0.50 inches (254 x 711 x 12.7 mm) high, 7.81/4-40 (5052) NP aluminum honeycomb core. The ribbon direction is parallel to the 28 inch (711 mm) dimension. The core is degreased, dried, primed and baked identically to the detail parts in the repair process. The panel assembly is made with one sheet bonded to core with 0.095 lb/sq. ft. supported adhesive and the other with 0.075 lb/sq. ft. unsupported adhesive. On the sheet being bonded with the supported adhesive, mark the word up. Bond this sample specimen panel to a procedure identical to that used in the Engine/Shop Manual repair. NOTE: Prior to bonding unsupported adhesive, a hole should be pricked in each cell to aid reticulation (beading). This may be accomplished by perforating the adhesive on a bed of phonograph needles, spaced to conform to honeycomb cell width. Back up adhesive with plywood covered with a sheet of rubber. (e) Upon completion of the specimen panel bonding, strip the skin from the supported adhesive side, which was marked up. This produces a specimen which should be similar to and is to be processed with the parts being repaired. Prepare the surface of the honeycomb for a second bond. Clean off excessive adhesive, degrease, dry, prime and bake identically to the detail parts in the
(c)
(d)
(f)
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STANDARD PRACTICES MANUAL AS907-1-1A repair process. Prepare the face sheet for a second bond, etch and prime as for detail parts of the repair. (g) Bead unsupported adhesive to the prepared honeycomb surface. A heat gun may be used. Prick each cell to reticulate adhesive to cell wall. Apply supported adhesive to the prepared surface of the face sheets. Be sure that the face sheet is marked up. Bond the specimen panel assembly identically to and con-currently with the detail parts of the repair being performed. NOTE: Process control specimens may be bagged on a separate tool provided that the vent line from this tool is interconnected with at least one of the vent lines from the assembly being bonded. Interconnection of the vent lines shall be accomplished in such a manner that any pressure variation on one assembly will be accurately reflected on the other. (i) Cut 4 climbing drum peel specimens from the panel assembly (see Figure 1, Page 2 and Figure 2, Page 3). Identify the up side on each specimen, as in paragraph 4.A.(4). Panels should not be cut into specimens until at least 24 hours after bonding. Panels may be cut with a bandsaw with the setting and spacing of the teeth and operational speed adjusted to hold frictional heating of the bond to a minimum. NOTE: Ribbon direction of the core is to be parallel to the long side of the specimen. (j) Prepare specimens by cutting back one face sheet and the core at both ends. See Figure 2, Page 3.
(h)
SUBTASK 70-71-06-700-074 E. Testing. (1) A suggested peel test apparatus consists of a drum with flanges, flexible loading straps around the flanges and clamps for holding the test specimen. See Figure 3, Page 4. The drum should have a counterweight, diametrically opposite the clamp and of such a mass as to balance the drum about its axis. The drum with flanges and clamp and the counter-weight should weigh 8 lbs. (3.6 kg) maximum. The drum radius is 1.995-2.005 inches (50.67-50.93 mm). The drum clamp fixes the specimen face sheet such that its center-line lies on the drum radius. The flange radius is to the centerline of the strap and is 0.495-0.505 inch (12.57-12.83 mm) greater than the drum radius. The test setup is made by clamping the sandwich securely in place at the top (see Figure 3, Page 4) and loading the apparatus in tension at a head speed of 1 0.01 inch (25 0.3 mm) per minute. A head speed of 2 inch (25 mm) per minute peels the sandwich facing at a rate of 4 inches (102 mm) per minute. The test machine should be capable of measuring load accurately within 1 percent. Prior to the start of the peeling test, the specimen and apparatus is suspended from the top head of the testing machine and the weighing apparatus balanced to zero. The loading bar is then pinned to the lower fixed fitting and an initial load (Fo) is applied that is
(2)
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STANDARD PRACTICES MANUAL AS907-1-1A equal to that required to overcome the resisting torque exerted by the weight of the drum and that required to bend the facing. NOTE: This load (Fo) can be determined by inserting a strip of metal of the same width, thickness, and material used in the facing of the sandwich panel to be tested in place of the facing of the sandwich specimen and applying a load sufficient to roll the drum upward around the metal sheet. (3) During the peel test, an autographic recording is made on the load (Fp) versus head movement or of the load versus distance peeled. The average load required for peeling shall be taken from the autographic curve for the 5 inches (127 mm) of peeling of the sandwich specimen and between 1 and 6 inches (25 and 152 mm) corresponding to 1.25 inches (31.8 mm) of head travel after the first 0.25 inch (6.4 mm). The average load is determined by scaling the curve by means of a planimeter. NOTE: For an alternate method, if autographic equipment is not available for acceptance testing, the approximate average may be obtained by averaging recorded loads at fixed increments of time after the start of the test. The load should be recorded 15 seconds after the start of the test and at each 5 second interval thereafter until 6 inches (152 mm) of the specimen are peeled. NOTE: During testing, specimens must be at a stabilized temperature of 708-808F (218-278C). (4) To peel specimen, load Fp is applied to the loading bar (see Figure 3, Page 4) to peel as in paragraph D.(3). The torque required to peel the adhesive bond is calculated from the formula: Torque = (Fp-Fo) x (R2-R1) divided by W where R1 and R2 are the 2 drum radii ( Figure 3, Page 4) Fo is the initial load and W is the width of the specimen to the nearest 0.010 inch (0.25 mm). See Figure 2, Page 3. (5) The required torque must meet or exceed the minimum values given in Table 1, Page 2 in TASK 70-70-00-700-001, Testing and Quality Analysis.
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ADHESIVE BOND STRENGTH - ADHESIVE BOND STRENGTH FLATWISE TENSILE TESTING TASK 70-71-07-700-008 1. Adhesive Bond Strength Flatwise Tensile Testing SUBTASK 70-71-07-99G-008 A. General. (1) This procedure describes the method and test specimens required for a flatwise tensile test to determine the tensile strength of a honeycomb panel assembly bondment. Use this test procedure when specified in Standard Practice film adhesive bonding procedure or applicable manual repair.
SUBTASK 70-71-07-700-081 B. Equipment. (1) (2) (3) Tooling to prepare test specimens. Test specimens per Figure 1, Page 2 and Figure 2, Page 3. Tensile testing machine.
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ADHESIVE BOND STRENGTH FLATWISE TENSILE TESTING Page 1 Dec 01/03
Test Specimen Bondment Figure 1
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Flatwise Tensile Specimen Figure 2
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-71-07-700-082 C. Material. (1) Material to be tested is specified in each Engine/Shop Manual repair.
SUBTASK 70-71-07-700-083 D. Preparation of Specimen. (1) Panel assemblies are fabricated sufficiently large to cut into 6 each 2 x 2 inch (51 x 51 mm) specimens. When repair also calls for climbing drum peel tests ( TASK 7071-06-700-007, Adhesive Bond Strength Climbing Drum Peel), the panel should be constructed large enough to contain specimens for both tests. See Figure 1, Page 2. (a) The panel assembly consists of 2 face sheets and a honeycomb core. These pieces are to be cleaned, prepared and primed in an identical manner and concurrently with the detail parts of the repair being performed. NOTE: All edges of the metal panels and specimens which will be within (or which will bound) the joints shall be machined true (without burrs or bevels and at right angles to faces) and smooth (16 AA maximum), before the panels are surface treated and bonded. (b) Unless otherwise specified by Engine/Shop Manual repair, both face sheets are made 10 x 28 x 0.020 inches (254 x 711 x 0.51 mm) 2024-T3 aluminum alclad. The face sheets are to be etched and primed identically to the detail parts in the repair process. Unless otherwise specified by the Engine/Shop Manual repair, the honeycomb core is made 10 x 28 x 0.50 inches (254 x 711 x 12.7 mm) high, 7.81/4-40 (5052) NP aluminum honeycomb core. The ribbon direction is parallel to the 28 inch (711 mm) dimension. The core is degreased, dried, primed and baked identically to the detail parts in the repair process. The panel assembly is made with one sheet bonded to core with 0.095 lb/sq. ft. supported adhesive and the other with 0.075 lb/sq. ft. unsupported adhesive. On the sheet being bonded with the supported adhesive, mark the work up. Bond this sample specimen panel to a procedure identical to that used in the Engine/Shop Manual repair. NOTE: Prior to bonding unsupported adhesive, a hole should be pricked in each cell to aid reticulation (beading). This may be accomplished by perforating the adhesive on a bed of phonograph needles, spaced to conform to honeycomb cell width. Back up adhesive with plywood covered with a sheet of rubber. (e) Upon completion of the specimen panel bonding, strip the skin from the supported adhesive side, which was marked up. This produces a specimen which should be similar to and is to be processed with the parts being repaired. Prepare the surface of the honeycomb for a second bond. Clean off excessive adhesive, degrease, dry, prime and bake identically to the detail parts in the
(c)
(d)
(f)
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STANDARD PRACTICES MANUAL AS907-1-1A repair process. Prepare the face sheet for a second bond, etch and prime as for detail parts of the repair. (g) Bead unsupported adhesive to the prepared honeycomb surface. A heat gun may be used. Prick each cell to reticulate adhesive to cell wall. Apply supported adhesive to the prepared surface of the face sheets. Be sure that the face sheet is marked up. Bond the specimen panel assembly identically to and con-currently with the detail parts of the repair being performed. NOTE: Process control specimens may be bagged on a separate tool provided that the vent line from this tool is interconnected with at least one of the vent lines from the assembly being bonded. Interconnection of the vent lines shall be accomplished in such a manner that any pressure variation on one assembly will be accurately reflected on the other. (i) Cut 6 flatwise tensile specimens from the panel assembly. See Figure 1, Page 2 and Figure 2, Page 3. Panels should not be cut into specimens until at least 24 hours after bonding. Panels may be cut with a bandsaw with the setting and spacing of the teeth and operational speed adjusted to hold frictional heating of the bond to a minimum. Machine all edges of the specimens, true, without burrs or bevels, at right angles to faces and to the dimensions. See Figure 2, Page 3.
(h)
SUBTASK 70-71-07-700-084 E. Testing. (1) The test specimens are bonded to aluminum blocks which are capable of mounting in a tensile test machine as follows: See Figure 2, Page 3. (a) Test specimens are bonded to aluminum blocks using adhesive EA934NA C01-011. Loading blocks are to be locally manufactured. See Figure 2, Page 3. Bond is cured at 3008F (1508C) and 25 psi (172.4 kPa) for 15 minutes. The specimens are assembled so that the holes in the 2 loading blocks, on opposite sides of the core, are at 90 degrees to each other. For normal temperature flatwise tensile tests 3 specimens are used. See TASK 70-70-00-700-001, Testing and Quality Analysis. The specimen is assembled to the tensile test machine and the tensile load applied at a constant rate of movement of the movable head of the testing machine of not less than 0.015 inch (0.38 mm) and not more than 0.020 inch (0.51 mm) per minute until failure. The maximum load and type of failure shall be recorded. All failing loads shall be expressed in psi (kPa) using the actual test area, calculated to the nearest 0.01 in.2 (0.065 cm2). The average and minimum strengths of the 3 specimens should equal or exceed that listed in TASK 70-70-00-700-001, Testing and Quality Analysis. For the elevated temperature flatwise tensile test, 3 specimens are also used. These tests are performed [refer to paragraphs 5.A.(1) and (2)] with the added requirement that a suitable oven or furnace be provided to maintain the specimens at 3008F (1508C). The tests are made 10 minutes after the
(b)
(c) (d)
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STANDARD PRACTICES MANUAL AS907-1-1A specimen has reached equilibrium at temperature. The specimen is brought to temperature within 3 minutes minimum to 10 minutes maximum. The final testing temperatures of all specimens for elevated temperature tests are those of the surface of the metal as close to the bonded area as possible. The temperature is determined with a thermocouple, firmly attached, in order to ensure accuracy and repeatability of test data. If radiant heating devices are used, the thermocouples must be properly shielded. (e) The average and minimum strengths of the 3 specimens should equal or exceed that listed in TASK 70-70-00-700-001, Testing and Quality Analysis.
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CONSUMABLE MATERIALS - CONSUMABLE MATERIALS SECTION TASK 70-80-00-800-011 1. Consumable Materials Section SUBTASK 70-80-00-99G-011 A. General. WARNING: TO PROTECT YOURSELF AND THE ENVIRONMENT, PRIOR TO USING ANY OF THE CONSUMABLE MATERIALS SPECIFIED IN THIS MANUAL OR RELATED COMPONENT-SPECIFIC MANUALS, YOU MUST KNOW AND OBEY ALL OF THE INSTRUCTIONS AND WARNINGS OF THE MANUFACTURER OR SUPPLIER OF THE MATERIALS. THEIR INSTRUCTIONS AND WARNINGS GIVE THE FOLLOWING: WARNING: HAZARDOUS PROPERTIES OF THE MATERIAL SAFE USE OF THE MATERIALS CORRECT STORAGE OF THE MATERIALS MEANS OF RECOGNIZING AND TREATING POSSIBLE HEALTH EFFECTS
WARNING:
YOU MUST UNDERSTAND AND FOLLOW THE MATERIAL SAFETY DATA SHEETS (MSDS) (OSHA FORM 20), AND THE CONTAINER WARNING LABELS FROM THE MANUFACTURER OR SUPPLIER OF THE MATERIAL. IF YOU DO NOT RESPECT AND FOLLOW THEIR INSTRUCTIONS AND WARNINGS, YOU CAN BECOME INJURED OR SICK.
(1)
The consumable section (70-80-XX) of the Standard Practices Manual is divided into the following sections: (a) 70-80-00: This section gives general instructions on how to use the consumable data in this manual and information on how order materials. It also includes a List of Suppliers that gives the current name, address, phone and fax numbers, and email data (where available) for each supplier. 70-80-01 thru 70-80-10: These sections give the listing for each consumable material, and are divided into three columns: 1 2 The left column gives the consumables in numerical order. The middle column gives the generic name of the consumable material and specific data about that material. The trade name (in bold) is the name given to the material by the supplier. If other data about a product is available (such as whether the product is unavailable or Notes about material usage) this information is listed in the line immediately below the specific trade name.
(b)
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CONSUMABLE MATERIALS SECTION Page 1 Dec 01/03
STANDARD PRACTICES MANUAL AS907-1-1A 3 The right column gives the suppliers name for each material that is currently available. The same supplier name is used in the List of Suppliers (Step 1.D.) along with the suppliers latest address and other ordering information - see Subtask 70-80-00-800-003, List of Suppliers.
(c) (d) (e) (2)
70-80-20: This section is a cross reference listing of all the trade names (the specific names given to each product by its manufacturer). 70-80-30: This section is a cross reference listing of all suppliers (in alphabetical order). 70-80-90: This section is a cross reference listing of every consumable material used in the SPM (sections 70-00-00 thru 70-71-08).
Each Consumable Material listed in the applicable manuals is given a code number that starts with a C. The categories of consumable materials are as follows: C01: Adhesives, Plastics, Sealants C02: Anti-Seize Compounds, Lubricants, Oils C03: Finishes and Protective Coatings C04: Cleaning Compounds and Solvents C05: Inspection and Marking Compounds C06: Weld, Braze C07: Thermal Spray C10: Miscellaneous
SUBTASK 70-80-00-800-001 B. How To Use This Information. (1) To find information on a consumable material, look it up in the 70-80-01 thru -10 sections by its reference number. If the material is currently available, there will be at least one specific trade name (in bold) under the consumable number. Chose a supplier in the right column and order the specific trade name immediately to the left of the chosen supplier. Get the suppliers address, phone number, and other ordering information from Subtask 70-80-00-800-003, List of Suppliers. Using sections 70-80-01 thru 70-80-10: Figure 1 shows a sample page of typical consumable listings. The legend for Figure 1 is as follows: 1 - The consumable number. 2 - The generic name. This is a name assigned by Honeywell to describe the material and any specifications for the material.
(2)
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STANDARD PRACTICES MANUAL AS907-1-1A 3 - The trade name (bold). This is the name given to the product by the supplier for use when ordering. For all currently available materials, the applicable supplier name is given in the third column immediately to the right of the trade name. NOTE: If the space to the right of the trade name is blank, that specific trade name is not available. See paragraph 1.B.(3). for information on unavailable materials. 4 - Status Comments. These comments are immediately UNDER the applicable material. Status comments tell whether the material is obsolete, deleted, or if it has an equivalent alternative. 5 - Notes. These comments are used to give additional ordering information about the material immediately ABOVE the Note. 6 - The supplier name. (3) Unavailable Materials: A new protocol has been established for removing products from the 70-80-00 consumable section of the Standard Practices Manual. When a product is removed, the generic and trade names will remain in the manual for historical purposes, but the name of the suppliers will be removed. For all listings where history is available, this format has been incorporated for all consumables in this manual. If a replacement consumable is not evident from reviewing all the repair documentation, please contact the SPM representative at Honeywell for clarification. (a) Obsolete (Repair requirement no longer exists) The supplier has discontinued this product and it is no longer available. There is no identified need for a replacement product. Remaining material in stock can still be used if the expiration date has not changed and another special application is identified. No supplier name is given in the third column immediately to the right of the obsoleted trade name. For example, in Figure 1, the listing for C01-020 shows an obsolete material. Note that there is no supplier name given to the right of the trade name. (b) Obsolete: (Replaced by C0x-xxx) (Product numbering change at supplier) The supplier has discontinued this product and it is no longer available. Remaining material in stock can still be used if the expiration date has not passed. Since there is still an identified need for this consumable product, an alternative replacement product will be referenced when identified. No supplier name is given in the third column immediately to the right of the obsoleted trade name. For example, in Figure 1, the listing for C01-020 shows an obsolete material. Note that there is no supplier name given to the right of the trade name. Sometimes, the supplier changes the numbering or identification of the product but there is no change in the actual product. This will usually result in a reference to the new product listed directly below the deleted or obsoleted product under the same C0x-xxx number.
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STANDARD PRACTICES MANUAL AS907-1-1A (c) Obsolete: (No additional note) The supplier has discontinued this product and it is no longer available. Remaining material in stock can still be used if the expiration date has not passed. If there are multiple products available for the consumable number, a specific replacement is not identified. One of the other products should be selected. (d) Deleted: (Replaced by C0x-xxx) (Repair requirement no longer exists) (Duplicate entry - see C0x-xxx) The product may have been deleted from the manual by Honeywell for some technical reason such as inadequate performance or problems in engine performance. The requirement for repair could also have been deleted from the applicable manual. No supplier name is given in the third column immediately to the right of the obsoleted trade name. For example, in Figure 1, the listing for C01-043 shows a deleted material. Note that there is no supplier name given to the right of the trade name. (e) Deleted: (for various environmental or safety reasons) (Ozone depleting chemical) (High VOC content) (Other environmental, health, or safety reasons) Many chemicals have been deleted from use due to environmental issues. In most cases replacements are listed for the consumables that are no longer environmentally friendly. However, in some situations (such as 1,1,1 trichloroethane) there is no standard replacement for all applications that use this cleaning consumable. Some replacement may be identified in the appropriate Standard Practices Manual section, such as the 70-21-xx cleaning methods, in this case. No supplier name is given in the third column immediately to the right of the obsoleted trade name. For example, in Figure 1, the listing for C01-043 shows a deleted material. Note that there is no supplier name given to the right of the trade name. (4) Mixing Instructions: Many consumables require mixing prior to application and use in the repair of aircraft engine hardware. Solution sheets (identified as Sxxxx) found in 70-00-99 of the SPM, are sometimes used to indicate the proper mixing instructions. If the mixing required note is shown in the consumable listing in 70-80-xx, please refer to the 70-80-90 section which lists the solution sheets for various consumables. If a solution sheet does not exist, follow the mixing instructions in the appropriate SPM task, or in the applicable manual repair. If the manufacturers instructions deviate from the steps listed in the Honeywell documentation, please contact the SPM representative at Honeywell for clarification. (5) Changes:
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STANDARD PRACTICES MANUAL AS907-1-1A (a) The consumable information in this manual is believed to be correct at time of publication of the latest revision. Due to the large number of materials covered in this manual and the constantly changing nature of consumable materials, this information can become out-of-date at any time. If you find an error, please tell your Honeywell Representative so we can change the data in the manual as soon as possible.
SUBTASK 70-80-00-800-002 C. Procurement Information. (1) The consumable products given in this manual can be obtained from the companies in the List of Suppliers (Step 4) As consumable products of companies change, the information will be changed in this manual. In the applicable manuals and in process documents, consumable products are frequently referred to by their Consumable Numbers and, in some cases, Trade Names are also referred to. In these cases, review the applicable 70-80-XX section of this Standard Practices Manual to get the newest information about the products approved for use, or recommended as replacements for a specific Consumable Number. It is recommended that you have the Thomas Register of American Manufacturers available to help you find source location and product information. The Thomas Register can be obtained from: The Thomas Publishing Company One Penn Plaza New York, NY, USA 10119 Ph: (212) 695-0500 Telex 12-6266 NYK Fax: (212) 290-7362 (2) Material Safety Data Sheets (MSDS) are available from the product manufacturer or supplier. These MSDS sheets are also available as a fee-paid service from Information Handling Services Inc. In the different lists of consumable products (70-80-XX), a Honeywell or aircraft industry specification is referred to in the description of some consumable products. In these cases, alternative products can replace the product described in the list, as far as we know, if they agree with the requirements of the specification that is referred to. Frequently, the specification includes a Data for Ordering (DFO) or a Qualified Products List (QPL) to show which products are approved. If the specification does not include a DFO or QPL, the user will have to accept the suppliers certification and request a copy of the test data. The test data must show that the alternative product agrees with the requirements of the specification that is referred to. If questions occur, contact your local Honeywell representative for technical assistance. In the different lists of consumable products (70-80-XX), the Manufacturer of a consumable product is usually given as the primary source of the product. Frequently, a group of authorized distributors are approved by the initial manufacturer to supply the product. These authorized distributors are considered approved sources for the consumable products given in this manual. Distributors who repackage or relabel the initial product with a different name or product identification are not considered approved sources for the products.
(3)
(4)
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STANDARD PRACTICES MANUAL AS907-1-1A SUBTASK 70-80-00-800-003 D. List of Suppliers. (1) This is the list of suppliers of consumable materials, equipment, and services. 3M Company 3M Center, (Product Information Center) Bldg, 304-0101 St. Paul, MN 55144 USA Phone: 800 364 3577 Alt Phone: 651 737 6501 Fax: 800 713 6329 Alt Fax: 651 737 7117 5 Star NDT 9206 Lakewood Blvd. Suite 168 Downey, CA 90240 USA Phone: 562 923 5532 Fax: 562 923 5032 A and B Deburring Co. 525 Carr St. Cincinnati, OH 45203 USA Phone: 513 723 0777 Fax: 513 723 0444 A.T. McAvoy 2650 Baird Road Fairport New York, NY 14450 USA Abrasive Finishing, Inc. 11770 Dexter Rd. Chelsea, MI 48118 USA Phone: 313 475 9111 Alt Phone: 313 475 3300 Email: AFI@aol.com Accumetric, LLC 350 Ring Road Elizabethtown, KY 42701 USA Phone: 270 769 3385 Fax: 270 765 2412
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STANDARD PRACTICES MANUAL AS907-1-1A Acheson Colloids Co. P.O. Box 611747 1600 Washington Ave. Port Huron, MI 48061 USA Phone: 800 255 1908 Alt Phone: 810 984 5581 Fax: 810 984 1446 Advanced Systems Technologies Incorporated (AST) 6000 Technology Drive, Bldg. 8 Huntsville, AL 35807-7019 USA Phone: 256 721 2313 Fax: 256 721 2529 Aeroquip E.F.G. Aerospace Group 300 South East Avenue Jackson, MI 49203-1972 USA Phone: 517 787 8121 Fax: 517 789 2786 Aerospace International Materials (AIM) 264 Center Street Miamiville, OH 45147 USA Phone: 513 831 2938 Fax: 513 831 3859 Air Products and Chemicals Inc. 7201 Hamilton Blvd. Allentown, PA 18195-1501 USA Phone: 800 722 3769 Alt Phone: 610 481 6799 Fax: 610 481 4381 Airtech International Inc. 5700 Skylab Road Huntington Beach, CA 92647 USA Phone: 714 899 8100 Fax: 714 899 8179 Airworthy Ltd. Elsted, Midhurst GU 29 OJT England Phone: 44 1730 811920
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STANDARD PRACTICES MANUAL AS907-1-1A Fax: 44 1730 811930 Email: zok@zok.com Akzo Nobel Aerospace Coatings E. Water Street Waukegan, IL 60085 USA Phone: 847 623 4200 Alt Phone: 847 625 3340 Fax: 847 623 9011 Alt Fax: 847 625 3332 Alconox, Inc. 9 East 40th Street Suite 200 New York, NY 10016 USA Phone: 212 532 4040 Fax: 212 532 4301 Email: cleaning@alconox.com Aldrich Chemical Co., Inc. P.O. Drawer 335 Milwaukee, WI 53201 USA Phone: 800 558 9160 Alt Phone: 414 273 3850 Fax: 800 962 9591 Alt Fax: 414 273 4971 AlliedSignal Amorphous Metals 101 Columbia Rd. Morristown, NJ 07962 USA Phone: 973 455 5592 Fax: 973 455 5596 Alloy Surfaces Co., Inc. 100 Locke Road Wilmington, DE 19809 USA Phone: 302 762 8900 Fax: 302 762 7213 American Casting and Mfg. Co. 51 Commercial St. Plainview, NY 11803 USA
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STANDARD PRACTICES MANUAL AS907-1-1A Phone: 800 342 0333 Alt Phone: 516 349 7010 Fax: 516 349 8389 American Gas and Chemical Company, Ltd. 220 Pegasus Ave. Northvale, NJ 06747 USA Phone: 800 288 3647 Alt Phone: 201 767 7300 Fax:201 767 1741 Anchor Chemical Company 777 Canterbury Road Westlake, OH 44145 USA Phone: 800-749-6843 Alt Phone:440-871-1660 Fax: 440-871-0665 Email: anchorlube@now-online.com Applied Chemicals International Pty. Ltd. 121 Lewis Road Private Bag 35 Wantirna South, Victoria 3152 Australia Phone: 613 9837 8888 Fax: 613 9837 8809 Email: info@apchem.com.au APW Zero Cases 500 West 200 North North Salt Lake, UT 84054 USA Phone: 801 298 5900 Fax: 801 292 9450 Arc Abrasives 190 Peters Avenue P.O. Box 387 Troy, OH 45373 USA Argent Ltd. 11966 Brookfield Livonia, MI 48150 USA Phone: 734 427 5533
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STANDARD PRACTICES MANUAL AS907-1-1A Fax: 734 427 4368 Arlon Inc., Silicone Technologies Division 1100 Governor Lea Rd. Bear, DE 19701 USA Phone: 800 635 9333 Alt Phone: 302 834 2100 Fax: 302 834 4021 Arrow Chemicals Ltd. Stanhope Road Swadincote, Derbyshire DE11 9BE England Phone: 01283 221044 Fax: 01283 225731 Email: info@arrowchem.com Ashland Chemical Inc. P.O. Box 2219 Columbus, OH 43216 USA Phone: 888 293 4427 Fax: 800 324 7519 Ashland Chemicals 5200 Blaxer Pky. Dublin, OH 43017 USA Phone: 800 322 6580 Fax: 614 790 3206 Asia Pacific Microspheres (Manufacturer) SDN BHD, P.O. Box 7086 40702 Shah Alam Selangor Darul Ehsan, Malaysia Phone: 60 3559 1801 Fax: 60 3550 2168 Associated Spring Barnes Group Inc. 18 Main Street Bristol, CT 06010 USA Phone: 860 582 9581 Fax: 860 582 1358 ASTM 100 Barr Harbor Drive
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STANDARD PRACTICES MANUAL AS907-1-1A West Conshohocken, PA 19428-2959 USA Phone: 610 832 9585 Fax: 610 832 9555 Astro Chemical Co., Inc. 3 Mill Road P.O. Box 1250 Ballston Lake, NY 12019 USA Phone: 518 399 5338 Fax: 518 399 8859 Astrolite Alloys Division of Astro Cosmos Metallurgical, Inc. 1201 Vanguard Dr. Oxnard, CA 93033 USA Phone: 888 278 7644 Fax: 805 487 9694 Email: carole@astrolite.com Atofina Chemicals 2000 Market St. Philadelphia, PA 19103 USA Phone: 215 419 5611 Alt Phone: 215 419 7688 Fax: 215 419 7064 Alt Fax: 215 419 5788 Email: rhonda.ellis@atofina.com B and B Tritech Inc. P.O. Box 660-776 Miami, FL 33266-0776 USA Phone: 305 888 5247 Fax: 305 887 4587 B.C.S Company, Inc. 763 Thompson Road Thompson, CT 06277 USA Phone: 800 367 3821 Fax: 860 923 2093 Bacon Industries 16731 Hale Ave. Irvine, CA 92606 USA
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STANDARD PRACTICES MANUAL AS907-1-1A Phone: 949 863 1499 Fax: 949 863 0105 Bassett Rotary Tool Co. 710 W. Fisher Street Monticello, IN 47900 USA 219 583 7166 219 583 6026 Bay State Surface Technologies, Inc. 201 Washington Street Auburn, MA 01501 USA 800 772 0104 508 366 2456 508 832 5043 508 366 7318 sales@aimtek.com Beck Chemical, Inc. 3350 W. 137th St. Cleveland, OH 44111 USA 216 941 8355 216 252 4249 Bergen Cable Technologies, Inc. 170 Gregg St. P.O. Box 1300 Lodi, NJ 07644 USA 800 237 4369 201 487 3521 201 368 0532 BF Goodrich Ice Protection Systems 1555 Corporate Woods Parkway Uniontown, OH 44685 USA 800 334 2377 330 374 3040 330 374 2290 BGF Industries 3802 Robert Porcher Way Greensboro, NC 27410 USA
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STANDARD PRACTICES MANUAL AS907-1-1A 800 925 1961 336 546 0233 BGR, INC. 6392 Gano Road West Chester, OH 45069 USA 800 628 9195 513 755 7100 513 755 7855 BH Thermal Corp. 1055 Gibbard Ave. Columbus, OH 43201 USA Phone: 800 959 0860 Alt Phone: 614 294 3376 Fax: 614 294 2672 BioChem Systems, Div. of Golden Tech. 3311 North Ohio Ave. Wichita, KA 67219 USA Phone: 800 777 7870 Alt Phone: 316 838 4739 Fax: 316 832 1211 Birchwood Casey Div., Birchwood Laboratories, Inc. 7900 Fuller Rd. Eden Prairie, MN 55344 USA Phone: 800 328 6156 Alt Phone: 612 937 7913 Fax: 612 937 7979 Boekel Scientific 855 Pennsylvania Blvd. Feasterville, PA 19053 USA Phone: 215 396 8200 Bollore ZI Route De Crulai 61300 LAigle, France Bostik, Inc. (Domestic Sales) 211 Boston Street Middleton, MA 01949 USA
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STANDARD PRACTICES MANUAL AS907-1-1A Phone: 978 777 0100 Fax: 978 750 7306 Bostik, Inc. (International Sales) 211 Boston Street Middleton, MA 01949 USA Phone: 978 777 0100 Fax: 978 750 7840 BP Amoco Polymers Inc. 4500 McGinnis-Ferry Rd. Alpharetta, GA 30005 USA Phone: 800 222 2448 Alt Phone: 770 772 8594 Fax: 770 772 8258 Branson Ultrasonics Corporation 41 Eagle Road Danbury, CT 06813-1961 USA Phone: 203 796 2298 Fax: 203 796 0320 Email: bsmith@bransoncleaning.com Breyden Products, Inc. 17485 Catalpa Suite B-2 Hesperia, CA 92345 USA Phone: 760 244 7948 Fax: 760 244 6704 Bron Tapes 845 Navajo Street Denver, CO 80204 USA Phone: 800 782 8807 Alt Phone: 303 534 7387 Fax: 303 534 3694 Brush Research Mfg. Co. Inc. 4642 E. Floral Dr. Los Angeles, CA 90022 USA Phone: 323 261 2193 Fax: 323 268 6587
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STANDARD PRACTICES MANUAL AS907-1-1A Buehler Limited 41 Waukegan Rd. Lake Bluff, IL 60044 USA Phone: 800 283 4537 Alt Phone: 847 295 6500 Fax: 847 295 7979 BYK-Gardner 1100 East-West Highway Silver Springs, MD 20910 USA Cabot Corporation 700 E. U.S. Hwy 36 Tuscola, IL 61953 USA Phone: 800 222 6745 Alt Phone: 217 253 3370 Fax: 217 253 5564 Caig Laborotories, Inc. 12200 Thatcher Court Poway, CA 92064 USA Phone: 858 486 8398 Fax: 858 486 8398 Email: caig123@caig.com Calvary Chemical Corp. 9233 Seward Rd. Fairfield, OH 45014-5407 USA Phone: 513 874 1113 Fax: 513 860 6184 Canvas Specialties 7344 Bandini Blvd. Los Angeles, CA 90040 USA Phone: 323 722 1156 Fax: 323 724 3848 Carbide Probes, Inc. 1328 Research Park Drive Dayton, OH 45432 Carborundum Co. 2770 West Washington St.
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STANDARD PRACTICES MANUAL AS907-1-1A Stephenville, TX 76401 USA Phone: 800 231 4154 Fax: 800 458 3448 Castrol Industrial North American Inc. Specialty Products Division 1001 W. 31st. Downers Grove, IL 60515 USA Phone: 800 590 9855 Alt Phone: 973 887 7410 Fax: 973 887 6930 Cataphote Inc. P.O. Box 2369 Jackson, MI 39225-2569 USA Phone: 601 939 4612 Fax: 601 932 5339 Ceramic Grains and Powder Division Norton Company / Division of Saint Gobain 1 New Bond St. Worcester, MA 01615-0008 USA Phone: 508 795 5238 Alt Phone: 508 795 2812 Fax: 508 795 2380 Alt Fax: 508 756 5556 Cerro Metal Products Co. Alloy Dept. P.O. Box 388 Bellefonte, PA 16823 USA Phone: 814 355 6357 Fax: 814 355 6227 Champions Choice, Inc. P.O. Box 5968 Orange, CA 92613 USA Phone: 714 635 4491 Fax: 714 635 9716 Chemetall Oakite 50 Valley Rd. Berkeley Heights, NJ 07922 USA Phone: 800 526 4473
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STANDARD PRACTICES MANUAL AS907-1-1A Alt Phone: 908 464 6900 Fax: 908 464 4658 Email: oakite.products@chemetall.com Chemetall Plc 65 Denbigh Road Bletchley Milton Keynes, MK1 1PB United Kingdom Phone: 44 1908 649333 Fax: 44 1908 373939 Chemtech Finishing Systems 23177 Commerce Drive Farmington Hills, MI 48335 USA Phone: 248 478 5200 Fax: 248 478 6810 Chicago Pneumatic Tool Co. 1800 Overview Rock Hill, SC 29730 USA Phone: 888 298 2905 Fax: 800 298 2905 Chromalox 701 Alpha Drive Pittsburgh, PA 15238 USA Phone: 412 967 3900 Fax: 412 967 3938 Cincinnati Milacron 4201 Marburg Ave. Cincinnati, OH 45209 USA Phone: 513 841 8121 Fax: 513 841 7178 Clemco Industries 1 Cable Car Drive Washington, MO 63090 USA Phone: 800 788 0599 Alt Phone: 636 239 0300 Fax: 636 239 0788 Email: info@clemcoindustries.com
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STANDARD PRACTICES MANUAL AS907-1-1A Coatings For Industry Inc. 319 Township Line Road Souderton, PA 18964 USA COMET 27, Avenue Etienne Audibert 60304 Senlis-Cedex, France Conap, Inc. 1405 Buffalo St. Olean, NY 14760 USA Phone: 800 836 3666 Alt Phone: 716 372 9650 Fax: 716 372 1594 Consortium International Pharmaceutiques et Chimique 7 Rue Lincoln 75008 Paris, France Corro Therm Inc. 19050 Philmont Ave. Feasterville, PA 19053 USA Phone: 800 726 7948 Alt Phone: 215 322 5255 Fax: 215 322 3023 Email: info@corrotherm.com CRC Industries, Inc 885 Louis Drive P.O. 5000 Warminster, PA 18974-0586 USA Phone: 215 674 4300 Alt Phone: 800 272 4620 Fax: 215-674-2196 Email: customerservice@crcindustries.com Cutler-Hammer Inc. Power Distribution and Control Div. 5201 North 27th Street Milwaukee WI 53216 USA Creanova 220 Davidson Ave.
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STANDARD PRACTICES MANUAL AS907-1-1A Somerset, NJ 8873 USA Phone: 732 981 5000 Fax: 732 560 6707 Alt Fax: 732 560 6912 Creative Coatings Co. Inc. 4650 Mound Rd., Dept. 5 Warren, MI 48091 USA Phone: 800 394 6552 Alt Phone: 810 755 0035 Fax: 810 755 0039 Cytec Engineered Materials Inc. Product Referral Office 5 Garret Mountain Plaza West Paterson, NJ 07424 USA Phone: 800 652 6013 Alt Phone: 973 357 3100 Fax: 973 225 3599 Cytec Eur. 3 Rue EA Peugeot 92508 Rueil Malmaison, France Phone: 33 (1) 30.61.90.01 D & B Industrial 2-4 Cedar Creek Ave. Georgetown, DE 19947 USA Phone: 302 855 0585 Fax: 302 855 0588 Daniels Mfg. Corp. 526 Thorpe Road Orlando, FL 32824 USA Phone: 407 855 6161 Fax: 407 855 6884 Email: dmctools@aol.com Dapra Corporation 66 Granby Street Blomfield, CT 06002 USA
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STANDARD PRACTICES MANUAL AS907-1-1A Phone: 860 286 8728 Alt Phone: 800 442 6275 Fax: 860 242 3017 Email: info@dapra.com Deft Inc. 17451 Von Karman Ave. Irvine, CA 92614 USA Phone: 714 474 0400 Fax: 714 474 7269 Delta Petroleum Inc. 10352 River Road St. Rose, LA 70087 USA Phone: 504 467 1399 Fax: 504 467 1398 Dentsply/Caulk Division P.O. Box 359 Milford, DE 19963 USA Phone: 800 532 2855 Alt Phone: 302 422 4511 Fax: 800 788 4110 DeWal Industries 15 Ray Trainor Dr. P.O. Box 372 Saunderstown, RI 02874 USA Phone: 401 789 9736 Fax: 401 783 6780 Email: mfoulke@dewal.com Dip Seal Plastic Inc. 2311 23rd. Ave. Rockford, IL 61104 USA Phone: 800 739 9059 Alt Phone: 815 398 3533 Fax: 815 398 0353 Dixie Industrial Supply Company 1105 Nandino Blvd. Lexington, KY 40511 USA
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STANDARD PRACTICES MANUAL AS907-1-1A Dixon Ticonderoga 2444 Ridgeway Blvd. Lakehurst, NJ 08733 USA Phone: 800 752 4739 Alt Phone: 632 757 2255 Fax: 632 757 2323 Dixon Ticonderoga Co. 195 International Pky. Heathrow, FL 32746 USA Phone: 800 824 9430 Alt Phone: 407 829 9000 Fax: 800 232 9396 Alt Fax: 407 829 2574 DODSSP Document Automation & Production Service 700 Robbins Avenue (Building 4/D) Philadelphia, PA 19111-5094 USA Phone: 215 697 6257 Dolan-Jenner Ind. Inc. 678 Andover Street Lawrence, MA 01843-1060 USA Phone: 978 681 8000 Fax: 978 689 2317 Dow Chemical Co. 2020 Willard H. Dow Center Midland, MI 48674 USA Phone: 800 232 2436 Fax: 517 832 1185 Dow Corning Corp. 2200 West Salzburg Rd. P.O. Box 994 Midland, MI 48686 USA Phone: 800 248 2481 Alt Phone: 517 496 6000 Fax: 517 496 6974 Dow Corning Corp. (France)
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STANDARD PRACTICES MANUAL AS907-1-1A 131 Bld. Carnot 78110 Le Vesinet, France Dow Corning Europe SA 62, Rue General De Gaulle Brussels, Belgium Phone: 32 2 655 21 11 Fax: 32 2 655 20 01 Dow Corning France SA Le Britannia 20, bd Eugene Derwelle 69432 Lyon CEDEX 03, France Phone: 33 478 60 51 48 Fax: 33 478 62 78 98 Drilube Co. 711 W. Broadway Glendale, CA 91204 USA Phone: 800 752 4739 Alt Phone: 632 752 4739 Fax: 632 757 2323 DuBois Chemical Co. 255 E. 5th St. Cincinnati, OH 45202 USA Phone: 800 438 2647 Alt Phone: 513 762 6000 Fax: 800 842 0597 DUMORE Corp. 1030 Veterans Street Mauston, WI 53948-9314 USA Phone: 888 467 8288 Alt Phone: 608 847 6420 Fax: 800 338 6673 Alt Fax: 608 847 7418 Email: dumore@mwt.net Dunstone Company Inc. 2104 Crown View Dr. Charlotte, NC 28227 USA
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STANDARD PRACTICES MANUAL AS907-1-1A Phone: 704 841 1380 Fax: 704 841 1383 Dynamation Research, Inc. 2301 Pontius Avenue Los Angeles, CA 90064-1809 USA Phone: 888 419 1489 Alt Phone: 310 477 1224 Fax: 310 479 5656 Dynamet Powder Products 600 Mayer Street Bridgeville, PA 15017 USA Phone: 412 257 5110 Fax: 412 257 5154 E. V. Roberts and Associates P.O. Box 868 8500 Stellar Dr. Culver City, CA 90232 USA Phone: 800 374 3872 Fax: 310 839 9427 E/M 100 Cooper Circle P.O. Box 3969 Peachtree City, GA 30269 USA Phone: 800 428 7802 Alt Phone: 770 261 4800 Fax: 770 261 4805 Eastman Kodak Co. 343 State St. Rochester, NY 14650 USA Phone: 800 242 2424 Alt Phone: 716 724 4000 Fax: 716 722 1862 Ecolink, Inc. 2227 Idlewood Road Tucker, GA 30084 USA Phone: 770 621 8240
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STANDARD PRACTICES MANUAL AS907-1-1A Fax: 770 621 8245 ECT Inc. Bridgeport Business Park, Bldg. 20 401 E. 4th St. Bridgeport, PA 19405 USA Phone: 610 239 5120 Fax: 610 239 7863 E ishin Kagaku Co., Inc. 1.2.13 Higashi. Shinbashi Minato. KU Tokyo, 105-0021 Japan Eldorado Chemical Co., Inc. 14350 Lookout Rd. P.O. Box 34837 San Antonio, TX 78265-4837 USA Phone: 210 653 2060 Fax: 210 653 0825 Email: info@eldoradochem.com Electrolube Wentworth House Blakes Road Wargrave, Bershire RG10 8AW England Phone: 44 1734 40301 Electronics Inc. 1520 North Main Street Mishawaka, IN 46545 USA Phone: 800 832 5653 Alt Phone: 219 256 5001 Fax: 219 256 5222 Email: shotpeener@shotpeener.com EM Science 480 Democrat Rd. PO Box 70 Gibbstown, NJ 08027 USA Phone: 609 423 6300 Fax: 609 423 4389
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STANDARD PRACTICES MANUAL AS907-1-1A Emhart Fastening Technologies Industrial Division 510 River Road, P.O. Box 889 Shelton, CT 06484 USA Phone: 203 924 9341 Fax: 203 925 3109 Email: emhart.teknologies@bdk.com Empire Abrasive Equipment Corp. 9990 Ganty Road Philadelphia, PA 19115 USA Enthone, Inc. 350 Frontage Rd. P.O. Box 1900 West Haven, CT 06508 USA Phone: 800 496 8326 Fax: 203 937 1680 EPM, Inc. 112-G West Burke Street Stockbridge, GA 30281 USA Phone: 800 659 5050 Alt Phone: 770 389 0501 Fax: 888 353 7325 Alt Fax: 770 389 0652 Epoxylite Corp. 9400 Toledo Way P.O. Box 1971 Irvine, CA 92713 USA Phone: 949 580 0777 Fax: 949 951 7265 Email: epoxy@aol.com Equilon Enterprise West Hollow Technical Center 3333 Highway 6 South Houston, TX 77082-3101 USA Phone: 800 231 6950 Alt Phone: 281 544 9260 (VM)
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STANDARD PRACTICES MANUAL AS907-1-1A Fax: 281 547 9281 Ernest F. Fullam, Inc. 900 Albany-Shaker Rd. Latham, NY 12110 USA Phone: 518 785 5533 Fax: 518 785 8647 Essex Group Inc. IWI Operations 1510 Wall St. Ft. Wayne, IN 46801 USA Phone: 800 805 4636 Alt Phone: 219 461 4000 Fax: 219 461 4165 EUREP Industries 2 Rue des Gaillards BP 20 - Zone Industrielle des Doucettes 95141 Garges Les Gonesse, 698795 France Phone: (3) 933.73.77 Fairchild Fasteners Direct 2060 Nordhoff Street Chatsworth, CA 91311 USA Phone: 818 998 1412 Fax: 818 998 2438 Feltman Research Laboratory Materials Engineering Division Picatinny Arsenal Dover, NJ 07801 USA Phone: 973 989 0713 Ferro Color Division 4150 E. 56 St. Cleveland, OH 44105 USA Phone: 800 257 9799 Alt Phone: 216 641 8580 Fax: 216 750 6536 Ferro Corp. 54 Kellogg Court Edison, NJ 08817 USA
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STANDARD PRACTICES MANUAL AS907-1-1A Phone: 800 233 6712 Alt Phone: 732 287 1930 Fax: 732 287 8966 Ferro Corp., Color Division 1301 North Flora Plymouth, IN 46563 USA Phone: 800 882 1456 Alt Phone: 219 641 8580 Fax: 219 935 5278 Fiber-Resin Corp. 3530 Lexington Ave. North ST. Paul, MN 55126 USA Phone: 800 624 9487 Alt Phone: 651 236 3019 Fax: 800 528 6079 Alt Fax: 651 236 3128 Fibre Glass Evercoat Co. 6600 Cornell Road Cincinnati, OH 45242 USA Phone: 513 489-7600 Fax: 513 489 7137 Field Abrasive Mfg. Co. Inc. 1303 Stanley Ave. Dayton, OH 45404 USA Phone: 800 227 2748 Alt Phone: 937 223 7209 Fax: 800 232 4778 Alt Fax: 937 223 0836 Fine Organics Corp. 205 Main Street P.O. Box 687 Lodi, NJ 07644-0687 USA Phone: 800 526 7480 Fire Research Lab. P.O. Box 9645 Albuquerque, NM 87119 USA
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STANDARD PRACTICES MANUAL AS907-1-1A Phone: 505 877 3119 Fax: 505 877 3013 Fisher Scientific Co. 585 Alpha Dr. Pittsburgh, PA 15238 USA Phone: 800 766 7000 Fax: 800 926 1166 Flame Control Coating Inc. P.O. Box 786 4120 Hyde Park Blvd. Niagara Falls, NY 14302 USA Phone: 716 282 1399 Fax: 716 285 6303 Flexbar Machine Corp. 250 Gibbs Rd. Islandia, NY 11722-26797 USA Phone: 800 883 5554 Alt Phone: 631 582 8440 Fax: 631 582 8487 Flexfab 1699 West M-43 Highway Hastings, MI 49058 USA Phone: 800 331 0003 Alt Phone: 616 945 2433 Fax: 616 945 4802 Email: sales @flexfab.com Flow International Corporation 23500 64th Avenue South Kent, WA 98032 USA Phone: 253 850 3500 Fax: 253 813 3285 Fluoro Plastics Inc. 36-1 G Street Philadelphia, PA 19134 USA Phone: 800 262 1910 Alt Phone: 215 425 5500
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STANDARD PRACTICES MANUAL AS907-1-1A Fax: 215 425 5521 Email: fluro@fluoro-plastics.com Foam Seal/Novagard 5109 Hamilton Ave. Cleveland, OH 44114 USA Phone: 800 829 0522 Alt Phone: 216 881 8111 Fax: 216 881 6977 Foucault International 920 36th Court S.W. Vero Beach, FL 32968 USA Phone: 800 655 6065 Fax: 561 978 1387 Email: sales@foucaultintl.com Fournier 11, Rue Des Freres Lumiere, ZI Nord 77100 Meaux, France Phone: 33 1 64 34 12 45 Alt Phone: 33 1 64 33 62 05 Freeman Mfg. and Supply Co. 1101 Moore Road Avon, OH 44011 USA Phone: 800 321 8511 Alt Phone: 440 934 1902 Fax: 440 934 7200 Fuchs Lubricants Co. 17050 Lathrop Ave. Harvey, IL 60426 USA Phone: 800 323 7755 Alt Phone: 708 333 8900 Fax: 708 333 3813 Furon Tape Division / Division of Saint Gobain 14 McCaffrey St. Hoosick Falls, NY 12090 USA Phone: 518 686 7301
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STANDARD PRACTICES MANUAL AS907-1-1A Fax: 518 686 4840 G and P Machinery Corp. 2801 Tobey Dr. Indianapolis, IN 46219 USA Phone: 317 898 0750 Fax: 317 899 1627 GDC / City Wire Cloth 13055 Jurupa Ave Fontana, CA 92337 USA Phone: 800 635 8296 Alt Phone: 909 361 1111 Fax: 909 361 1112 G E Aircraft Engines, CSC Customer Support Center 111 Merchant Street Cincinnati, OH 45246 USA Phone: 877 432 3272 Alt Phone: 513 552 3272 Fax: 877 432 3329 Alt Fax: 513 552 3329 Email: geae.csc@ae.ge.com GE Aircraft Engines, QTC Attention: Brenda Tenley One Neumann Way, MD: Q8 Cincinnati, OH 45215 USA Phone: 513 552 4701 Fax: 513 552 4892 Email: brenda.tenley@ae.ge.com GE Company, Silicone Products Division 260 Hudson River Road Waterford, NY 12188 USA Phone: 800 332 3390 Alt Phone: 518 237 3330 Fax: 518 233 2308 GEAE Data Center Room 364
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STANDARD PRACTICES MANUAL AS907-1-1A 111 Merchant Street Cincinnati, OH 45246 USA Phone: 877 432 3272 Alt Phone: 513 552 3272 Gebruder M. und M. Morant GMBH BahnhofstraBe 110 Grassau D-83224 Germany Phone: 0 17 13 30 30 36 Alt Phone: 0 17 13 30 30 38 General Electric Co. Nela Park Cleveland, OH USA General Electric France BP67 91002 EVRY CEDEX, France Gerard Daniel Company 5 Plain Ave. New Rochelle, NY 10801 USA Phone: 914 235 2525 Fax: 914 632 1078 GLYPTAL, INC. 305 Eastern Ave. Chelsea, MA 02150 USA Phone: 800 457 1201 Alt Phone: 617 884 6918 Fax: 617 884 8376 Golden Empire Corp. P.O. Box 2129 Morehead City, NC 28557 USA Phone: 252 808 3511 Fax: 252 808 3711 Grainger Parts Branch 138 820 N Orleans Chicago, IL 60610 USA
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STANDARD PRACTICES MANUAL AS907-1-1A Phone: 312 988 9088 Fax: 312 988 9286 Greenfield Industries 470 Old Evans Road Evans, GA 30809 USA Phone: 888 434 4311 Alt Phone: 706 863 7708 Fax: 888 434 4313 Groov-Pin Corporation 1125 Hendricks Causeway Ridgefield, NJ 07657 USA Phone: 201 945 6780 Fax: 201 945 8998 Email: info@groov-pin.com H.B. Fuller Co. 3530 Lexington Ave. N. St. Paul, MN 55126 USA Phone: 888 351 3527 Alt Phone: 651 236 3061 Fax: 800 528 6079 Alt Fax: 651 236 3158 H.C. Starck GmbH and Co KG P.O Box 2540 D-38615 Goslar, Germany Phone: 49 5321 751 0 Fax: 49 5321 751192 H.C. Starck Inc. 45 Industrial Place Newton, MA 02161 USA Phone: 617 630 5923 Fax: 617 630 5908 Hampshire Chemical Corp. 2 E. Spit Brook Road Nashua, NH 49674 USA Phone: 800 232 2436
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STANDARD PRACTICES MANUAL AS907-1-1A Alt Phone: 603 888 2320 Fax: 603 888 7190 Harry Miller Corp. 4th and Bristol Streets Philadelphia, PA 19140 USA Phone: 215 324 4000 Fax: 215 324 1258 Hawk NDT Systems Inc. Goodell Rd. Mohawk, MI 49950 USA Phone: 906 289 1023 Heatbath Corp. P.O. Box 2978 Springfield, MA 01102 USA Phone: 413 543 3381 Fax: 413 543 2378 Henkel Surface Technologies 32102 Stephenson Hwy. Madison Heights, MI 48071 USA Phone: 800 521 6895 Alt Phone: 248 583 9300 Fax: 248 583 2976 Hexcel Corporation Customer Service Center 5794 W. Las Positas Blvd. Pleasanton, CA 94588 USA Phone: 800 688 7734 Alt Phone: 925 847 9500 Fax: 925 734 8172 Hohman Plating and Mfg., Inc. 814 Hillrose Ave. Dayton, OH 45404 USA Phone: 937 228 2191 Fax: 937 228 5171 Holland Manufacturing Co. 1300 Bank Street
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Baltimore, MD 21231 USA Phone: 800 411 3606 Alt Phone: 410 732 4455 Fax: 410 732 4331 Honeywell Amorphous Metals 440 Allied Drive Conway, SC 29526 USA Phone: 800 581 7654 Alt Phone: 843 349 7319 Fax: 843 349 6815 Email: jimmy.jordan@honeywell.com Honeywell Hardware Products Group 1160 South St. Suffield, CT 06078 USA Phone: 860 668 1201 Fax: 860 668 4139 Hoskins Mfg. Co 10776 Hall Road Hamburg, MI 48139 USA Phone: 810 231 1900 Fax: 810 231 4311 Houghton International Madison and Van Buren Aves. P.O. Box 930 Valley Forge, PA 19482 USA Phone: 610 666 4000 Fax: 610 666 1376 HTG Metal Methods 260 Chenault Road Frankfort, KY 40601 USA Phone: 502 695 5700 Fax: 502 695 5702 Email: htg40601@aol.com ICI Paints Division Wexham Road Slough, Berkshire SL2 5DS United Kingdom
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Phone: 44 1753 550000 Ideal Stencil Machine Co. 102 Iowa Ave. Belleville, IL 62222 USA Phone: 800 388 0162 Alt Phone: 618 233 0162 Fax: 618 233 5091 Index-Werkeeg Hahn & Tessky 73 Esslingen P.O. Box 809 West Germany Industrial Quartz 7552-B St. Clair Ave. Mentor, OH 44060 USA Phone: 440 942 0909 Fax: 440 946 6131 Industrial Services, Inc. 5718 Hillside Avenue Cincinnati, OH 45233 USA Phone: 513 941 2700 Fax: 513 941 2708 International Products Corporation (USA) P.O. Box 70 201 Connecticut Drive Burlington, NJ 08016-0070 USA Phone: 609 386 8770 Fax: 609 386 8438 IR Fluid Products Ingersoll Rand Company One ARO Center Bryan, OH 43506-0151 USA Phone: 419 636 4242 Fax: 419 633 1674 ISP Technologies, Inc. 767 N. Thompson Ave. Bround Brook, NJ 08805 USA
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Phone: 800 622 4423 Fax: 732 271 8999 ITW Devcon 30 Endicott Danvers, MA 01923 USA Phone: 978 777 1100 Fax: 978 774 0516 ITW Industrial Finishing Binks, Devilbiss 195 International Blvd. Grendale Heights, IL 60139 USA Phone: 800 338 4448 Fax: 800 368 0117 ITW Magnaflux 3624 W. Lake Ave. Glenview, IL 60025 USA Phone: 847 657 5300 Fax: 800 952 5823 ITW Mark-Tex 805 East Old 56 Highway Olathe, KS 66061 USA Phone: 913 829 6296 Fax: 913 780 9459 ITW-Dykem Co. 3624 W. Lake Ave. Glenview, IL 60025 USA Phone: 800 443 9536 Alt Phone: 847 657 4665 Fax: 800 323 9536 Alt Fax: 847 657 4666 J.S. McCormick Co. 650 Smithfield St. Suite 1050 Pittsburgh, PA 15222 USA Phone: 412 471 7246 Fax: 412 471 7247
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A JAD Chemical Co. P.O. Box 6786 Rancho Palos Verdes, CA 90734 USA Phone: 310 833 7457 Fax: 310 548 3240 Josef Frohn Postfach 7012 D5990 Altena 7, Germany (02352) 25442 JT Baker Inc. 222-T Red School Ln. Phillipsburg, NJ 08865 USA Phone: 908 859 2151 Fax: 908 859 9318 Kahrs Thermal Technology 4854 OHear Avenue North Charleston, SC 29406 USA Phone: 843 747 1295 Fax: 843 747 1395 Email: ktti@msn.com Kamen Wiping Materials Co., Inc. 441 N. Santa Fe P.O. Box 2077 Wichita, KS 67201-2077 USA Phone: 800 835 2912 Alt Phone: 316 265 8615 Fax: 800 889 1890 Alt Fax: 316 267 1957 Kano Laboratories 1000 S. Thompson Lane Nashville, TN 37211 USA Phone: 615 833 4101 Fax: 615 833 5790 Kenneth Industrial Products, Inc. 290 Pratt St. Meriden, CT 06450 USA Phone: 800 322 3306
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Alt Phone: 203 238 2623 Fax: 203 238 4329 Kerr Corp. 1717 West Collins Ave. Orange, CA 92867 USA Phone: 800 537 7123 Alt Phone: 714 516 7400 Fax: 800 537 7345 Alt Fax: 714 516 7673 Kindt-Collins Co. 12651 Elmwood Ave. Cleveland, OH 44111 USA Phone: 216 252 4122 Fax: 216 252 5639 Kirkhill-TA Co. 300 East Cypress St. Brea, CA 92821 USA Phone: 714 529 4901 Fax: 714 529 6783 Email: sales@tamfg.com Kleer-Flo Co. 15151 Technology Dr. Eden Prairie, MN 55344 USA Phone: 612 934 2555 Fax: 612 934 3909 KME Postfach 1565 D5990 Altena 7, Germany (02352) 25442 Kolene Corp. 12892 Westwood Ave. Detroit, MI 48223 USA Phone: 800 521 4182 Alt Phone: 313 273 9220 Fax: 313 273 5207 Kop-Coat, Inc. P.O. Box 911207
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Commerce, CA 90091 USA Phone: 800 932 2239 Alt Phone: 213 560 5700 Fax: 213 560 5734 Kop-Coat, Inc. (Vernon, CA) 5431 District Blvd. Vernon, CA 90040 USA Phone: 800 932 2239 Alt Phone: 213 560 5700 Fax: 213 560 5734 Krylon Products Group, the Specialty Div. of Sherwin-Williams Co. 31500 Solon Road Solon, OH 44139 USA Phone: 800 777 2966 Alt Phone: 614 294 6040 Fax: 800 243 3075 LabCem Inc. 200 William Pitt Way Pittsburg, PA 15238 USA Phone: 800 394 5230 Alt Phone: 412 826 5230 Fax: 412 826 5234 Labinal Division, Systeme Aeronautique 5 Ave. Newton B.P 78051 St. Quentin En Yvelines, France Phone: 33 13 30 85 32 77 Laminated Shim Co. 1691 California Ave. Corona, CA 92881 USA Phone: 800 959 1311 Alt Phone: 909 273 3900 Fax: 909 273 3919 Lapmaster International 6400 W. Oakton St. Morton Grove, IL 60053 USA
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Phone: 800 527 2631 847 967 2975 Fax: 847 967 3903 Lectroetch Co. 5342 Evergreen Pkwy. Sheffield Village, OH 44054 USA Phone: 440 934 1249 Fax: 440 934 1293 Lee Company 2 Pettipaug Road Westbrook, CT 06498-0424 USA Phone: 860 399 6281 Fax: 860 399 7037 Lily Industries Inc. 210 E. Alondra Blvd. Gardena, CA 90248 USA Phone: 310 352 3087 Fax: 310 327 3041 Liquid Development Company (LDC) 3748 East 91st Street Cleveland, OH 44105 USA Phone: 800 321 9194 Alt Phone: 216 641 9366 Fax: 216 641 6416 Email: ldc@bblink.net Local Purchase Local Purchase from Dental Supplier Lockheed Martin Space Systems Company - Michoud Operations P.O. Box 29304 (Attn: Dept. 3600) New Orleans, LA 70189 USA Phone: 504 257 1386 Fax: 504 257 4406 Loctite Aerospace
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A 2850 Willow Pass Rd. P.O. Box 312 Bay Point, CA 94565 USA Phone: 925 458 8000 Fax: 925-458-8030 Loctite Corp. 1001 Trout Brook Crossing Rocky Hill, CT 06067 USA Phone: 800 243 4874 Alt Phone: 203 278 1280 Fax: 800 344 4503 Lord Corp. Chemical Products Group 2000 W. Gradview Blvd. Erie, PA 16514 USA Phone: 814 868 3611 Fax: 814 864 3452 LPS Laboratories, Inc. P. O . Box 105052 Tucker, GA 30085 USA Phone: 800 241 8334 Alt Phone: 770 934 7800 Fax: 770 493 9206 Lubri-Film Div. Cedar Concepts Corp. 4342 S. Wolcott Ave. Chicago, IL 60609 USA Phone: 773 890 5790 Fax: 773 890 1606 Email: cedarTR@aol.com Lucas-Milhaupt Inc. 5656 S. Pennsylvania Ave. Cudahy, WI 53110 USA Phone: 800 558 3856 Alt Phone: 414 769 6000 Fax: 414 769 1093 Ludlow Corp., Packaging Div.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A P.O. Box 749 1 Minden Road Homer, LA 71040 USA Phone: 318 927 2531 Fax: 318 927 9825 Lumatec GmbH Steinerstr. 15 Munich, D-81369 Germany Phone: 49 89 723 7021 Fax: 49 89 723 5064 MacDermid, Inc. 245 Freight St. Waterbury, CT 60720 USA Phone: 800 325 4158 Alt Phone: 203 575 5700 Fax: 203 575 5916 Alt Fax: 203 575 5630 MacLean Maynard 50855 E. Russell Schmidt Blvd. Chesterfield, MI 48051 USA Phone: 810 949 0471 Fax: 810 949 7940 Email: johnh@maynard.maclean-fogg.com MagChem 190 Boul. Industriel Boucherville, Que Canada J4B 2X3 Phone: 800 363 9929 Alt Phone: 514 655 1344 Fax: 514 655 5428 Magnaflux Corporation 3624 West Lake Avenue Glenview, IL 60025 USA Phone: 847 657 5300 Fax: 847 657 5388 Magnus Equipment 450 Beidler Rd.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Willoughby, OH 44094 USA Phone: 800 456 6423 Alt Phone: 440 942 8488 Fax: 440 942 8590 Mallinckrodt Baker, Inc. 222 Red School Lane Phillipsburg, NJ 08865 USA Phone: 800 354 2050 Alt Phone: 908 859 2151 Fax: 908 859 6974 Email: infombi@mkg.com Mallinckrodt, Inc. 675-T McDonnell Blvd. St. Louis, MI 631345 USA Phone: 314 895 2000 Fax: 314 895 1251 Malsbary Manufacturing Co. 9615 Inter Ocean Dr. Cincinnati, OH 45246-1029 USA Phone: 513 870 0200 Fax: 513 870 0182 Manson Tool and Supply 732 Commerce St. P.O.Box 204 Thornewood, NY 10594 USA Phone: 800 287 7077 Email: info@mansontool.com Marian Inc. 1011 East Saint Clair Street Indianapolis, IN 46202 USA Phone: 317 638 6525 Fax: 317 638 8664 Markel Corp. School Ln. Norristown, PA 19404 USA Phone: 800 462 4479
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Alt Phone: 610 272 8960 Fax: 610 270 3138 Email: sales@markelcorp.com Markem Corp. 150 Congress St. Keene, NH 03431 USA Phone: 603 352 1130 Fax: 800 435 2923 Email: durek@markem.com Marktec Corp. 3-10 SAMMO 2-CHOME OTA-KU, 143 Japan Phone: 81 3 3777 1852 Fax: 81 3 3777 1856 Marston Lubricants, LTD 7-11 Naylor St. Liverpool, England Master Chemical Co. P.O. Box 10001 Perrystown, OH 43552 USA Phone: 419 874 7902 Fax: 419 874 0684 MaxiBlast, Inc. 630 East Bronson St. South Bend, IN 46601 USA Phone: 800 535 3874 Alt Phone: 219 233 1161 Fax: 219 234 0792 McGean-Rohco, Inc., Cee-Bee Division 2910 Harvard Ave. Cleveland, OH 44105 USA Phone: 800 327 0466 Alt Phone: 216 441 4900 Fax: 216 441 1377 McMaster Carr 600 County Line Road
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Elmhurst, IL 60126 USA Phone: 630 833 6300 Fax: 630 834 9427 Merck KGaA 64293 Darmstadt (address) P.O. Box 64271 Darmstadt Frankfurter StraBe 250, Germany Phone: 49 6151 72 0 Fax: 49 6151 72 2000 Email: service@merck.de Metal Improvement Co. Peenamatic Division 472 Barell Ave. Carlstadt, NJ 07072 USA Phone: 201 935 1200 Fax: 201 935 8670 Metcut Research 3980 Rosslyn Drive Cincinnati, OH 45209 USA Phone: 513 271 5100 Fax: 513 271 9511 Micromatic Textron 1101-T Wohlert Street Angola, IN 46703 USA Phone: 219 665 9457 Fax: 219 665 9162 Miller Stephenson Chemical Co. George Washington Hwy. P.O. Box 950 Danbury, CT 06810 USA Phone: 203 743 4447 Fax: 203 791 8702 Miltix-Morgan Fabrics 4265 Exchange Ave. P.O. Box 58523 Los Angeles, CA 90058 USA
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Phone: 323 583 9981 Fax: 323 588 0614 Modern Chemical, Inc. 7023 Centennial Road P.O. Box 368 Jacksonville, AR 72078 USA Phone: 501 988 1311 Fax: 501 988 2229 Mohawk Fabric Co. Inc. 96 Guy Park Ave. P.O. Box 587 Amsterdam, NY 12010-0587 USA Phone: 518 842 3090 Fax: 518 842 3095 Monode Marking Products Inc. 7620 Tyler Blvd. Mentor, OH 44060 USA Phone: 440 974 6200 Fax: 440 975 1364 Monogram/Aerospace Fasteners P.O. Box 6847 Los Angeles, CA 90022-0547 USA Phone: 323 722 4760 Fax: 323 721 1851 MPC Industries, Patent Plastics, Inc. 638 Maryville Pike SW P.O. Box 9246 Knoxville, TN 37940 USA Phone: 423 573 5411 MTU Maintenance GmbH Department SP20, P.O. Box 1720, D-3012 Munchen Strasse 31 30855 Langenhagen, Germany Phone: 49 511 7806 0 Fax: 49 511 7806 1 11 Netherland Rubber Co.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A P.O. Box 62165 2931 Exon Ave. Cincinnati, OH 45241 USA Phone: 800 733 6107 Alt Phone: 513 733 0883 Fax: 513 733 1096 Newco 2811 West Palmetto St Florence, SC 29501 USA Phone: 843-669-2988 Fax: 843-664-0197 Noble Tool Corp. 1535 Stanley Avenue Dayton, OH 45404 USA Phone: 937 461 4040 Fax: 937 461 1943 Norton Company 15501 Industrial Parkway, S.W. Cleveland, OH 44135 Norton Company / Division of Saint Gobain 1 New Bond St. Worcester, MA 01615-0008 USA Phone: 800 543 4335 Alt Phone: 508 795 5000 Fax: 800 762 8585 Alt Fax: 508 795 4130 Norton Performance Plastics Corporation 150 Dey Road Wayne, NJ 07470 USA Phone: 800 526 7844 Fax: 973 628 5550 Nuvite Chemical Compounds, Corp. 213 Freeman Street Brooklyn, NY 11222 USA Phone: 800 394 8351 Alt Phone: 718 383 8351
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Fax: 718 383 0008 Nyco SA 51 rue de Ponthieu Paris 75008, France Phone: 33 145 61 50 00 Fax: 33 145 61 50 13 O.M.G Americas 2601 Weck Drive Research Triangle Park, NC 27709 USA Phone: 919 544 8315 Fax: 919 544 0917 O.M.T. ZI Des Bordes 9 Rue Gustave Madiot CE No. 2117 91921 Bondoufle, France Phone: 331 69 86 64 64 Fax: 331 86 43 61 Oakite Products Inc., Div. of Chemetall 16961 Knott Ave. La Mirada, CA 90638 USA Phone: 714 739 2821 Fax: 714 670 6480
Olin Corporation
501 Merritt 7 P.O. Box 4500 Norwalk, CT 06856 USA Phone: 203 750 3000 Olympus Industrial America Inc. 414 Airport Executive Park Nanuet, NY 10954 USA Phone: 866 642 4725 Alt Phone: 845 425 3100 Fax: 800 233 0697 Alt Fax: 845 425 2192 Email: info@olympusindustrial.com Omni Specialty Corp.
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A 500 Frank W. Burr Blvd. Teanec, NJ 07866 USA Phone: 201 692 8800 Fax: 201 692 0559 Osborn International 5401 Hamilton Ave. Cleveland, OH 44114 USA Phone: 800 767 2676 Alt Phone: 216 361 1900 Fax: 888 672 1900 Alt Fax: 216 361 1913 Owens-Corning Fiberglass Corporation Fiberglass Tower Toledo, OH 43659 USA Phone: 800 237 7755 Fax: 864 296 4374 P. Viennot S. A. 174 Bd Camelinat 92240 Malakoff France Paasche Airbrush Co. 7440 W. Lawrence Ave. Harwood Heights Harwood Heights, IL 60706-3412 USA Phone: 708 867 9191 Fax: 708 867 9198 Parker-Hannifin Corp., Stratoflex Division 220 Roberts Cut-off Road P.O. Box 10398 Fort Worth, TX 76114 USA Phone: 817 738 6543 Fax: 817 738 7562 Parkway Products, Inc. 10293 Burlington Rd. Cincinnati, OH 45231 USA Phone: 513 851 5550 Fax: 513 851 1926
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A PAS 10540 Ridge Road New Port Richy, FL 34654 USA Phone: 727 849 9240 Fax: 727 842 1740 Patco Corp. 51-Ballou Blvd. Bristol, RI 02809 USA Phone: 401 254 0600 Fax: 401 253 5557 Patterson Dental Supply 2864 E. Kemper Road Cincinnati, OH 45241 USA Phone: 513 771 3077 Fax: 513 771 3196 Paul N. Gardner Company, Inc. 316 NE 1st ST. Pampano Beach, FL 33060 USA Phone: 800 762 2478 Alt Phone: 305 946 9454 Fax: 954 946 9809 Pechiney World Trade Inc. 500-T Plaza Dr. Secaucus, NJ 07096 USA Phone: 201 863 2400 Fax: 201 863 9201 Penn-Fibre and Specialty Co. 401 Commerce Dr. Ft. Washington, PA 19034 USA Phone: 800 662 7366 Alt Phone: 215 793 9200 Fax: 215 793 0700 Pentacon Aerospace Group 21123 Nordhoff Street Chatsworth, CA 91311 USA Phone: 800 554 4449
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Alt Phone: 818 727 7800 Fax: 818 727 9636 Email: information@pentacon-inc.%20com Permabond International Corp. 480 South Dean St. Englewood, NJ 07631 USA Phone: 201 567 9494 Fax: 201 567 3747 Permacel U.S. Highway No. 1 New Brunswick, NJ 08903 USA Phone: 800 755 8273 Alt Phone: 732 418 2501 Fax: 732 418 2474 Petroferm Inc. 2416 Lynndale Road Fernandina Beach, FL 32034 USA Phone: 904 261 8286 Fax: 904 261 6994 Email: techservice@petrofern.com Phillips Supply Co. 1 Crosley Field Lane Cincinnati, OH 45214 USA Phone: 513 579 1550 Fax: 513 579 1903 Polaroid, Inc. 784 Memorial Drive Cambridge, MA 02139 USA Phone: 781 386 2000 Poly-Pacific International Inc. 8910-18 Street Edmonton AB, Canada, T6P Phone: 800 663 1220 Alt Phone: 780 467 3612 Fax: 780 464 1852 Polycraft Products, Inc.
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A 5511 State Route 128 Cleves, OH 45002 USA Phone: 513 353 3334 Fax: 513 353 4421 Email: tel@polycraftproducts.com Polymet Corp. 10073 Commerce Park Drive Cincinnati, OH 45246 USA Phone: 513 874 3586 Fax: 513 874 2880 Email: polmet@cinti.net Portland Plastics P.O. Box 436 Portland, MI 48875 USA Phone: 517 647 4115 Fax: 517 647 4152 Email: plastics@power.net.net Powder Alloy Corp. 5871 Creek Road Cincinnati, OH 45242 USA Phone: 513 984 4016 Fax: 513 984 4017 PPG Industries, Inc. 23002 St. Claire Ave. Cleveland, OH 44177 USA Phone: 216 486 6830 Fax: 216 486 1214 Praxair / TAFA Concord 146 Pembroke Road Concord, NH 03301-5706 USA Phone: 603 224 9585 Fax: 603 225 4342 Praxair / TAFA Indianapolis 1555 Main Street Indianapolis, IN 46224 USA Phone: 800 825 3093
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Alt Phone: 317 240 2650 Fax: 800 234 6738 Alt Fax: 317 825 3093 PRC-Desoto International Inc. 5430 San Fernando Road Glendale, CA 91209 USA Phone: 818 240 2060 Fax: 818 549 7606 Precision Abrasives and Tools 170 5th Avenue Hawthorne, NJ 07506 USA Phone: 973 423 1147 Fax: 973 423 6054 Precision Fabrics Group Inc. 6012 High Point Road Greensboro, NC 27407 USA Phone: 888 733 5759 Alt Phone: 336 888 2529 Fax: 336 888 2557 Premier Shot Company 1203 West 65th St. Cleveland, OH 44105 USA Phone: 800 327 0466 Alt Phone: 216 441 4900 Fax: 216 441 1377 Prescott and Co., Ltd. 8615 Devonshire Rd. Montreal, Quebec H4P2L3 Canada Phone: 514 735 6191 Fax: 514 735 5803 PROFTECHNIK AG P.O. Box 1263 Ismaning, D-85730 Germany Phone: 49 0 89 99 6160 Fax: 49 0 89 99 616200 Progressive Technologies
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A 4201 Patterson Grand Rapids, MI 49512-4092 USA Phone: 616 957 0871 Fax: 616 957 3484 Protech Lab Corporation 9940 Reading Road Cincinnati, OH 45241 USA Phone: 513 563 5005 Fax: 513 563 5004 PT. KOGELAHAR INDONUSA Jl. G. Krakatan No. 6-6A-6B Medan, 20238 Indonesia Phone: 62 61 662 0616 Alt Phone: 62 61 662 0617 Fax: 62 61 662 0605 Quaker Chemical Corp. Elm and Lee Sts. Conshohocken, PA 19428 USA Phone: 610 832 4000 Fax: 610 832 8682 Radiac Abrasives National Grinding Wheel Division 1015 S. College Salem, IL 62881 USA Phone: 618 548 4200 Fax: 618 548 4207 Radiator Specialty Co. 1400 W. Independence Blvd. Charlotte, NC 28206 USA Phone: 704 377 6555 Alt Phone: 800 421 9525 Fax: 704 374 0979 RAE Bearing Service 170 Elliot Street Hartford, CT 06114 USA
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Phone: 860 296 6147 Fax: 860 543 7172 Ratioplast GmbH Spitalwaldstrasse 9 D-91126 Schwabach, West Germany Phone: +49 9122/ 7 55 03 Fax: +49 9122/70 43 Research, Incorporated 6425 Flying Cloud Drive Eden Prairie, MN 55344 USA Phone: 612 941 3300 Fax: 612 941 3628 Email: info@researchinc.com Rexco Chemical Co. P.O. Box 80996 Conyers, GA 30013 USA Phone: 800 888 1060 Alt Phone: 700 483 7610 Fax: 770 483 8550 Rhone-Poulenc 18 Boucle DAlcace 92400 Courbevoie, France Richmond Aircraft Prod. 13503 Pumice St. Norwalk, CA 90650 USA Phone: 562 404 2440 Fax: 562 404 9011 Richwood Industries Inc. 12700 Knott St., Bldg. A Garden Grove, CA 92841-3904 USA Phone: 714 892 8100 Fax: 714 892 8818 Roly International P.O. Box 5103 Ventura, CA 93005 USA Phone: 805 644 8664
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A Fax: 805 650 8222 Royal Lubricants Co., Inc. P.O. Box 518 215 Merry Lane East Hanover, NJ 07936 USA Phone: 800 989 7692 Alt Phone: 973 887 7410 Fax: 973 887 6930 Ruger Chemical Co. 837 Cordier St. Irvington, NJ 07111 USA Phone: 800 274 7843 Alt Phone: 973 926 0331 Fax: 973 926 4921 S.S. White Technologies 151 Old New Brunswick Road Piscataway, NJ 08854 USA Phone: 732 752 8300 Fax: 732 752 7622 SAE 400 Commonwealth Drive Warrendale, PA 15096-0001 USA Phone: 724 776 4841 Fax: 724 776 0790 Saint-Gobain Performance Plastics Metacon Avenue Bristol, RI 02809 USA Phone: 800 223 4966 Alt Phone: 401 253 2000 Fax: 401 253 1755 Sandstrom Products Co. 224 Main St. Port Byron, IL 61275 USA Phone: 800 747 1084 Alt Phone: 309 523 2121 Fax: 309 523 3912
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Sanford Corp. 2711 Washington Blvd. Bellwood, IL 60104 USA Phone: 800 438 3703 Alt Phone: 708 649 3110 Fax: 800 457 9208 Alt Fax: 708 649 3463 Satair A/S 147A Amager Landevej DK-2770 Kastrup, Denmark Phone: 45 3247 0100 Fax: 45 3251 3434 Scientific Control Labs 3158 S. Kolin Avenue Chicago, IL 60623-4889 USA Phone: 773 254 2406 Fax: 773 254 6661 SEFAR America 333 South Highland Ave. Briarcliff Manor, NY 10510 USA Phone: 800 469 6836 Alt Phone: 914 941 7767 Fax: 914 762 8599 Alt Fax: 914 941 2446 Select-Tech, Inc. P.O. Box D Route 208 Wallkill, NY 12589 USA Phone: 800 432 4068 Alt Phone: 914 895 8111 Fax: 914 895 8112 Selig Chemical Industries, Inc. Div. of National Services Industries, Inc. 840 Selig Drive Atlanta, GA 30336 USA Phone: 404 691 9220 Fax: 404 691 7024
EFFECTIVITY: ALL
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STANDARD PRACTICES MANUAL AS907-1-1A SEMCO 5450 San Fernando Road Glendale, CA 91203 USA Phone: 818 247 7140 Fax: 818 549 7606 SEPR Ceramic Beads and Powders 1122 Hwy 22 Mountainside, NJ 07092 USA Phone: 908 654 0660 Fax: 908 654 0669 Sermatech International Inc. 155 S. Limerick Road Limerick, PA 19468 USA Phone: 610 948 5100 Fax: 610 948 0811 Email: lthumm@sermatech.com Seymour of Sycamore 917 Crosby Avenue Sycamore, IL 60178 USA Phone: 815 895 9101 Fax: 815 895 8475 Shell Chemical Co. Shell Chemical, Customer Service Center One Shell Plaza Houston, TX 77002 USA Phone: 800 872 7435 Alt Phone: 713 246 8241 Fax: 713 241 8196 Shell International Trading Co., International Aviation Division Shell Center London SE1, England Sherwin, Inc. 5530 Borwick Ave. South Gate, CA 90280 USA Phone: 562 861 6324 Fax: 562 923 8370
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Sherwin-Williams, Inc. Tri-Flow/Performance Products Group 101 Prospect Ave. Cleveland, OH 44115 USA Phone: 216 566 2000 Fax: 216 515 4932 Shimpo 3500 Devon Ave. Lincolnwood, IL 60659 USA Phone: 708 679 5033 Shurtape P.O. Box 1530 Hickory, NC 28603 USA Phone: 828 322 2700 Fax: 828 322 5583 Email: smackie@shurtape.com SIA Adhesives, Inc. 123 W. Bartges St. Akron, OH 44311 USA Phone: 330 374 2900 Fax: 330 374 2860 SIFCO Selective Plating-Div., SIFCO Industries 5708 Schaaf Road Cleveland, OH 44131 USA Phone: 216 524 0099 Fax: 216 524 6331 Smooth-On Inc. 2000 St. John Street Easton, PA 18042 USA Phone: 610 252 5800 Fax: 610 252 6200 Snap-On Special Products 2425 West Vineyard Ave. Escondido, CA 92029 USA Phone: 262 656 5599 Fax: 262 656 5129
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Solutia Inc. 10300 Olive Blvd. St. Louis, MO 63166 USA Phone: 800 426 7022 Alt Phone: 314 674 1000 Fax: 314 674 7433 Sovitec France S.A. BP 50098 ZI.Ste Agathe 57192 Florange, Cedex France Phone: 33 03 82 59 17 89 Fax: 33 03 82 52 01 22 Special Metals Corporation, Powder Division 100 Industrial Ln. Princeton, KY 42445 USA Phone: 270 365 9551 Fax: 270 365 5910 Email: tbanik@ziggycom.net SREM 22 Rue Raymond Lefevre 94250 Gentilly BP 71 France Starkey Chemical 9600 W. Ogden Ave. P.O. Box 10 La Grange, IL 60525 USA Phone: 800 323 3040 Alt Phone: 708 353 2565 Fax: 708 352 2573 Email: starkeychemical@earthlink.net Stellite Coatings Deloro Stellite, Inc. 1201 Eisenhower Dr. North P.O. Box 807 North Goshen, IN 46526-5396 USA Phone: 219 534 2585 Fax: 219 534 3417
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Sulzer Metco, Inc. 1101 Prospect Ave. Westbury, NY 11590 USA Phone: 516 334 1300 Fax: 516 338 2342 Sunnen Products Co. 7910 Manchester Ave. St. Louis, MO 63143 USA Phone: 314 781 2100 Fax: 314 781 2268 Swagelok 29500 Solon Road Solon, OH 44139 USA Phone: 440 349 5934 Fax: 440 349 5843 Sweco Inc. 8029 U.S. Hwy 25 Florence, KY 41042 USA Phone: 800 807 9326 Alt Phone: 859 371 4360 Fax: 859 283 8469 Email: a-s-ap@sweco.com Syon Corporation 280 Eliot St. Ashland, MA 01721 USA Phone: 508 881 8852 Fax: 508 881 4703 Email: syon@attmail.com T. C. Specialties, Inc. 460 Industrial Way Placentia, CA 92870 USA Phone: 714 524 4490 Fax: 714 524 4595 Tape Works 2170 Weaverville Road Allentown, PA 18103 USA
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Phone: 610 264 5115 Fax: 610 264 5241 Technifor SA 114 Quai du Rhone Z1 de la Tuilliere Miribel CEDEX, 01708 France Phone: +33 478 55 85 55 Fax: +33 478 55 85 54 Email: tf@technifor.com Telesis Technologies, Inc. P.O. Box 1000 Circleville, OH 43113 USA Phone: 800 654 5696 Alt Phone: 740 477 5000 Fax: 740 477 5001 Email: donovan@telesis.com Tempil Inc. / Division of ITW 2901 Hamilton Blvd. South Plainfield, NJ 07080 USA Phone: 908 757 8300 Fax: 908 757 9273 Tesa Tape Inc. (TTI) 5825 Carnegie Blvd. Charlotte, NC 28209 USA Phone: 800 367 8825 Alt Phone: 704 554 0707 Fax: 800 852 8831 Alt Fax: 704 553 5677 The Brulin Corporation P.O. Box 270 Indianapolis, IN 46206 USA Phone: 317 923 3211 Fax: 317 925 4596 The M.F. Cachat Co. 1391 W. 110th St. Cleveland, OH 44102 USA
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Phone: 800 729 8900 Alt Phone: 216 228 8900 Fax: 216 228 9916 The Milburn Co. 520 Bellevue St. Detroit, MI 48207 USA Phone: 313 259 3410 Fax: 313 259 3415 The Westaim Corporation Suite #201, Box 106 9405 50th St. Edmonton, Alberta Canada T6B2T4 Phone: 403 440 7940 Fax: 403 440 7948 Thomas and Betts Corp. 8155 T and B Blvd. Memphis, TN 38125 USA Phone: 800 888 0211 Alt Phone: 901 252 8000 Fax: 800 816 7810 Timminco Corp. 3555 Moline St. Aurora, CO 80010 USA Phone: 800 525 7572 Alt Phone: 303 367 0960 Fax: 303 367 0970 Tiodize Co., Inc. 5858 Engineer Dr. Huntington Beach, CA 92649 USA Phone: 714 898 4377 Fax: 714 891 7467 Titeflex, Inc. 603 Hendee St. Springfield, MA 01104-2893 USA Phone: 413 739 5631 Alt Phone: 413 271 8233
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Fax: 413 781 1207 Tokushu Toryo Co. LTD 3-10 Sann, 2-Chome Ota-Ku, Tokyo, 143, Japan TORAY Plastics of America 50 Belver Ave. North Kingstown, RI 02852-7500 USA Phone: 401 294 4511 ext. 2509 Fax: 401 294 3410 Treibacher-Schleifmittel 2000 College Ave. Niagara Falls, NY 14305 USA Phone: 716 286 1234 Fax: 716 286 1251 Turco Products, Inc. Subsidiary of Henkel Surface Technologies 3300 Montreal Industrial Way Tucker, GA 30084-5290 USA Phone: 770 939 8332 Fax: 770-496-5830 Tyco Electronics / Raychem Interconnect 300 Constitution Dr. Menlo Park, CA 94025-1164 USA Phone: 800 926 2425 Alt Phone: 650 361 3860 Fax: 650 361 5579 Tyrolit North America Inc. 12 Union St. Westborough, MA 01581-1459 USA Phone: 800 366 4431 Fax: 508 366 6291 Email: tyrolit-us@tyrolit.com U. S. Gypsum Co. 125 South Franklin Street Chicago, IL 60606 USA Phone: 312 606 4000 Fax: 312 606 4093
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A U.S. Technology Corp. 220 7th. St. S.E. Canton, OH 44702 USA Phone: 330 455 1181 Fax: 330 455 1191 Email: ustechlinda@juno.com Ultrachem, Inc. 900 Centerpoint Blvd. New Castle, DE 19720 USA Phone: 302 325 9880 Fax: 302 325 0035 Ultrafine Technology Ltd Scientific & Optical Instruments Brook La Business Centre Brook Lane Nth Brentford, TW8 0PP England Phone: 020 8569 9920 Fax: 020 8569 9649 Unifrax Corporation 2351 Whirlpool St. Niagara Falls, NY 14305-2413 USA Phone: 716 278 3800 Alt Phone: 716 278 3896 Fax: 716 278 3904 Email: sandrews@unifrax.com Union Carbide Corp. 10235 West Little York Road Suite 300 Houston, TX 77040 USA Phone: 800 568 4000 Alt Phone: 713 849 7000 Fax: 713 849 7193 Uniroyal Chemical Co. Benson Rd. Middelburry, CT 06749 USA Phone: 800 243 3027 Alt Phone: 203 537 3677
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Fax: 203 573 2669 Unisorb Installation Technologies P.O. Box 1000 4117 Felters Road Jackson, MI 49201 USA Phone: 517 764 6060 Fax: 517 764 5607 United States Welding 3579 Hwy 50 East #104 Carson City, NV 89701 USA Phone: 800 423 5964 Alt Phone: 775 883 7878 ext. 31 Fax: 775 833 7776 Email: miker@usweldingcorp.com USF / Surface Preparation 712 East Ohio St. Fortville, IN 46040 USA Phone: 800 428 4456 Alt Phone: 317 485 7701 Fax: 800 423 5929 Van Waters and Roger, Inc. 10235 West Little York Rd. Suite 300 Houston, TX 77040 USA Phone: 253 872 5000 Alt Phone: 513 563 2440 Fax: 425 889 4100 Vantico 4917 Dawn Ave. East Lansing, MI 48823 USA Phone: 800 367 8793 Alt Phone: 517 351 5900 Fax: 517 351 6255 Vapor Blast Mfg. Co. 3025 W. Atkinson Ave. Milwaukee, WI 53209 USA
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Phone: 414 871 6500 Fax: 414 871 7683 Vitta Corporation 7 Trowbridge Drive Bethel, CT 06801 USA Phone: 203 790 8155 Fax: 203 778 6478 Email: Info@vitta.com W. W. Grainger 4420 Glendale-Milford Road Cincinnati, OH 45242 USA Phone: 513 563 7100 Fax: 513 563 6929 Email: mailbox@grainger.com W.L. Gore and Associates, Inc. 1505 N. 4th St. Flagstaff, AZ 86004 USA Phone: 800 344 3644 Fax: 520 526 2919 Wall-Colmonoy Corp. 30261 Stephenson Hwy. Madison Heights, MI 48071 USA Phone: 248 585 6400 Fax: 248 585 7960 Email: wcc@wallcolomony.com Walters Manufacturing Co. 297 Anna St. Watsonville, CA 95076-2487 USA Phone: 831 724 1377 Fax: 831 724 1378 Watkins & Associates 5395 Webb Parkway Lilburn, GA 30047 USA Phone: 770 279 9200 Fax: 770 279 9203 Email: jlittlejohn@watkins-associates.com
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A WD-40 Company 1061 Cudahy Place San Diego, CA 92110 USA Phone: 619 275 1400 Fax: 619 275 5823 Wesgo Metals, A Division Morgan Technical Ceramics, Inc. 610 Quarry Road San Carlos, CA 94070-6224 USA Phone: 650 631 4700 Fax: 650 631 4701 Westaim Corp. 10102 114 Street Fort Saskatchewan, Alberta T8L 3W4 Canada Phone: 800 661 4139 Alt Phone: 780 992 5277 Fax: 780 992 5275 Email: sbakke@westaim.com Witco Corp. One American Lane Greenwich, CT 06831 USA Phone: 800 494 8673 Alt Phone: 203 552 2000 Fax: 203 552 2448 Wm. Buchanan Supply Co. 6314 Wiehe Rd. Cincinnati, OH 45237 USA Phone: 513 731 1411 Zip-Chem Products 1860 Dobbin Dr. San Jose, CA 95133 USA Phone: 408 729 0291 Fax: 408 272 8062 Zircoa Products 31501 Solon Rd. Solon, OH 44139 USA Phone: 440 349 7218
EFFECTIVITY: ALL
70-80-00
STANDARD PRACTICES MANUAL AS907-1-1A Fax: 440 248 8864 Email: zircoa@zircoa.com Zokman Products, Inc 1220 East Gump Road Ft. Wayne, IN 46845-9794 USA Phone: 800 727 6027 Alt Phone: 219 637 4038 Fax: 800 844 3227 Alt Fax: 219 637 5031 Email: zzokman@aol.com Zoltek 3101 McKelvey Road St. Louis, MO 63044 USA Phone: 314 291 5110 Fax: 314 291 6511
EFFECTIVITY: ALL
70-80-00
EFFECTIVITY: ALL
70-80-00
ADHESIVES, PLASTICS, SEALANTS - CONSUMABLE PRODUCTS ADHESIVES, PLASTICS, SEALANTS TASK 70-80-01-800-012 1. Consumable Products - Adhesives, Plastics, and Sealants SUBTASK 70-80-01-99G-012 A. Ref No. General. Consumable Name / Remarks White Star C01-002 Catalyst Cream Hardener C01-003 Compound, Sealing Permatex, Form-A-Gasket No. 2 C01-004 Adhesive, Liquid Plastiseal F C01-005 Catalyst Fascat 2003 STO C01-006 RTV, Silicone Elastomer (MIL-A-46106 Type I) 732 Black Multi-Purpose Sealant RTV 103 (Black) C01-007 RTV, Silicone Elastomer (MIL-A-46106 Type I) 736 Red Heat Resistant Sealant RTV 106 (Red) C01-008 RTV, Potting Compound, Two Part RTV 560 (Red) C01-009 Polymer, Urethane Adiprene L-167 and Curing Agent Moca
EFFECTIVITY: ALL
Supplier Fibre Glass Evercoat Co. Fibre Glass Evercoat Co. W. W. Grainger
C01-001 Potting Compound, Two Part
Kenneth Industrial Products, Inc. Atofina Chemicals GE Company, Silicone Products Division Dow Corning Corp. GE Company, Silicone Products Division Dow Corning Corp. GE Company, Silicone Products Division GE Company, Silicone Products Division
70-80-01
CONSUMABLE PRODUCTS ADHESIVES, PLASTICS, SEALANTS Page 1 Dec 01/03
Ref No.
Consumable Name / Remarks Obsolete: Replaced by C03-027 and C03-028
Supplier
C01-010 Adhesive, Paste, Two Part Hysol EA 901NA/B-1 Hysol EA901/B-1 Deleted: Replaced by Hysol EA 901-NA/B-1 NOTE: Contains Asbestos C01-011 Adhesive, Paste, Two Part NOTE: C01-155 and C01-156 may be used as one way alternatives for C01-011. C01-011 may not be used as an alternative for C01155 or C01-156. Hysol EA 934 (Part A and B) Deleted: Contains Asbestos NOTE: Replaced by Hysol EA 934NA Hysol EA 934NA C01-012 Liquid Locking Agent (MIL-S-46163A, Type 3, Grade R) Loctite 088 Deleted: Duplicate Entry, See C01-187 Loctite 290 C01-013 Potting Compound, Polysulfide EC 612 (Ribbon form only) C01-014 Primer, Sealant, Adhesive Silicone (MIL-A-46106) Alternative: C01-159 Dow Corning 1200 Primer Red or Clear C01-015 Insulation, Ablative Silicone MA-25 Ablative Coating Parts A, B, & C Lockheed Martin Space Systems Company - Michoud Operations Dow Corning Corp. Accumetric, LLC Loctite Corp. Loctite Aerospace Loctite Aerospace
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks NOTE: Type I (Sprayable) NOTE: Type II (Trowelable) NOTE: Type III (Sheet Stock)
Supplier
C01-016 Adhesive, Epoxy Resin Hysol EA 901/B-3 Deleted: Contains Asbestos, Replaced by C01-156 C01-017 Resin, Epoxy, Liquid NOTE: If this material is to be used in the formulation of an abradable compound, C01-060 may be used as an alternative EPON 828 EPON 828 EPON 828 C01-018 Microballoons, Phenolic Type B5O-0930 Obsolete: Replaced by C10-093 NOTE: Mfg. Discontinued in USA. International Distributor listed in C10-093 C01-019 Adhesive Epoxy, Two Part E-400-12 Obsolete: Replaced by C01-011 or C01-155 C01-020 RTV, Fluorosilicone Elastomer Dispersion Coating Dow Corning 94-003 Obsolete: Replaced by C01-038 C01-021 Adhesive, Epoxy, Two Part Metal-Set A4 Part A and B C01-022 Primer Cati Coat, E42GP15 Smooth-On Inc. E. V. Roberts and Associates Miller Stephenson Chemical Co. Shell Chemical Co.
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks Deleted: Repair requirement no longer exist
Supplier
C01-023 Catalyst V66RP15 Deleted: Repair requirement no longer exist C01-024 Catalyst Diethylenetriamine (High Purity Grade) Diethylenetriamine (High Purity Grade) Diethylenetriamine (High Purity Grade), Product Code: 803274 Diethylenetriamine (High Purity Grade), Product Code: H768 or 3356 C01-025 Foam, Urethane, Convolute Foam, Urethane, 2 in. (51 mm) thick C01-026 Resin, Epoxy, Liquid (MIL-R-9300, Type I) MIL-R-9300, Type I C01-027 Adhesive, Synthetic 3M Super 77 Spray Adhesive Scotch Grip 77 Obsolete: Replaced by 3M Super 77 Spray Adhesive C01-028 Adhesive, Liquid, Two Part Barco Bond MB-165 C01-029 Adhesive Film, Supported FM-123-5 Deleted: Duplicate Entry, See C01-066 C01-030 Sealer, Phenolic Metcoseal AP C01-031 Thinner Metcoseal APT C01-032 Adhesive Film, Supported Metlbond 329, Type I Sulzer Metco, Inc. Sulzer Metco, Inc. Astro Chemical Co., Inc. 3M Company Local Purchase Local Purchase Fisher Scientific Co. Union Carbide Corp. Merck KGaA
Mallinckrodt Baker, Inc.
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks Obsolete: Replaced by C01-182
Supplier
C01-033 Adhesive Film, Supported Aerobond 3038 Obsolete: Replaced by C01-044 C01-034 Binder, Acrylic Laquer, Clear Krylon No. K1302 Krylon Products Group, the Specialty Div. of SherwinWilliams Co. Krylon Products Group, the Specialty Div. of SherwinWilliams Co.
Krylon No. S-500
C01-035 Binder Plastibond Obsolete: Replaced by C06-019 C01-036 Binder Nicrobraz No. 300 Obsolete: Material Contained ODC. Replaced by C01-036 Nicrobraz 320 Nicrobraz No. 320 C01-037 Adhesive, Synthetic 1870 Scotch Grip Industrial Adhesive C01-038 Varnish, Alkyd Glyptal 1201 C01-039 Catalyst Ancamine-Z Curing Agent NOTE: (SETA) Possible Carcinogen Epon Z Obsolete: Replaced by Ancamine-Z Curing Agent NOTE: (SETA) Possible Carcinogen Product ID numbering change at vendor C01-040 Primer Air Products and Chemicals Inc. GLYPTAL, INC. 3M Company Wall-Colmonoy Corp.
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks LOCQUIC Primer Grade N7649 Obsolete: Replaced by Loctite 19269 NOTE: Product ID Numbering Change by Vendor Loctite 19269 Loctite 21348 NOTE: Aerosol same as Loctite 19269
Supplier
Loctite Corp. Loctite Corp.
C01-041 Liquid Locking Agent Loctite 638 Loctite 680 C01-042 RTV, Potting Compound, Two Part RTV 630 (Blue) C01-043 Adhesive, Epoxy, Two Part Hysol EA911F/NA (Part A and B) Obsolete: Repair requirement no longer exist C01-044 Adhesive Film, Supported Metlbond 328 (Supported) Deleted: Contains Asbestos, Replaced by C01-136 C01-045 Adhesive Film, Unsupported Metlbond 328 (Unsupported) Deleted: Contains Asbestos, Replaced by C01-139 C01-046 Kit, Epoxy Repair, Two Part AA5629-1D1A NOTE: International Sales AA5629-1D1A NOTE: US Sales C01-047 Kit, Epoxy Repair Epoxy Repair Kit
EFFECTIVITY: ALL
Loctite Corp. Loctite Corp. GE Company, Silicone Products Division
Satair A/S
PAS
70-80-01
Ref No.
Consumable Name / Remarks Obsolete: Repair requirement no longer exist
Supplier
C01-048 Liquid Locking Agent Loctite 271 NOTE: European Loctite 275 is equivalent to this product. C01-049 RTV, Potting Compound, Two Part RTV 577 (White) C01-050 Adhesive, Rubber (Fed. Spec. MMM-A-00185) Alternative: C01-037 Rubber Cement and Thinner C01-051 Adhesive, Synthetic 3M Shipping Mate Labeling Adhesive C01-052 Adhesive Epocast 31A/9216 Obsolete: Replaced by C01-147 NOTE: When using the approved alternate be sure to use the mixing instructions for the C01-147 consumable supplied by the manufacturer. C01-053 Adhesive, Paste, Two Part HT424 Two Part Thixotropic Paste NOTE: Contains Formaldehyde HT424 Two Part Thixotropic Paste NOTE: Contains Formaldehyde C01-054 Adhesive Film, Supported Cytec Engineered Materials Inc. Cytec Eur. 3M Company Starkey Chemical GE Company, Silicone Products Division Loctite Corp.
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks NOTE: MMM-A-132, Type II & III, Form F Group 4; MIL-A-45263 Type III Class 2, Group 4) HT424 Supported Film (0.135 psf)
Supplier
Cytec Engineered Materials Inc. Loctite Corp. GE Company, Silicone Products Division
C01-055 Liquid Locking Agent (MIL-S-46163A, Type 1, Grade L) Loctite 277 C01-056 RTV, Silicone Elastomer (MIL-A-46106, Type 1) RTV 108 (Translucent) C01-057 Adhesive, Liquid Alternative: C01-118 Loctite Superbonder 496 NOTE: Formerly (IS12) Product ID numbering change by Vendor. Permabond 910 Pro Grip 5500 Obsolete: Replaced by Loctite Superbonder 496 C01-058 Binder, Acryloid Grade JB with Toluol Obsolete: Replaced by C06-019 (slurry appl.) or C01-034 (powder retention) C01-059 Adhesive, Epoxy, Two Part ADX 311.1 (Part A and B) Obsolete: Replaced by C01-011 C01-060 Abradable Seal Material NOTE: Consists of C01-017, C01-024, and C10-093 Resin Pack # 039-080055-685 RSP-3 Kit C01-061 Tape, Duct N-K5 First Grade Obsolete: Replaced by C10-021 Syon Corporation Accumetric, LLC Permabond International Corp. Loctite Corp.
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks PR 1422 NOTE: Chromated version PR-1440 AMS-S-8802 NOTE: Chromate Free environmentally prefered product
Supplier PRC-Desoto International Inc.
C01-062 Compound, Sealing, Temperature Resistant
PRC-Desoto International Inc.
C01-063 Adhesive, Epoxy Reliabond 380 C01-064 Rubber, Silicone Rubber, Silicone, Shore A40 (1/4 in. thick) C01-065 Film, Plastic Tedlar Plastic (Film, 0.015 thick) Obsolete: Replaced by C10-133 C01-066 Adhesive Film, Supported Alternative: C01-142 NOTE: MMM-A-132, Type I, Class 2, Form F Group 3; MIL-A-45263, Type I Class 2 Group 3 FM-123-5 .06 psf C01-067 Primer, Adhesive (A50TF119 Class A or B) M6725-1 C01-068 Adhesive, Foam Core Splice FM-37 Deleted: Contains Asbestos, Replaced by C01-132 FM-37 NA Deleted: Replaced by C01-132 C01-069 Adhesive, Foam Core Splice FM-40 Deleted: Contains Asbestos, Replaced by: C01-132 Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Local Purchase Hexcel Corporation
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks Epocast 1636 A/B NOTE: Formerly Epocast 33A/9216 Epocast 33A/9216 Obsolete: Replaced by Epocast 1636 A/B NOTE: Product ID numbering change by vendor Epocast 8067 Obsolete: Replaced by 33A/ 9216 NOTE: Product ID numbering change by vendor
Supplier Vantico
C01-070 Potting Compound, Two Part
C01-071 Potting Compound, Two Part EC 3500 B/A C01-072 Adhesive, Synthetic Pliobond 20 C01-073 Compound, Sealing, Temperature Resistant (AMS 3276) PR 1750 B-2 C01-074 RTV, Adhesive, Paste, Two Part Epibond 1210A / 9610 C01-075 RTV, Potting Compound, Two Part RTV 60 (Red) C01-076 RTV, Silicone Elastomer (MIL-A-46106) RTV 109 (Aluminum) C01-077 Potting Compound, Two Part (Martin Marietta Spec. MIS45356) Epoxylite, 6203 C01-078 Adhesive, Liquid, Two Part Cycle-Weld C14 Obsolete: Replaced by EY 4014 A and B Epoxylite Corp. GE Company, Silicone Products Division GE Company, Silicone Products Division Vantico PRC-Desoto International Inc. Ashland Chemicals 3M Company
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks NOTE: Product ID numbering change by Vendor EY 4014 A and B
Supplier
Fiber-Resin Corp.
C01-079 Adhesive, Epoxy Resin High Temperature Jelcoat Resin 31A Obsolete: Replaced by C01-157 C01-080 Catalyst Furane 9216 Obsolete: Replaced by C01-157 C01-081 Polyethylene Film Polyethylene Film (0.0005 min. thick) Deleted: Replaced by C10-128 C01-082 Adhesive, Epoxy, Two Part Resin EA 958 (Part A & B) Deleted: Repair requirement no longer exist C01-083 Adhesive, Two Part Dental Cement Kit (Liquid/ Catalyst and Powder) Grip Cement Kit No. 675570 Liquid No. 675568, Powder No. 675564 Obsolete: Replaced by Kit No. 675570 Powder No. 675571 Catalyst No. 675572 Obsolete: Replaced by Kit No. 675570 C01-084 Sealant, Pipe, with Teflon Loctite 567 Loctite 592 C01-085 Adhesive Film, Supported FM 400-6 Deleted: Repair requirement no longer exist C01-086 RTV, Potting Compound, Two Part Loctite Corp. Loctite Corp. Local Purchase from Dental Supplier Dentsply/Caulk Division
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks RTV 664 (Blue)
Supplier GE Company, Silicone Products Division
C01-087 Primer, Epoxy A/B P-415-66 Primer/Resin and Catalyst/Thinner Deleted: Repair requirement no longer exist C01-088 Adhesive Film, Supported Metlbond 328 Deleted: Contains Asbestos Replaced by: C01-136 C01-089 Adhesive, Paste Pro Seal 735 Obsolete: Replaced by C01-115 C01-090 Primer, Catalyst (MIL-S-22473E, Grade T, Form R) Alternative: C01-160 Loctite Primer T 7471 NOTE: Non-Chlorinated C01-091 Potting Compound, Polysulfide EC 1788 (Ribbon Form Only) Obsolete: Replaced by C01-013 C01-092 Primer, Silicone SS4155 (Blue) NOTE: Primer for two part adhesives SS4155 (Blue) NOTE: Primer for two part adhesives C01-093 Adhesive, Liquid (MIL-C-4003) EC-847 C01-094 RTV, Silicone Elastomer (MIL-A-46106, Type II, Grade 1) RTV 118 (Translucent) C01-095 Elastomer, Polyurethane, Two Part Flexobond 329 Kit Bacon Industries GE Company, Silicone Products Division 3M Company GE Company, Silicone Products Division General Electric France Loctite Corp.
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks Hysol EA 901 NA/LR100 Obsolete: Replaced by C01-156
Supplier
C01-096 Adhesive, Epoxy, Two Part
C01-097 Tape, Brown Ceramic Filled TFE, Etched one side Tape, Brown Ceramic Filled TFE, Etched one side Tape, Brown Ceramic Filled TFE, Etched one side Deleted RM 827 C01-098 Adhesive, Film (and Primer) BR-34B-18 Primer Deleted: Contains Asbestos BR-34B-32 Primer FM-34B-18 Adhesive Deleted: Contains Asbestos FM-34B-32 Adhesive (Supported or Unsupported) C01-099 Primer HT424 Two Part Primer NOTE: Contains Formaldehyde C01-100 Adhesive, Paste Conapoxy AD-3 Obsolete: Replaced by Conapoxy AD-10 Conapoxy AD-10 C01-101 Catalyst Conacure EA-03 Deleted: Repair requirement no longer exist C01-102 Coloring Pigment Dispersion, Phthalocyanine Blue 22-38010 Resiweld No. 7925 Obsolete: Replaced by No. 2238010
EFFECTIVITY: ALL
Saint-Gobain Performance Plastics
Kahrs Thermal Technology
Cytec Engineered Materials Inc.
Cytec Engineered Materials Inc. Cytec Engineered Materials Inc.
Conap, Inc.
Ferro Corp.
70-80-01
Ref No.
Consumable Name / Remarks NOTE: Product ID numbering change at Vendor
Supplier
C01-103 Adhesive Film FM-1000 .03 psf 0.005 in. to 0.007 in. thick Type FM-1000 0.005 in. to 0.007 in. thick NOTE: Material available in small quantities starting at 5 sq. ft. (0.46 sq. M) Type FM-1000 0.005 in. to 0.007 in. thick NOTE: Material available in small quantities starting at 5 sq. ft. (0.46 sq. M) C01-104 Adhesive Film Type FM-1000 Deleted: Duplicate Entry, See C01-103 C01-105 Adhesive, Liquid 2086 Scotchweld Epoxy Adhesive EC2186 Obsolete: Replaced by 2086 Scotchweld Epoxy Adhesive C01-106 Adhesive, Paste Alternative: C01-147 Hysol EA 956 C01-107 Adhesive, Epoxy Hysol EA 9309 Deleted: Repair requirement no longer exist C01-108 Fibers, Milled Glass Milled Cat. No. 731ED 1/16 in. or 1/8 in. long C01-109 Adhesive, Liquid Owens-Corning Fiberglass Corporation Loctite Aerospace 3M Company Protech Lab Corporation Cytec Engineered Materials Inc. Metcut Research
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks CA-5 Pronto Instant Adhesive Scotchweld CA-5 Obsolete: Replaced by CA-5 Pronto Instant Adhesive
Supplier 3M Company
C01-110 Liquid Locking Agent (MIL-R-46082B, Type 1) Loctite 601 Obsolete: Replaced by Loctite 609 Loctite 609 C01-111 Adhesive, Film, Supported (Fed Spec. MMA-A-132, Type I, Class 3) FM-96 C01-112 Adhesive, Film, Unsupported ( Fed Spec. MMM-A-132, Type I, Class 3) FM-96U C01-113 PTFE, Porous Sheet (Teflon) Grade 50-55 Porous PTFE Porous PTFE (NATO Supply Code F0585) Zitex C01-114 Liquid Locking Agent (MIL-R-46082B, Type 1) Loctite 620 C01-115 Adhesive, Sealant (MIL-PRF-81733, Type II-2) PR1436G B-2 Obsolete: Replaced by Pr1440B-2 PR1440-B-2 PS 870-B-2 C01-116 Adhesive, Epoxy Casting Resin Epocast 1310 Obsolete: Replaced by C01-011 or C01-155 C01-117 RTV, Adhesive, Paste, Two Part (BMS 5-123 Type 1, Class 3) Epibond 8543 (Parts A/B) PRC-Desoto International Inc. PRC-Desoto International Inc. Loctite Corp. Fluoro Plastics Inc. P. Viennot S. A. Norton Performance Plastics Corporation Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Loctite Corp.
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks Obsolete: Replaced by Epibond 8543 (Parts C/B) Epibond 8543 (Parts C/B)
Supplier
Vantico
C01-118 Adhesive, Liquid (A-A-3097, Type 1, Class 2) Alternative: C01-057 Loctite 430 C01-119 Tape Flashbinder No. 5, one in. wide Deleted: Repair requirement no longer exist C01-120 Adhesive, Structural Plastisol PP-0274 Plastisol SP 198 Deleted: Replaced by Plastisol PP-0274 C01-121 Adhesive, Film EA 9649R (Unsupported) Obsolete: Replaced by C01-136 EA9205 (Supported) Obsolete: Replaced by C01-136 C01-122 RTV, Silicone Elastomer RTV 157 (Gray) C01-123 Plaster, Stable Ultracal All C01-124 Plaster, Stable Ultracal 30 C01-125 Adhesive, Epoxy, Two Part EC-3524 B/A C01-126 Fabric, Netting, Dacron Polyester D117 C01-127 Prepreg, Woven Graphite CYCOM 919 GFK 3070 PW T300 Fiber Weavestyle 3K C01-128 Adhesive Film, Supported (0.85 psf wt (0.42 kg/m sq.)) AF3109-2K 0.085 psf C01-129 Adhesive, Paste, Fast Cure 3M Company Cytec Engineered Materials Inc. Mohawk Fabric Co. Inc. 3M Company U. S. Gypsum Co. U. S. Gypsum Co. GE Company, Silicone Products Division Portland Plastics Loctite Corp.
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks Hysol EA 960F
Supplier Loctite Aerospace 3M Company Loctite Aerospace
C01-130 Adhesive Film, Supported, Low Temperature Cure AF163-2K .085 EA 9628NW .085 psf FM 73 Deleted Metlbond 1133 Obsolete C01-131 Adhesive Film, Unsupported, Low Temperature Cure AF163-2U EA 9628UNS FM 73U .05 psf Deleted M1133-2 Obsolete C01-132 Adhesive, Foam Core Splice AF-3024 FM410-1 FM490A MA557 C01-133 Primer, Adhesive EC 3917 Deleted: Duplicate Entry, See C01-166 C01-134 Adhesive, Sprayable EC 3964 C01-135 Adhesive Film, Supported Metlbond 328 Deleted: Contained Asbestos, Repair requirement no longer exist C01-136 Adhesive Film, Supported 3M Company 3M Company Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. SIA Adhesives, Inc. 3M Company Loctite Aerospace
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks NOTE: C01-165 is not an approved alternative for C01-136 unless specified in the process document. EA 9689.08 (Class E) NOTE: Use with Primer EA9205 or EA9205R EA 9689.08 (Class E) EA 9689.10 PSF GK (Class D) NOTE: Use with Primer EA9205 or EA9205R. NOTE: 30 Sq. Ft. available quote Dexter Code AT9154 EA 9689.10 PSF GK (Class D) NOTE: Use with Primer EA9205 or EA9205R
Supplier
Watkins & Associates
Loctite Aerospace Watkins & Associates
Loctite Aerospace
C01-137 Adhesive Film, Nitrile-Phenolic NOTE: (0.015-0.019 psf wt (0.073-0.093 kg/m sq.)) AF-15 C01-138 Primer, Adhesive EC 2174 NOTE: For use with C01-137 C01-139 Adhesive Film, Unsupported NOTE: (0.244 - 0.317 kg/m square) FM350U NA .06 psf Hysol EA 9689.06 psf Scotch Weld AF-191U 0.50 psf C01-140 Adhesive Pro-Seal 501 C01-141 Adhesive, Metal Primer
EFFECTIVITY: ALL
3M Company 3M Company
Cytec Engineered Materials Inc. Loctite Aerospace 3M Company PRC-Desoto International Inc.
70-80-01
Ref No.
Consumable Name / Remarks EC 3901
Supplier 3M Company
C01-142 Adhesive Film, Supported Alternative: C01-066 AF126-2 0.06 psf C01-143 Liquid Locking Agent (MIL-S-46163A, Type 2, Grade N) Loctite 242 C01-144 Elastomer, Polyurethane, Two Part RP6402-1 Resin and Hardener C01-145 Compound, Jointing Hylomar PL32, Medium Deleted: Replaced by SQ32L SQ32L C01-146 Adhesive, Epoxy Liquid 3M 2214 Scotchweld Structural Adhesive C01-147 Adhesive, Structural, Liquid Hysol EA 9396 NOTE: Standard B Catalyst C01-148 Adhesive Adhesive Deleted: Repair requirement no longer exist C01-149 Liquid Locking Agent (MIL-R-46082B, Type 2) Loctite 640 C01-150 RTV, Potting Compound, Two Part RTV 88 (Red) C01-151 RTV, Silicone Elastomer, Two Part (MIL-PRF-23586F Grade B, Type 1, Class 2) Sylgard 170 Parts A and B C01-152 Maskant, Liquid Turco 522 Obsolete: Replaced by C10-014 C01-153 RTV, Fluorosilicone Sealant, Room Temperature Cure Dow Corning 730 Solvent Resistant Sealant Dow Corning Corp. Dow Corning Corp. GE Company, Silicone Products Division Loctite Corp. Loctite Aerospace 3M Company Marston Lubricants, LTD Vantico Loctite Corp. 3M Company
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks FRV 1106
Supplier GE Company, Silicone Products Division Dow Corning Corp. Loctite Aerospace
C01-154 RTV, Sealant, Silicone Rubber 90-006 C01-155 Adhesive, Paste, Two Part Hysol EA 9394 NOTE: Standard B Catalyst C01-156 Adhesive, Paste, Two Part (MMM-A132B Type II, Form P Group 2) Hysol EA 9394/C2 NOTE: C2 Catalyst C01-157 Adhesive, Structural, Liquid (MMM-A132B Type I, Class 3, Form P Group 1) Hysol EA 9396/C2 NOTE: C2 Catalyst C01-158 RTV, Sealant, Silicone Rubber 93-006 C01-159 Primer, RTV (MIL-A-46106; MIL-A-46146; MIL-S-23586) SS4004 (Pink) C01-160 Primer, Catalyst Alternative: C01-090 Loctite 7090 NOTE: Non-Chlorinated C01-161 Abradable Seal Material Hysol EA 9891RP NOTE: Product may be ordered in Semkit C01-162 Abradable Seal Material Hysol EA 9890 C01-163 Lubricant, Solid Film, Heat Cured Surfkote LOB-1800-G Deleted: Listed in error, Replaced by C02-065 Loctite Aerospace Loctite Aerospace Loctite Corp. GE Company, Silicone Products Division Dow Corning Corp. Loctite Aerospace Loctite Aerospace
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks RTV 615 (Clear)
C01-164 RTV, Potting Compound, Two Part
C01-165 Adhesive Film, Supported C01-136 may be used as a one way alternative NOTE: ( 0.08 - 0.095 psf wt., (0.391 - 0.464 kg/m sq.)) AF-191K (Class B) FM 350 NA S .09 psf Hysol EA 9689.09 psf Hysol EA 9689.09 psf C01-166 Primer, Adhesive BR-154 EC-3917 Hysol EA 9205 C01-167 RTV, Silicone Elastomer RTV 148 C01-168 RTV, Silicone Elastomer RTV 147A C01-169 Catalyst Catalyst 147B NOTE: Catalyst for RTV 147A, C01-168, and RTV 148, C01-167 C01-170 Primer, Silicone Primer - MB C01-171 Polyurethane Dispersion C01-073 and C01-115 are possible replacements for some applications - consult with appropriate engineering authority for approval. PR-715 Deleted Rhone-Poulenc Rhone-Poulenc Rhone-Poulenc Rhone-Poulenc Cytec Engineered Materials Inc. 3M Company Loctite Aerospace 3M Company Cytec Engineered Materials Inc. Watkins & Associates Loctite Aerospace
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks 3145 RTV RTV 167
Supplier Dow Corning Corp. GE Company, Silicone Products Division 3M Company
C01-172 Sealant, Silicone Rubber (MIL-A-46146)
C01-173 Adhesive, Rubber and Gasket 1300L Scotch-Grip Rubber and Gasket Adhesive C01-174 Adhesive, Paste, Two Part Hysol EA 9395 C01-175 Adhesive Film, Unsupported (0.035 psf wt. (0.17 kg/m sq.)) AF-3109-2U 0.035 psf C01-176 RTV, Silicone Elastomer RTV 133 (Black) C01-177 Abradable Seal Material Hysol EA 9891RP Deleted: Duplicate Entry, See C01-161 C01-178 RTV, Silicone Elastomer RTV 159 (Red) C01-179 Primer S2260 Prime Coat Thixon 305 Obsolete: Replaced by S2260 Prime Coat C01-181 Adhesive, Epoxy, Flexible Elastolock 2710 Part A & Part B C01-182 Adhesive Film, Supported FM 300M .08 psf C01-183 Potting Compound EC-3439 C01-184 Adhesive Film, Nitrile-Phenolic NOTE: (0.050-0.060 psf wt. (0.242-0.290 kg/m sq.)) AF-32
EFFECTIVITY: ALL
Loctite Aerospace
3M Company GE Company, Silicone Products Division
GE Company, Silicone Products Division Dow Corning Corp.
SIA Adhesives, Inc. Cytec Engineered Materials Inc. 3M Company
3M Company
70-80-01
Ref No.
Consumable Name / Remarks
Supplier
C01-185 Compound, Polyurethane Sheet with Adhesive/Primer Coating 74-451-182 C01-186 Adhesive Film, Supported NOTE: (0.075-0.085 psf wt. (0.366-0.415 kg/m sq.)) AF-191K (Class C) (0.08 wt) C01-187 Liquid Locking Agent (MIL-S-22473E, Grade A) Grade A Obsolete: Replaced by Loctite 088 NOTE: Product ID numbering change by the Vendor Loctite 088 C01-188 Adhesive, Aluminum Filled Epoxy Film MA-529 WCG NOTE: Width: 1.48-1.52 in. (3.8-3.9 cm) NOTE: Length: 56-66 in. (142168cm) MA-529 WCG NOTE: Width: 1.48-1.52 in (3.8-3.9 cm) NOTE: Length: 56-66 in. (142168 cm) C01-189 Rubber, Silicone Sheet, molded Rubber, Silicone Sheet, molded, 0.125 inch (3.2 mm) thick C01-190 Sealant, Polythioether PR-1826 Class B-1/4 C01-191 RTV, Silicone Elastomer, White RTV 5812 C01-192 RTV, Silicone Elastomer, Black GE Company, Silicone Products Division PRC-Desoto International Inc. Furon Tape Division / Division of Saint Gobain SIA Adhesives, Inc. SIA Adhesives, Inc. Loctite Corp. 3M Company BF Goodrich Ice Protection Systems
EFFECTIVITY: ALL
70-80-01
Ref No.
Consumable Name / Remarks RTV 5813
EFFECTIVITY: ALL
70-80-01
ANTI-SEIZE COMPOUNDS, LUBRICANTS, OILS - CONSUMABLE PRODUCTS ANTI-SEIZE COMPOUNDS, LUBRICANTS, OILS TASK 70-80-02-800-013 1. Consumable Products - Anti-Seize Compounds, Lubricants, and Oils SUBTASK 70-80-02-99G-013 A. Ref No. General. Consumable Name / Remarks NOTE: C02-058 may be used as a one way alternative to assure graphite purity Braycoat 655 Fel-Pro-C601 Deleted: Replaced by Loctite Graphite 50 Loctite Graphite 50 Deleted Nyco GA47 Royco 44 Shell compound No 8 Obsolete C02-002 Compound, Anti-Seize Ease-Off 990 Obsolete: Replaced by C02-001 or C02-058 C02-003 Lubricant, Sprayable Air Drying NOTE: This is not the same product as the Dow Corning 321 Dry Film Lubricant (Aerosol) that is available in the USA. Molykote D 321 R Molykote D 321 R
EFFECTIVITY: ALL
Supplier
C02-001 Compound, Anti-Seize (AMS 2518)
Castrol Industrial North American Inc.
Nyco SA Royal Lubricants Co., Inc.
Fournier Dow Corning France SA
70-80-02
CONSUMABLE PRODUCTS ANTI-SEIZE COMPOUNDS, LUBRICANTS, OILS Page 1 Dec 01/03
Ref No.
Consumable Name / Remarks Molykote D 321 R
Supplier Dow Corning Europe SA
C02-004 Lubricant, Sprayable Air Drying Sandstrom 26A Deleted: Replaced by Sandstrom 27A Sandstrom 27A MoS2 Base and Corrosion Inhibitor (GE Spec. A50TF192 Class B) Surfkote A-1625 MoS2 Base MIL-L-23398 (GE Spec. A50TF192 Class A) Obsolete Tiolube 70 organic solvent base dry film lubricant (GE Spec. A50TF192 Class B) Tiolube 75/75 Water base, dry film lubricant (GE Spec. A50TF192 Class B) ZIP-D-5460NS MoS2 Colloidal Suspension (GE Spec. A50TF192 Class C) C02-005 Lubricant, Solid Dry Film Everlube 811 or MIL-L-81329 equivalent C02-006 Lubricant Everlube ESNA 382 C02-00 7Assembly Fluid (GE Spec. A50TF92) Ultrachem Assembly Fluid No. 1 C02-008 Petroleum Jelly Alternative: C02-033 Petrolatum VV-P-236 C02-009 Lubricant Molykote Type Z C02-010 Lubricant, Dryfilm Spray Mix Type I C02-011 Graphite, Powdered Dixon No. 635 C02-012 Grease Aeroshell-7, MIL-G-23827
EFFECTIVITY: ALL
Sandstrom Products Co.
Tiodize Co., Inc.
Tiodize Co., Inc.
Zip-Chem Products
E/M
E/M Ultrachem, Inc.
Local Purchase Dow Corning Corp. Drilube Co. Dixon Ticonderoga
70-80-02
Ref No.
Consumable Name / Remarks Deleted: Replaced by C02-016
Supplier
C02-013 Lubricant, O-Ring and Assembly Fluid Acryloid HF825 Deleted Royco HF825 C02-014 Grease, Molybdenum Disulphide (MIL-G-21164) Aeroshell Grease 17 M-Everlube 211-G Royco 64 C02-015 Grease, Molybdenum Disulphide (MIL-G-21164) M-Everlube 211-G Deleted: Replaced by C02-014 C02-016 Grease (MIL-G-23827) Aeroshell Grease 7 Aeroshell Grease 7 Equilon Enterprise Shell International Trading Co., International Aviation Division Castrol Industrial North American Inc. Equilon Enterprise LPS Laboratories, Inc. Royal Lubricants Co., Inc. Royal Lubricants Co., Inc.
Castrol EASE AI Exxon 827 Obsolete Exxon S114EP Obsolete Royco 27 Royco 27A Obsolete: Replaced by Royco 27 NOTE: Product ID numbering change by Vendor C02-017 Grease, General Purpose (MIL-PRF-81322) Exxon 322 Obsolete: Replaced by Royco 22CF Royco 22 Obsolete: Replaced by Royco 22CF Royco 22CF
Royal Lubricants Co., Inc.
Royal Lubricants Co., Inc.
EFFECTIVITY: ALL
70-80-02
Ref No. C02-018 Oil, Penetrating
Consumable Name / Remarks WD-40
Supplier WD-40 Company Local Purchase
C02-019 Oil, Engine Lubricating (GE Spec. D50TF1) Oil, Engine Lubricating NOTE: See CF6 Service Bulletin 79-1 for approved oil brands and suppliers C02-020 Oil, Lubricating High Temp Silicone base with MoS2 (DOD-L-25681) Royco 81MS C02-021 Oil, Grade 1010 (MIL-PRF-6081) Aeroshell Turbine Oil 2 Aeroshell Turbine Oil 2 Equilon Enterprise Shell International Trading Co., International Aviation Division Castrol Industrial North American Inc. Delta Petroleum Inc. Royal Lubricants Co., Inc. Fuchs Lubricants Co. GE Company, Silicone Products Division Local Purchase Royal Lubricants Co., Inc.
Brayco 460 Hydrocol Jet Royco 481 Windsor L-110 C02-022 Fluid, Silicone (GE Spec. SF96) 3-10 CS Viscosity C02-023 Oil, Engine Lubricating (MIL-L-23699) Oil, Engine Lubricating (MIL-L23699) C02-024 Preservative Soft Film (MIL-C-11796) Class 3 AMS 3079 C02-025 Oil, Preservation (MIL-C-6529C) Aeroshell Fluid 2T Brayco 483 Royco 483 C02-026 Oil, Penetrating (GE Spec. A50TF54) Approved alternatives are C02-039 and C02-053 L1 Liquid Wrench, Industrial Grade
EFFECTIVITY: ALL
Local Purchase Equilon Enterprise Castrol Industrial North American Inc. Royal Lubricants Co., Inc.
Radiator Specialty Co.
70-80-02
Ref No.
Consumable Name / Remarks Molydag 254 NOTE: Contains Inorganic Lead Compounds and Antimony Troxide
Supplier Acheson Colloids Co.
C02-027 Lubricant, Solid Film (Heat Cured)
C02-028 Coating, Colloidal Graphite Dag Dispersion No. 154 Dag Dispersion No. 99 Obsolete: Replaced by Dag Dispersion No. 154 C02-029 Coating, Colloidal Graphite Dag Dispersion No. 200 C02-030 Coating, Colloidal Graphite Dag Dispersion No. 213 C02-031 Lubricant, Silicone Grease G-300 Obsolete: Replaced by Versilube G-321 Versilube G-321 C02-032 Anti-Seize Compound, High Temp Loctite C5A Copper C02-033 Petrolatum, Soft (Fed Spec. VV-P-236) Alternative: C02-008 White Fonoline White Fonoline C02-034 Grease, G 392 Grease, G 392 Obsolete: Repair requirement no longer exist C02-035 Lubricant, Anti-Seize Graphite/Molydisulfide Formkote T-50 Tioform LF 22 C02-036 Lubricant, Anti-Seize Compound Fel-Pro C5A Deleted: Duplicate Entry. See C02-032 C02-037 Lubricant, Grease (MIL-G-81827) E/M Lubri-Film Div. Ruger Chemical Co. Witco Corp. Loctite Corp. Foam Seal/Novagard Acheson Colloids Co. Acheson Colloids Co. Acheson Colloids Co.
EFFECTIVITY: ALL
70-80-02
Ref No.
Consumable Name / Remarks Mobil 29 Obsolete: Replaced by C02-044
Supplier
C02-038 Oil, Lubricating SAE 20-20 C02-039 Oil, Penetrating Approved alternatives are C02-026 and C02-053 Dag 2404 C02-040 Lubricant Microfinish C02-041 Grease, Hi-Temp Royco No. 201 Obsolete: Repair requirement no longer exist C02-042 Airoilene Oil No. P-89507 / 8 C02-043 Grease, Molybdenum, Disulphide (MIL-G-21164) Aeroshell # 17 Obsolete: Replaced by C02-014 C02-044 Grease (MIL-G-81827) Aeroshell Grease 23 Obsolete Royco Grease 22 MS Shell International Trading Co., International Aviation Division Dow Corning Corp. Loctite Corp. Cincinnati Milacron Chicago Pneumatic Tool Co. Champions Choice, Inc. Acheson Colloids Co. Local Purchase
C02-045 Lubricant, Molydisulfide M8800 C02-046 Lubricant Loctite C 200 Solid C02-047 Lubricant, Cutting Fluid Cimperial 1070 Cimperial 12-C Obsolete: Replaced by Cimperial 1070 C02-048 Preservation Treatment Steelgard 1315 C02-049 Lubricant Harry Miller Corp.
EFFECTIVITY: ALL
70-80-02
Ref No.
Consumable Name / Remarks Everlube 810 (Concentrate)
Supplier E/M Local Purchase Castrol Industrial North American Inc.
C02-050 Oil, Preservation (MIL-PRF-6085) MIL-PRF-6085 C02-051 Corrosion Inhibitor (GE Spec. D50TF6 Class A) Brayco 599 C02-052 Oil, Preservation (MIL-L-6085) MIL-L-6085 Obsolete: Replaced by C02-050 C02-053 Oil, Penetrating Approved alternatives are C02-026 and C02-039 Aerokroil (Aerosol) Kroil (Liquid) LPS-1 LPS-LST Supertect ST-A Turbinade TA-A C02-054 Preservative Fingerprint Neutralizer (MIL-C-15074 or AMS 3065) Braycoat 120 Cosmoline 1104 Tectyl 275 C02-055 Preservative Storage Ferrocoat 364AC Ferrocoat 366 C02-056 Inhibitor, In-Process Coolad 1020 Obsolete: Replaced by Immunol 1228 Immunol 1228 Sodium Nitrite (1%) Commercial Quality Steelgard 1301DC C02-057 Lubricant, Dry Solid Film Molykote 3400A Dow Corning Corp. Harry Miller Corp. Local Purchase Harry Miller Corp. Quaker Chemical Corp. Quaker Chemical Corp. Castrol Industrial North American Inc. Houghton International Ashland Chemical Inc. Kano Laboratories Kano Laboratories LPS Laboratories, Inc. LPS Laboratories, Inc. Roly International Roly International
EFFECTIVITY: ALL
70-80-02
Ref No.
Supplier
C02-058 Compound, Thread Lubricating (GE Spec. A50TF201 Class A) NOTE: C02-001 is not an alternate for C02-058 unless specified in the process document. C02-058 is a synthetic graphite version of C02-001. NOTE: C02-079 is an alternate for C02-058 for threaded fasteners 0.250 inch diameter and greater when applied per 70-43-28. Acheson GP460 C02-059 Oil, Water Displacing Turco 5442WD Obsolete Valvoline Tectyl 894 (MIL-C16173 Type 3) C02-060 Anti-Seize and Lubricating Lithium Base Compound (GE Spec. D6Y28A1) Never-Seez Regular Grade Never-Seez Regular Grade Never-Seez Regular Grade C02-061 Anti-Seize Compound Magnesium Hydroxide plus Water NOTE: Mix white powder with enough water to make a thick liquid with paint-like consistency. Milk-of-Magnesia (unflavored) C02-062 Grease, Low Temperature Silicone With Lithium Soap Molykote 33 Dow Corning1 33 Extreme Low Temperature Grease C02-063 Oil, Preservation Dow Corning Corp. Dow Corning Corp. Local Purchase Local Purchase Bostik, Inc. (International Sales) Bostik, Inc. (Domestic Sales) Ashland Chemical Inc. Acheson Colloids Co.
EFFECTIVITY: ALL
70-80-02
Ref No.
Consumable Name / Remarks Ardrox 311
Supplier Oakite Products Inc., Div. of Chemetall Turco Products, Inc. Subsidiary of Henkel Surface Technologies Oakite Products Inc., Div. of Chemetall McGean-Rohco, Inc., Cee-Bee Division
C02-064 Oil, Water Displacing Aquasorb
Ardrox 3962 Cee-Bee WDO C02-065 Lubricant, Solid Film (Heat Cured) (GE Spec. A50TF305 Class A - Spray, Class B - Brush) Surf-kote LOB-1800G C02-066 Lubricant, Graphite Varnish D180 C02-067 Lubricant, Solid Film, (Heat Cured) (GE Spec. A50TF170) Dag 143 Obsolete: Replaced by C02-065 C02-068 Lubricant, MoS2 Dry Film, Heat Cured D85 TER C02-069 Lubricant, MoS2 Solid Lubricant Molykote M-77 Molykote U-n (Available in Europe Only) C02-070 Conductive Grease Brisol-ox SGB/2GX C02-071 Anti-Seize and Lubricating Compound, (GE Spec. D6Y28C1 or A50TF198) Never-Seez Pure Nickel Special Grade C02-072 Corrosion Inhibitor, In Process MagChem Corrotek C02-073 Oil, Honing IC-9 MV-30 C02-074 Tapping Fluid (Non-Chlorinated) Trim Tap NC
EFFECTIVITY: ALL
Hohman Plating and Mfg., Inc. Acheson Colloids Co.
Acheson Colloids Co. Dow Corning Corp. Dow Corning Corp. (France)
Labinal Division, Systeme Aeronautique Electrolube
Bostik, Inc. (Domestic Sales)
MagChem Argent Ltd. Sunnen Products Co. Master Chemical Co.
70-80-02
Ref No. C02-075 Fluid, Hydraulic
Consumable Name / Remarks Trim Tap NC Heavy Skydrol 500B-4
Supplier Master Chemical Co. Solutia Inc. International Products Corporation (UK) International Products Corporation (USA) Sherwin-Williams, Inc.
C02-076 Lubricant, Rubber P-80 P-80 C02-077 Oil, Lubricating Tri-Flow Superior Lubricant NOTE: This product contains zinc C02-078 Lubricant, Assembly Paste Molykote G-n Paste (USA), (GE Spec. A50TF313, Class C) NOTE: Aerospace International Materials C02-079 Lubricant, Liquid Thread (GE Spec. A50TF310 Class A) NOTE: C02-001 is not an alternate for C02-079 unless specified in the process document. NOTE: C02-079 is an alternate for C02-058 for threaded fasteners 0.250 inch diameter and greater when applied per 70-43-28. Cal Lube 7030 C02-080 Lubricant, Silicone Spray All Purpose Silicone Spray P/N S00206 C02-081 Lubricant, Metalworking Semi-Paste Anchorlube G-771 Anchor Chemical Company Krylon Products Group, the Specialty Div. of SherwinWilliams Co. Calvary Chemical Corp. Aerospace International Materials (AIM)
EFFECTIVITY: ALL
70-80-02
FINISHES AND PROTECTIVE COATINGS - CONSUMABLE PRODUCTS FINISHES AND PROTECTIVE COATINGS TASK 70-80-03-800-014 1. Consumable Products - Finishes and Protective Coatings SUBTASK 70-80-03-99G-014 A. Ref No. General. Consumable Name / Remarks Supplier
C03-001 Primer, Zinc Chromate (TT-P-1757 Type 1 or 2, Class C or Class N; AMS 3110, Color Y) Alternatives: C03-005, C03-079, or C03-085 TT-P-1757 Type 1 or 2 Class C (AMS3110) Color Y C03-002 Primer, Epoxy (GE Spec. A50TF107 Class B, Dip Type) Primer Deleted: Replaced by C03-005 C03-003 Paint, Intumescent, White (GE Spec. A50TF121 Class A,) Ocean No. 1522 C03-004 Paint, Enamel, White Chemglaz 11, White A276 C03-005 Primer, Epoxy, Green (GE Spec. A50TF107 Class A, Spray Type) 463-12-8 and Catalyst CA-116 C03-006 Conversion Coating, Chromated (MIL-C-5541, Yellow) Alocrom 1200 Obsolete: Replaced by C03-083 Alodine 1200S NOTE: Mixing Required Alodine 1200SRTU Obsolete Alodine 1201 Obsolete Alodine No. 1200 Henkel Surface Technologies T. C. Specialties, Inc. Lord Corp. Chemical Products Group Fire Research Lab. Local Purchase
EFFECTIVITY: ALL
70-80-03
CONSUMABLE PRODUCTS FINISHES AND PROTECTIVE COATINGS Page 1 Dec 01/03
Ref No.
Consumable Name / Remarks Obsolete: Replaced by Alodine 1200S
Supplier
C03-007 Primer, Epoxy BR-127 C03-008 Conversion Coating, Chromated Alodine No. 1500 C03-009 Paint, Epoxy, Gloss Orange (MIL-C-22750; Fed. Std. 595 Color Code 12197) 4224-T12197 and Catalyst 0200T129 NOTE: New designation for Finch. 443-3-1022 (GE Spec. A50TF17 canceled) Superseded by MIL-C22750 C03-010 Paint Epoxy, Black (MIL-C-22750) NOTE: Fed. Std, 595, Color Code Black, 17038gloss, 27038semigloss, 37038lusterless 4229-T17038 and Catalyst 0200T129 (Gloss) 4229-T27038 and Catalyst 0200T126 - Semigloss 4229-T37038 and Catalyst 0200T126 - Lusterless C03-011 Reducer, Epoxy (MIL-T-81772 Type II) MIL-T-81772 Type II Deleted: Duplicate Entry, See C04-029 (Type II Epoxy) C03-012 Paint, Sermetel Sermetel 409 C03-013 Paint, Teflon, Light Gray 23T3-105 (Fastcure) 24T3-105 (Fastcure) Akzo Nobel Aerospace Coatings Akzo Nobel Aerospace Coatings Sermatech International Inc. T. C. Specialties, Inc. T. C. Specialties, Inc. T. C. Specialties, Inc. T. C. Specialties, Inc. Henkel Surface Technologies Cytec Engineered Materials Inc.
EFFECTIVITY: ALL
70-80-03
Ref No.
Consumable Name / Remarks NOTE: 24T3-105 has higher solid content than deleted product (7 X33-FC Laminar X-500) 7 X-33-FC Laminar X-500 Deleted: High VOC content, NOTE: Replace by 23T3-105 (Fastcure)
Supplier
C03-014 Catalyst No. 10-C-81 Deleted: High VOC content NOTE: Replaced by PC-216 PC-216 C03-015 Paint, Intumesent, Red GE PN 9193M42 (Red) C03-016 Paint, Sermetel, (GE Spec. A50TF112 Class B) Sermetel 405 Deleted: Contained Cadmium Oxide NOTE: Repair requirement no longer exist C03-017 Primer, Epoxy, Yellow (MIL-PRF-23377 Type I Class C) NOTE: Type I, Yellow NOTE: Type II, Green Akzo Nobel 10-P20-13 and Catalyst EC-213 P-527F (Primer), and C-527F (Converter) Deleted: Replaced by Dexter 10-P20-13 & Catalys EC 213 C03-018 Paint, Polyurethane, Gloss White (MIL-PRF-85285 Type I, Fed. Std. 595, Color Code 17925) NOTE: Paint shall be mixed per manufacturers instructions. T. C. Specialties, Inc. Parkway Products, Inc. Akzo Nobel Aerospace Coatings
EFFECTIVITY: ALL
70-80-03
Ref No.
Consumable Name / Remarks Akzo Nobel 646-58-7925 and Catalyst X-501
Supplier T. C. Specialties, Inc.
C03-019 Coloring Pigment, Yellow Class B Unical 6610 Obsolete: Replaced by Class B Unical 8661810 NOTE: Product ID numbering change by Vendor Class B Unical 8661810 C03-020 Coloring Pigment, Thalo Blue Unical 6614 Obsolete: Replaced by Unical 7214 NOTE: Product ID numbering change by Vendor Unical 7214 C03-021 Paint, Epoxy, Red Enamel Glyptal No. 1201 Deleted: Duplicate Entry, See C01-038 C03-022 Ceramic Cement PBX Ceramic Cement C03-023 Coloring Pigment, Black 61-860700 (Black) V1747 (Black) Obsolete: Replaced by 61860700 (Black) NOTE: Product ID numbering change by Vendor C03-024 Paint, Intumescent (GE Spec. A50TF183 Class C) Flame Control No. 170 NOTE: Formerly 1001-9B, Mod 8 C03-025 Paint, Intumescent Flame Control No. 190 Top Coat Flame Control Coating Inc. Flame Control Coating Inc. Ferro Corp., Color Division Sermatech International Inc. Creanova Creanova
EFFECTIVITY: ALL
70-80-03
Ref No. C03-026 Primer, Epoxy
Consumable Name / Remarks Aeroglaze 9929 Chemglaze 9922 Obsolete: Replaced by Aeroglaze 9929
Supplier Lord Corp. Chemical Products Group
C03-027 Elastomer, Polyurethane, Abrasion Resistant (GE Spec. A50TF19 Class B) Adiprene, L-167 C03-028 Catalyst (GE Spec. D5F18A2, A50TF19 Class B) Caytur 21 Caytur 21 C03-029 Coloring Pigment, Lamp Black No. 6607 Pigment Obsolete: Replaced by No. 866 Pigment NOTE: Product ID numbering change by Vendor No. 866 Pigment C03-030 Paint, Silicone, Aluminum 86009 C03-031 Paint, Aluminum, Heat Resistant Thermalite Obsolete: Replaced by C03-030 C03-032 Paint, Aluminum, Heat Resistant G66SC69 Obsolete: Repair requirement no longer exist C03-033 Paint, Aluminum, Heat Resistant No. 909 Aluminum Obsolete: Repair requirement no longer exist C03-034 Paint, Epoxy, Aircraft Gray 283E200 S1193 NOTE: Formerly Nubelon S C03-035 Reducer, Epoxy S1195
EFFECTIVITY: ALL
Uniroyal Chemical Co. Uniroyal Chemical Co. Omni Specialty Corp.
Creanova GLYPTAL, INC.
GLYPTAL, INC.
GLYPTAL, INC.
70-80-03
Ref No.
Consumable Name / Remarks NOTE: Formerly RL 16474
Supplier
C03-036 Paint, Enamel, Light Gray TT-E-527 Color 36231 C03-037 Catalyst Cat-A-Lac X-304 Obsolete: Repair requirement no longer exist C03-038 Paint, Sermetel Sermetel W C03-039 Paint, Sermetel, Touch-up Sermetel 196 C03-040 Paint, Sermetel, Touch-up Alternative: C03-039 CT-404 Sermetel 250 Obsolete: Replaced by CT-404 C03-041 Paint, Epoxy, Clear Resin RL-11884 Obsolete: Replaced by S1194 Resin S1194 Deleted: Duplicate Entry, same as S1194 S1194 C03-042 Reducer, Epoxy Resin, RL-78108 Obsolete: Replaced by C03-035 C03-043 Conversion Coating, Molten Salt Nickel Penetrate Salts C03-044 Conversion Coating, Chromated (MIL-C-5541, Yellow) Alodine 1200 Deleted: Duplicate Entry. See C03-006 C03-045 Conversion Coating, Chromated Turcoat 4178 Obsolete: Replaced by C03-006 C03-046 Conversion Coating, Chromated Heatbath Corp. GLYPTAL, INC. Corro Therm Inc. Sermatech International Inc. Sermatech International Inc. Creative Coatings Co. Inc.
EFFECTIVITY: ALL
70-80-03
Ref No.
Consumable Name / Remarks Deoxylyte No. 11 (Chromic Acid Solution) Deleted: Replaced by Parcolene 41 Parcolene 41
Supplier
Henkel Surface Technologies Sermatech International Inc.
C03-047 Coating, Sermetel, Diffused Sermalloy J C03-048 Acid, Phosphoric, 10% -12% Acid, Phosphoric, 10% -12% Deleted: Replaced by C04-150 Gelled PR-50 Obsolete: Replaced by C04-150 C03-049 Conversion Coating, Black Oxide, Touch-up Presto-Black BST4 (Dilute Aqueous Acid) C03-050 Plating Supplies Selective Plating Supplies C03-051 Plating Supplies LDC Plating Solutions C03-052 Maskant Turco 524 Maskant Obsolete: Replaced by C10-014 C03-053 Solvent, Demasking Turco Demask 625 Turco Products, Inc. Subsidiary of Henkel Surface Technologies Akzo Nobel Aerospace Coatings Corro Therm Inc. Liquid Development Company (LDC) SIFCO Selective Plating-Div., SIFCO Industries Birchwood Casey Div., Birchwood Laboratories, Inc.
C03-054 Paint, Silicone, Aluminum Sikkens S 21/8 C03-055 Paint, Inorganic, Aluminum Corrotherm CT33M C03-056 Paint, Epoxy, Flat Gray (MIL-C-22750; Fed. Std. 595, Color Code 36231) 4222T36231 and Catalyst 0200T126 MIL-C-22750 C03-057 Reducer, Epoxy, (BMS 1020 Type 2 Grade A)
EFFECTIVITY: ALL
T. C. Specialties, Inc. Local Purchase
70-80-03
Ref No.
Consumable Name / Remarks TL-29
Supplier T. C. Specialties, Inc.
C03-058 Elastomer, Polyurethane, Abrasion Resistant Conathane TU 900 Part A and B (A15B90B1) Obsolete: Replaced by Conathane TU 901 Conathane TU 901 C03-059 Paint, Polyurethane, Gray Glossy (BMS 1060 Type 1 Grade A) 643-3-9 and Catalyst X-310A C03-060 Paint, Epoxy, Black Conductive (BMS 10-21, Type II or Type III) 10-P2-3 and Catalyst EC-110 (Type III) 528X310 and Activator 910X464 (Type III) 538C306 and Activator 910X464 (Type II) C03-061 Reducer, Epoxy TL-59 Deleted: Repair requirement no longer exist C03-062 Reducer, Epoxy, (BMS1020 Type 2 Grade A) TL-52 C03-063 Primer, Epoxy, Green 515X349-Base, 910X533 Activator C03-064 Conversion Coating, Chromated Iridite 14-2 C03-065 Surfactant ARP 2 Agent Deleted: Replaced by C04-222 C03-067 Maskant Turco Maskolene Turco Products, Inc. Subsidiary of Henkel Surface Technologies Krylon Products Group, the Specialty Div. of SherwinWilliams Co. MacDermid, Inc. PRC-Desoto International Inc. T. C. Specialties, Inc. T. C. Specialties, Inc. PRC-Desoto International Inc. PRC-Desoto International Inc. T. C. Specialties, Inc. Conap, Inc.
C03-068 Paint, Lacquer-Acrylic, Clear Krylon No. 1303
EFFECTIVITY: ALL
70-80-03
Ref No.
Supplier
C03-069 Paint, Polyurethane, Gloss Black (MIL-PRF-85285, Type 1; FED STD-595 Color Code 17038) NOTE: Paint shall be mixed per manufacturers instructions. 643-18-6 (MIL-C-83286) Deleted: Material Contained ODC NOTE: Replaced by 646-587038 (MIL-C-85285) 646-58-7038 and Catalyst X-501 CC-750-4 Deleted C03-070 Paint, Polyurethane, Gloss Gold (MIL-PRF-85285, Type 1; Fed. Std. 595 Color Code 13695) NOTE: Paint shall be mixed per manufacturers instructions. 646-58-3695 and Catalyst X-501 MIL-C-83286 Deleted: Material Contained ODC NOTE: Replaced by 646-583695 (Mil-C-85285) C03-07 1Coating, Temporary, Alkaline, Removable Ardrox 321-N C03-072 Primer, Epoxy (GE Spec. A50TF107 Class A or C) 463-12-8 Deleted: Replaced by C03-005 NOTE: Class C was deleted because material contained ODC. See C03-005 for Class A C03-073 Paint, Epoxy (MIL-C-22750) Oakite Products Inc., Div. of Chemetall T. C. Specialties, Inc. T. C. Specialties, Inc.
EFFECTIVITY: ALL
70-80-03
Ref No.
Consumable Name / Remarks NOTE: Color Codes Per: FedStd-595; Pink Beige, 21433; Yellow, 23538; Bright Green, 24193; Blue, 25102; White, 27875. Color Codes Per AFNOR: Pink Beige, 2-270; Yellow, 2-310; Bright Green, 2455; Blue, 2-540; White, 2-665. 4221-T27875 NOTE: Color Codes Per, Fed. Std. 595; White, 27875, Color Codes Per AFNOR; White 2-655 FE 2640
Supplier
T. C. Specialties, Inc.
Bollore Krylon Products Group, the Specialty Div. of SherwinWilliams Co.
C03-074 Primer, All Purpose, Gray Krylon 1358
Krylon 91318 Obsolete: Replaced by Krylon 1358 C03-075 Paint, Enamel-Lacquerized, Gloss Black Krylon 1601 Krylon Products Group, the Specialty Div. of SherwinWilliams Co.
Krylon 91601 Obsolete: Replaced by Krylon 1601 C03-076 Paint, Polyurethane Flat Black (MIL-PRF-85285, Fed. Std. 595 Color Code 37038) NOTE: Paint shall be mixed per manufacturers instructions. Akzo Nobel 666-58-7038 and Catalyst X-503 C03-077 Primer, Epoxy, Water-Reducible, (BMS-10-11V Type I, Class A, Grade E) 44-GN-11
EFFECTIVITY: ALL
T. C. Specialties, Inc.
Deft Inc.
70-80-03
Ref No.
Consumable Name / Remarks NOTE: Contains Strontium Chromate
Supplier
C03-078 Coloring Pigment, Tan V-9119 (Tan) C03-079 Primer, Epoxy, (MIL-P-53030 No class needed) Deft 44-W-7 C03-080 Paint, Polyurethane, Aircraft Gray, (MIL-PRF-85285; Fed. Std 595, Color Code 16473) NOTE: Paint shall be mixed per manufacturers instructions. Series 646-58-6473 C03-081 Conversion Coating, Chromated Alodine 1200SRTU C03-082 Conversion Coating, Chromated, (MIL-C-5541, Yellow) Alodine 1201 C03-083 Conversion Coating, Chromated Alocrom 1200 DIP NOTE: Mixing Required C03-084 Conversion Coating, Chromated Alocrom 1200 Brush NOTE: Mixing Required C03-085 Primer, Epoxy, Yellow Zinc Phosphate, (EMPIS Spec. A8B94A1) Seymour Hi Tech 16-897 C03-086 Primer, Epoxy (GE Spec. A50TF311, Class A) BR 6747-1 C03-087 Primer, Fluid Resistant Interior Super Koropon 515-700 C03-088 Coating, Aluminum Oxide Pigmented (GE Spec. A50TF308, Class B) Sermetel 1636 C03-089 Coating, Chromium Oxide Pigmented (GE Spec. A50TF308, Class A Sermatech International Inc. PRC-Desoto International Inc. Cytec Engineered Materials Inc. Seymour of Sycamore ICI Paints Division ICI Paints Division Henkel Surface Technologies Henkel Surface Technologies Creative Coatings Co. Inc. Deft Inc. Ferro Color Division
EFFECTIVITY: ALL
70-80-03
Ref No.
Consumable Name / Remarks Sermetel 1076HS
Supplier Sermatech International Inc.
C03-090 Coating, Solid Film Inorganic Sealant (GE Spec. A50TF196, Class B) Sermaseal 565 C03-091 Paint, Inorganic, Aluminum ALSEAL 519 C03-092 Conversion Coating, Chromated Alodine 1132 C03-093 Paint, Inorganic, Aluminum Ceral 114 Gebruder M. und M. Morant GMBH Henkel Surface Technologies Coatings For Industry Inc. Sermatech International Inc.
EFFECTIVITY: ALL
70-80-03
CLEANING COMPOUNDS AND SOLVENTS - CONSUMABLE PRODUCTS CLEANING COMPOUNDS AND SOLVENTS TASK 70-80-04-800-015 1. Consumable Products - Cleaning Compounds and Solvents SUBTASK 70-80-04-99G-015 A. General. Table 1. Consumables Table Ref No. C04-001 Solvent, General Alternatives: C04-160 or C04196 Solvent, Methyl-Ethyl-Ketone (ASTM D 740) C04-002 Solvent, General Mineral Spirits (ASTM D-235 Type II, Class C) NOTE: Environmentally preferred product Solvent, Stoddard (MIL-PRF 680 Type I, Type II, or Type III) C04-003 Solvent, General Solvent, Acetone (Fed. Spec. 0-A-51) C04-004 Solvent, General Solvent, Trichloroethylene, Technical (Fed. Spec. O-T-634) C04-005 Solvent, General NOTE: For alternate General Cleaning of Composites, see 7046-01. For all other materials, see 70-2123. For applications other than General Cleaning, specific alternate consumable products will need to be approved. Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Consumable Name / Remarks Supplier
EFFECTIVITY: ALL
70-80-04
CONSUMABLE PRODUCTS CLEANING COMPOUNDS AND SOLVENTS Page 1 Dec 01/03
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks Solvent, Chlorothene NU (Fed. Spec. O-T-620a) Obsolete: Ozone Depleting Substance Solvent, Triethane (Fed. Spec. O-T-620a) Obsolete: Ozone Depleting Substance C04-006 Remover, Paint/Carbon Compound Carbon Removal (Fed. Spec. P-C-111b) C04-007 Surface Treatment, Compound Tetra-Etch C04-008 Remover, Coating Enstrip L-90 C04-009 Cleaner, Heavy Duty Alkaline Turco 4181 Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Henkel Surface Technologies Henkel Surface Technologies Local Purchase Enthone, Inc. W.L. Gore and Associates, Inc. Local Purchase Supplier
Turco 4181-L
C04-010 Chemical Additive, Inhibitor Rodine 213 Rodine XL1090 C04-011 Acid Acid, Hydrofluoric (70%) C04-012 Epoxy Stripper (polyurethane) (MIL-R-81294) Cee-Bee A-214 Obsolete: Repair requirement no longer exist C04-013 Chemical Additive, Detergent Additive 73B (DuBois) KYRO EOB (Procter And Gamble) Obsolete C04-014 Solvent, General Alcohol, Denatured Local Purchase DuBois Chemical Co.
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks Poly-Tergent B-300 Obsolete: Replaced by Triton X-100 Triton X-100 Triton X-100 C04-016 Cleaning Compound TR-200 C04-017 Abrasive, Tumbling Sweco XC5-16 C04-018 Solvent, General Napth, Fed. Spec. (TT-N-95 Type II) C04-019 Abrasive, Tumbling Sweco XC 11-8t C04-020 Abrasive, Tumbling Sweco XC3-16 C04-021 Solvent, General Solvent, Hexane C04-022 Remover, Epoxy Cee-Bee A-202 C04-023 Cleaner, Acid Descaler Cee-Bee No. B-55 C04-024 Solvent, General (Spec. TT-T-548C) Brolite AA-59107 C04-025 Oil, Rust Preventative Rust Lick B C04-026 Abrasive, Other Powdered Coke C04-027 Chemical, Surface Treatment (GE Spec. A15D3A1) A15D3 Pasa-Jell 107 C04-028 Cleaner, Compound Coconut Oil, Coco 20 Coconut Oil, Misty Coco-15 Phillips Supply Co. Phillips Supply Co. PRC-Desoto International Inc. J.S. McCormick Co. ITW Magnaflux Kop-Coat, Inc. (Vernon, CA) McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division Local Purchase A and B Deburring Co. A and B Deburring Co. Local Purchase A and B Deburring Co. A and B Deburring Co. Van Waters and Roger, Inc. Union Carbide Corp. Supplier
C04-015 Chemical Additive, Wetting Agent
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks NOTE: Type I is Polyurethane, Type II is Epoxy Polyamide Kop-Coat Reducer, T-1329-66 (Type II Epoxy) Paint Thinner TL102 Obsolete: Replaced by TR 48 (Type I Polyurethane) NOTE: Product ID numbering change by Vendor Paint Thinner, T1184-66 Obsolete: Replaced by TR 49 (Type II Epoxy) Paint Thinner, TL137 Obsolete: Replaced by TR 49 (Type II Epoxy) NOTE: Product ID numbering change by Vendor TR-48 (Type I Polyurethane) TR-49 (Type II Epoxy) C04-030 Solvent, General MIL-T-81533 Deleted: Ozone depleting substance. Trichloroethane 1,1,1, Technical Inhibited (O-T620-C) Deleted: Ozone depleting substance. C04-031 Solvent, General SKC-NV (Spray) Deleted: Ozone depleting substance NOTE: Replaced by C04-035 or C04-003 ZC-7 (Spray)
EFFECTIVITY: ALL
Supplier
C04-029 Reducer, (MIL-T-81772) Type I or Type II
Kop-Coat, Inc.
T. C. Specialties, Inc. T. C. Specialties, Inc.
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks Deleted: Ozone depleting substance. NOTE: Replaced by C04-035 or C04-003 C04-032 Abrasive, Tumbling Alternative: C04-038 SWECO F3-8T C04-033 Cleaner, Mild Alkaline Turco Vitro-Klene Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Local Purchase Local Purchase Chemetall Oakite Chemetall Oakite A and B Deburring Co. Supplier
C04-034 Remover, Paint/Carbon Turco Stripper No. 5351 Thick
C04-035 Solvent, General Isopropyl Alcohol C04-036 Solvent, General Toluene Industrial C04-037 Remover, Paint/Carbon Oakite 156 Oakite 157 C04-038 Abrasive, Tumbling Alternative: C04-032 Tumblex 4TL C04-039 Cleaner, Heavy Duty Alkaline Cee-Bee C-46 C04-040 Cleaner, Compound SWECO Burnishing No. 1 (Burnishing Soap) C04-041 Remover, Paint/Cleaner Diver Strip WS-1 Obsolete: Repair requirement no longer exist C04-042 Remover, Paint/Cleaner No. T-251-C
EFFECTIVITY: ALL
Abrasive Finishing, Inc. McGean-Rohco, Inc., Cee-Bee Division A and B Deburring Co.
Beck Chemical, Inc.
70-80-04
Table 1. Consumables Table (Cont) Ref No. C04-043 Cleaner, Compound Turco 5279-A Turco Products, Inc. Subsidiary of Henkel Surface Technologies McGean-Rohco, Inc., Cee-Bee Division Consumable Name / Remarks Supplier
C04-044 Cleaner, Compound Intex 8201 (Liquid) C04-045 Cleaner, Compound Aerosteam No. 20 (Liquid) Obsolete C-1102 (Liquid) Citrikleen HD Sprex AC-3 (Powder) Obsolete C04-046 Cleaner, Mild Alkaline DELCHEM 789 Deleted: Repair requirement no longer exist C04-047 Cleaner, Compound Streamrite MD Deleted NOTE: This Product is no longer available. See TASK 70-00-99-801025, Solution Sheet S1025 for alternate. C04-048 Cleaner, Heavy Duty Alkaline Turco 4008 Turco Products, Inc. Subsidiary of Henkel Surface Technologies DuBois Chemical Co. Local Purchase
Turco 4008-3 Obsolete: Replaced by Turco 4008 C04-049 Cleaner, Heavy Duty Alkaline Cee-Bee J-84A Cee-Bee J-84AL McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks Ferlon C04-051 Cleaner, Heavy Duty Alkaline Magnus Aero-Dip Deleted: Repair requirement no longer exist C04-052 Cleaner, Heavy Duty Alkaline Ardrox 185 Ardrox 185L C04-053 Cleaner, Heavy Duty Alkaline Turco 4781-7 Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Supplier Henkel Surface Technologies
C04-050 Cleaner, Heavy Duty Alkaline
Turco 4781-7L
C04-054 Cleaner, Alkaline Permanganate Turco 4338-C
Turco 4338-L
C04-055 Cleaner, Alkaline Permanganate Cee-Bee J-88 Cee-Bee J-88A Cee-Bee J-88L C04-056 Cleaner, Alkaline Permanganate Wyandotte 1113 Obsolete: Repair requirement no longer exist C04-057 Cleaner, Alkaline Permanganate Magnus 2400 Deleted: Repair requirement no longer exist
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks Ardrox 188 and Additives 188LC/188LP Ardrox 188RFU and additives 188LC/188LP C04-059 Remover, Paint/Carbon Turco 2538 Turco Products, Inc. Subsidiary of Henkel Surface Technologies McGean-Rohco, Inc., Cee-Bee Division Supplier Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall
C04-058 Cleaner, Alkaline Permanganate
C04-060 Remover, Paint/Carbon Cee-Bee R-43C C04-061 Remover, Paint/Carbon Wyandotte (P1753A) Obsolete: Repair requirement no longer exist C04-062 Remover, Paint/Carbon Ardrox 690 C04-063 Cleaner, Heavy Duty Alkaline Cee-Bee C-46 Deleted: Duplicate Entry, See C04-039 C04-064 Cleaner, Mild Alkaline Ardrox 631 C04-065 Cleaner, Acid Descaler Wyandotte 1112 Obsolete: Repair requirement no longer exist C04-066 Cleaner, Acid Descaler Ardrox 1873 C04-067 Cleaner, Acid Descaler Ardrox 1871 C04-068 Cleaner, Mild Alkaline Turco 4215 Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks Deleted: Repair requirement no longer exist C04-069 Chemical Additive, Inhibitor Ridoline 409 Deleted: Repair requirement no longer exist C04-070 Cleaner, Molten Salt Virgo Molten Salts C04-071 Acid Hydrochloric Acid, 22 degrees Be O-H-765 C04-072 Acid Nitric Acid (Commercial Grade), 42 degrees Be O-N-350 C04-073 Acid Turco 4104 Turco Products, Inc. Subsidiary of Henkel Surface Technologies Oakite Products Inc., Div. of Chemetall Local Purchase Local Purchase Kolene Corp. Supplier
C04-074 Cleaner, Acid Descaler Ardrox 1635 C04-075 Acid Herbert Miac Obsolete: Replaced by C04-073 C04-076 Remover, Paint/Carbon Turco Super Carb Turco Products, Inc. Subsidiary of Henkel Surface Technologies
C04-077 Remover, Paint/Carbon Wyandotte P-1075 Obsolete: Repair requirement no longer exist C04-078 Cleaner, Compound Jet Clean B Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies
Plaudit
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. C04-079 Cleaner, Mild Alkaline Magnus 149-X Obsolete: Replaced by C04-191 C04-080 Cleaner, Alkaline Permanganate Turco 4316 Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Oakite Products Inc., Div. of Chemetall Enthone, Inc. Enthone, Inc. Consumable Name / Remarks Supplier
Turco 4316-L
C04-081 Cleaner, Compound Ardrox 1630 C04-082 Remover, Plating Enstrip A (Powder) C04-083 Remover, Plating Enstrip T-L (Concentrated Power) C04-084 Chemical Sodium Hydroxide C04-085 Remover, Coating Metex Strip Aid C04-086 Remover, Plating Sodium Cyanide C04-087 Remover, Paint/Carbon Metex 812 Obsolete: Repair requirement no longer exist C04-088 Remover, Paint/Carbon MS-111 Stripper C04-089 Remover, Plating Metex M-681 Obsolete: Repair requirement no longer exist C04-090 Solvent, General M-PYPROL ISP Technologies, Inc. Miller Stephenson Chemical Co. Local Purchase MacDermid, Inc. Local Purchase
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. C04-091 Cleaner, Molten Salt Kolene DGS C04-092 Remover, Plating Enstrip Q516 C04-093 Acid Phosphoric Acid C04-094 Acid Chromic Acid C04-095 Chemical Dimethyl Sulfoxide (DMSO) Dimethyl Sulfoxide (DMSO) Dimethyl Sulfoxide (DMSO) Dimethyl Sulfoxide (DMSO) C04-096 Chemical Meta Nitrobenzenesulfonic Acid - Sodium Salt C04-097 Acid, Acetic Acid, Acetic, (Commercial Grade or Better, A-A-55829 C04-098 Chemical Ferric Chloride (Commercial Grade or Better) C04-099 Acid Oxalic Acid (Commercial Grade or Better) C04-100 Acid Tartaric Acid (Commercial Grade or Better) C04-101 Acid Sulfuric Acid (Commercial Grade 65 deg. Be O-S-809) C04-102 Solvent, General Toluene Solvent (Reagent Grade) C04-103 Cleaner, Molten Salt Kolene 1 C04-104 Cleaner, Acid Descaler
EFFECTIVITY: ALL
Supplier Kolene Corp. Enthone, Inc. Local Purchase Local Purchase Pechiney World Trade Inc. Mallinckrodt, Inc. JT Baker Inc. Aldrich Chemical Co., Inc. Local Purchase
Local Purchase
Local Purchase
Local Purchase
Local Purchase
Local Purchase
Local Purchase
Kolene Corp.
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks Turco 4931 Obsolete: Replaced by C04-195 C04-105 Remover, Paint/Carbon Turco 5668 and Additives #1, #2, and #3 NOTE: The additives listed are used for Turco 5668 solution control per S1171 C04-106 Remover, Paint/Carbon Dubois Stryppaway Obsolete: Replaced by 70-2301 C04-107 Remover, Paint/Carbon Flame Control No. 11 C04-108 Chemical Potassium Dichromate O-P-559 C04-109 Chemical Additive, Anti-Solidifying No-Pack C04-110 Chemical Additive, Wetting Agent Surfacto C04-111 Chemical Additive, Antirust Metrolux C04-112 Abrasive, Grit 500 Mesh NOTE: Reference (GE Spec. D50TF5) C04-113 Abrasive, Grit 220 Mesh NOTE: Reference (GE Spec. D50TF5) C04-114 Abrasive, Grit 120 Mesh Treibacher-Schleifmittel Treibacher-Schleifmittel Treibacher-Schleifmittel Vapor Blast Mfg. Co. Vapor Blast Mfg. Co. Vapor Blast Mfg. Co. Local Purchase Flame Control Coating Inc. Turco Products, Inc. Subsidiary of Henkel Surface Technologies Supplier
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks NOTE: Reference (GE Spec. D50TF5) C04-115 Abrasive, Other Walnut Shells C04-116 Abrasive, Other Rice Hulls C04-11 7Abrasive, Other Fruit Stones (Pits) C04-118 Chemical Potassium Permanganate (MIL-P-19970) C04-119 Acid Turco 4409 (Inhibited Phosphoric Acid) C04-120 Acid Phos-It (Inhibited Phosphoric Acid) C04-121 Acid Ardrox 11 (Inhibited Phosphoric Acid) Obsolete: Replaced by Ardrox 1218 Ardrox 1218 (Inhibited Phosphoric Acid) C04-122 Acid Corrosol 853 (Inhibited Phosphoric Acid) Magnus 853 (Inhibited Phosphoric Acid) Obsolete: Replaced by Corrosol 853 C04-123 Chemical Sodium Carbonate (O-S-571) C04-124 Chemical Additive Inhibitor Ardrox 690-I C04-125 Solvent, General
EFFECTIVITY: ALL
Supplier
Local Purchase Local Purchase Local Purchase Local Purchase
Turco Products, Inc. Subsidiary of Henkel Surface Technologies Chemtech Finishing Systems
Oakite Products Inc., Div. of Chemetall PPG Industries, Inc.
Local Purchase Oakite Products Inc., Div. of Chemetall
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks Kerosene, Deodorized (VV-K220) C04-126 Acid Hydrofluoric Acid (48%) O-H795 C04-127 Chemical Potassium Hydroxide O-P-566 C04-128 Cleaner, Heavy Duty Alkaline Turco 3976 Turco Products, Inc. Subsidiary of Henkel Surface Technologies A and B Deburring Co. Local Purchase Local Purchase Supplier Local Purchase
C04-129 Abrasive, Tumbling Sweco 30 deg. Angle Cut Cylinders B3-16 ( 3/16 dia. x 11/32) Sweco 30 deg. Angle Cut Cylinders B3-16 ( 3/16 dia. x 11/32) C04-130 Abrasive, Tumbling Sweco 30 deg. Angle Cut Cylinders B1-4 (1/4 dia. x 11/ 32) Sweco 30 deg. Angle Cut Cylinders B1-4 (1/4 dia. x 11/ 32) C04-131 Chemical TR-103B C04-132 Cleaner, Compound Turco 4848-92 Turco Products, Inc. Subsidiary of Henkel Surface Technologies Local Purchase A and B Deburring Co. A and B Deburring Co.
Sweco Inc.
Sweco Inc.
C04-133 Chemical Ammonium Chloride, Crystal Certified or Reagent Grade C04-134 Chemical Ammonium Hydroxide, Reagent Grade C04-135 Chemical Calcium Carbonate, Powder Certified or Reagent Grade
EFFECTIVITY: ALL
Local Purchase
Local Purchase
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks Hydrochloric Acid, Reagent Grade C04-137 Chemical Potassium Nitrate, Crystal Certified or Reagent Grade C04-138 Chemical Methylthymol Blue Fisher Reagent 0-3716 Deleted: Replaced by AC414940010 Methylthymol Blue Fisher Reagent AC-414940010 C04-139 Cleaner, Compound Versene 220 C04-140 Cleaner, Gas Path (MIL-C-85704, Type I, II, or II RTU) Ardrox 6366 Ardrox 6367 Ardrox 6368 B and B 3100 (Type I) B and B TC-100 (Type II) MA 109C (Type II) MA 110RTU (Type II) R-MC Engine Cleaner, (4070 Type II) R-MC Engine Cleaner, (4072 Type II RTU) Turco 5884, (Type I) Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall B and B Tritech Inc. B and B Tritech Inc. JAD Chemical Co. JAD Chemical Co. ECT Inc. ECT Inc. Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Zokman Products, Inc Airworthy Ltd. Zokman Products, Inc Dow Chemical Co. Fisher Scientific Co. Local Purchase Supplier Local Purchase
C04-136 Hydrochloric Acid, Reagent Grade
Turco 6783-50 (Type II)
ZOK27, (Type II) ZOK27, (Type II) ZOK27-RTU, (Type II RTU)
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. C04-141 Remover, Paint/Carbon Oakite Stripper A2 C04-142 Cleaner, Acid Descaler Cee-Bee J-19 Cee-Bee J-19L C04-143 Acid Cee-Bee C-623 C04-144 Abrasive, Tumbling BCS No. 08-PB C04-145 Abrasive, Tumbling BCS No. 08-PC C04-146 Cleaner, Compound BCS No. 11L84 C04-147 Remover, Silicone Rubber Ardrox 2204 C04-148 Remover, Silicone Rubber Cee-Bee C-105 HF C04-149 Remover, Silicone Rubber Turco 6045 Turco Products, Inc. Subsidiary of Henkel Surface Technologies PRC-Desoto International Inc. Accumetric, LLC Local Purchase Turco Products, Inc. Subsidiary of Henkel Surface Technologies McGean-Rohco, Inc., Cee-Bee Division Oakite Products Inc., Div. of Chemetall B.C.S Company, Inc. B.C.S Company, Inc. B.C.S Company, Inc. McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division Chemetall Oakite Consumable Name / Remarks ZOK27-RTU, (Type II RTU) Supplier Airworthy Ltd.
C04-150 Compound, Surface Treatment Pasa-Jell 105 Pasa-Jell 105 C04-151 Solvent, General Isobutyl Alcohol C04-152 Cleaner, Mild Alkaline Turco 5948-R
C04-153 Abrasive, Plastic
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks AMMO-301 (20/40), Plastic Blast Media (MIL-P-85891, Type II, Grade A, 3.5 Mohs Hardness) MB-2 (20/30), Plastic Blast Media (MIL-P-85891, Type II, Grade A, 3.5 Mohs Hardness) MB-3 (30/40), Plastic Blast Media (MIL-P-85891, Type II, Grade A, 3.5 Mohs Hardness) Multicut Plastic Media Type 2UREA 20/40 mesh PolyPlus 20/40 Mesh, Plastic Blast Media (MIL-P-85891, Type II, Grade A, 3.5 Mohs Hardness) X-OFF P/N SFC 1735 (20/40), Plastic Blast Media (MIL-P85891, Type II, Grade A, 3.5 Mohs Hardness) C04-154 Cleaner, Molten Salt Alko N Salt C04-155 Remover, Plating EN-79 Nickel Stripper Part A and Part B C04-156 Remover, Plating Enstrip GT 317 NOTE: Three component mixture C04-157 Chemical Additive, Regenerator Enstrip Regenerator C04-158 Remover, Coating ASC 2-N (Aluminide Coating) C04-159 Abrasive, Tumbling F7-16C 0.44 in (11.2 mm) cylinder fine cut F7-16C 0.44 in (11.2 mm) cylinder fine cut C04-160 Solvent, General A and B Deburring Co. Sweco Inc. Alloy Surfaces Co., Inc. Enthone, Inc. Enthone, Inc. Enthone, Inc. Kolene Corp. Supplier Select-Tech, Inc.
MaxiBlast, Inc.
MaxiBlast, Inc.
Poly-Pacific International Inc. U.S. Technology Corp.
MPC Industries, Patent Plastics, Inc.
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks Ardrox 1064-K NOTE: Solvent wipe cleaner. Available as MEK substitute, or alternate for C04-001 C04-161 Abrasive, Peening Z150, Ceramic Peening Media, 0.006 - 0.008 in. (0.15 - 0.29 mm) C04-162 Abrasive, Peening Z210, Ceramic Peening Media 0.008 -0.016 in. (0.20 -0.41 mm) C04-163 Cleaner, Mild Alkaline Ardrox 6333 Ardrox 6333A C04-164 Cleaner, Mild Alkaline, Water Based Blue Gold Industrial Cleaner C04-165 Cleaner, Mild Alkaline, Water Based Cee-Bee A-7X7 C04-166 Abrasive, Peening CCW14 CCW14 CCW14, Conditioned Cut Wire Steel Shot (GE Spec. D50TF11 Class B) C04-167 Abrasive, Peening CCW20 CCW20 CCW20, Conditioned Cut Wire Steel Shot (GE Spec. D50TF11 Class B) C04-168 Cleaner, Mild Alkaline Water Based Daraclean 282 Daraclean 282GF ITW Magnaflux ITW Magnaflux Josef Frohn KME Premier Shot Company KME Premier Shot Company Josef Frohn McGean-Rohco, Inc., Cee-Bee Division Modern Chemical, Inc. Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall SEPR Ceramic Beads and Powders SEPR Ceramic Beads and Powders Supplier Oakite Products Inc., Div. of Chemetall
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. C04-169 Cleaner, Compound Ardrox 163 Diammonium EDTA Hampene Diammonium EDTA C04-170 Solvent, General MIBK (Methyl Isobutyl Ketone) C04-171 Solvent, General Degreasol 99-R C04-172 Solvent, General Jettacin C04-173 Grit, Aluminum Oxide 60-Grit NOTE: 95 percent pure C04-174 Grit, Aluminum Oxide 36-Grit NOTE: 95 percent pure C04-175 Cleaner, Compound # 42 Compound C04-176 Cleaner, Compound # 43 Compound C04-177 Abrasive, Tumbling RC Tumbling Nuggets, Size # 10 C04-178 Abrasive, Peening CCW31, Conditioned Cut Wire Steel Shot (GE Spec. D50F11CLB) CCW31, Conditioned Cut Wire Steel Shot (GE Spec. D50F11CLB) CCW31, Conditioned Cut Wire Steel Shot (GE Spec. D50F11CLB) C04-179 Abrasive, Peening Josef Frohn Richwood Industries Inc. Richwood Industries Inc. Richwood Industries Inc. Local Purchase Local Purchase DuBois Chemical Co. Kleer-Flo Co. Local Purchase Oakite Products Inc., Div. of Chemetall Dow Chemical Co. Hampshire Chemical Corp. Consumable Name / Remarks Supplier
KME
Premier Shot Company
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks Z300, Ceramic Peening Media, 0.011 -0.017 in. (0.30 -0.425 mm) C04-180 Alcohol, Methyl Alcohol, Methyl C04-181 Suspension Fluid (AMS 2641) Ardrox Base Oil HF Deodorized, High Flash Point Kerosene, Carrier II Deodorized, High Flash Point Kerosene, Turco 6809 C04-182 Cleaner, Heavy Duty Alkaline MagChem HDL-202 and Additive Deox NOTE: Additive listed is used for HDL-202 solution control per S1150 and S1151 C04-183 Cleaner, Acid Descaler MagChem AP-988 C04-184 Cleaner, Mild Alkaline MagChem DG-Kleen C04-185 Remover, Paint/Carbon MagChem Kemstrip-596 and additives: OIS-96, A-96, and S96 NOTE: The additives listed are used for Kemstrip-596 solution control per S1155 C04-186 Cleaner, Mild Alkaline MagChem Soluwax C04-187 Cleaner, Heavy Duty Alkaline MagChem HDP-2888 C04-188 Cleaner, Alkaline Permanganate MagChem HDP-2524
EFFECTIVITY: ALL
Supplier SEPR Ceramic Beads and Powders
Local Purchase Oakite Products Inc., Div. of Chemetall ITW Magnaflux Turco Products, Inc. Subsidiary of Henkel Surface Technologies MagChem
MagChem MagChem MagChem
MagChem MagChem MagChem
70-80-04
Table 1. Consumables Table (Cont) Ref No. C04-189 Cleaner, Acid Descaler MagChem AP-9186 C04-190 Cleaner, Acid Descaler MagChem AP-954 C04-191 Cleaner, Compound MagChem Aerodet C04-192 Cleaner, Acid Descaler Magnus 8500 Deleted: Repair requirement no longer exist C04-193 Cleaner, Mild Alkaline Turco Liquid Sprayeze NP-LT Turco Products, Inc. Subsidiary of Henkel Surface Technologies McGean-Rohco, Inc., Cee-Bee Division MagChem MagChem MagChem Consumable Name / Remarks Supplier
C04-194 Remover, Paint/Carbon Cee-Bee A-477 and Additives: Additive A, Additive O NOTE: The additives listed are used for Cee-Bee A-477 solution control per S1160 C04-195 Cleaner, Acid Descaler Turco Scale Gon #5 Turco Products, Inc. Subsidiary of Henkel Surface Technologies Local Purchase MagChem Ecolink, Inc. Selig Chemical Industries, Inc. Div. of National Services Industries, Inc. Solutia Inc.
C04-196 Solvent, General Solvent, Methyl-Propyl-Ketone C04-197 Solvent, General MagChem Teksol C04-198 Solvent, General Positron C04-199 Solvent, General Isoparaffinic Solvents CE-SX94, GB-SX-94, and L-SX-94 C04-200 Solvent, General SkyKleen
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. C04-201 Solvent, General Turco 4460-BK Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Oakite Products Inc., Div. of Chemetall MagChem Nuvite Chemical Compounds, Corp. BioChem Systems, Div. of Golden Tech. Turco Products, Inc. Subsidiary of Henkel Surface Technologies Consumable Name / Remarks Supplier
C04-202 Solvent, General Turco 6869
C04-203 Solvent, General Turco 6780
C04-204 Cleaner, Compound Ardrox 6077 C04-205 Cleaner, Compound MagChem Evasol C04-206 Cleaner, Compound Nu-Gear-SC C04-207 Cleaner, Compound Bio-T-Max C04-208 Cleaner, Compound Turco 5948 DPM
Turco 5948 DPM Thick Obsolete: Replaced by C04-232 C04-209 Cleaner, Mild Alkaline Ardrox 6085 C04-210 Cleaner, Compound Ardrox 1900B C04-211 Cleaner, Compound Super Bee 262 C04-212 Cleaner, Mild Alkaline McGean-Rohco, Inc., Cee-Bee Division Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks Eldorado HTP-1150 and Additive ATP 1150A C04-213 Cleaner, Mild Alkaline Eldorado HTP-1150L and Additive HTP-1150A C04-214 Cleaner, Alkaline Permanganate Eldorado HTP-1190 C04-215 Cleaner, Alkaline Permanganate Eldorado HTP-1190L C04-216 Cleaner, Acid Descaler Eldorado AC-111 C04-217 Acid Eldorado AC-183 C04-218 Cleaner, Heavy Duty Alkaline Eldorado ED-306LF C04-219 Cleaner, Mild Alkaline Magnus 147-X Deleted: Repair requirement no longer exist C04-220 Abrasive, Grit 320 Mesh (USA), 325 Mesh (International), Aluminum Oxide 325 Mesh (International) C04-221 Cleaner, Mild Alkaline Super Bee 300LF C04-222 Surfactant ARP 2 Agent NOTE: 5 gal container (to be used with C03-064) C04-223 Tacks, Upholstery Tacks, #3 Blued Cut C04-224 Solvent, General Ardrox 552 Oakite Products Inc., Div. of Chemetall Holland Manufacturing Co. MacDermid, Inc. McGean-Rohco, Inc., Cee-Bee Division Treibacher-Schleifmittel Eldorado Chemical Co., Inc. Eldorado Chemical Co., Inc. Eldorado Chemical Co., Inc. Eldorado Chemical Co., Inc. Eldorado Chemical Co., Inc. Eldorado Chemical Co., Inc. Supplier Eldorado Chemical Co., Inc.
Treibacher-Schleifmittel
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. C04-225 Solvent, General Turco IND 79 Turco Products, Inc. Subsidiary of Henkel Surface Technologies Olin Corporation Consumable Name / Remarks Supplier
C04-226 Cleaner, Liquid Caustic Solution (Membrane Grade) Caustic Soda, Liquid (50% Concentration) C04-227 Acid, Acetic Acetic Acid, Liguid (50% Concentration) C04-228 Solvent, General (94-96% assay Ethanol) Alcohol, Ethyl, Anhydrous, Denatured C04-229 Chemical Sodium Dichromate C04-230 Chemical Cellosolve Acetate C04-231 Solvent, Blend SB-2 C04-232 Cleaner, Compound Turco 5948 DPM Thick Turco Products, Inc. Subsidiary of Henkel Surface Technologies Applied Chemicals International Pty. Ltd. Applied Chemicals International Pty. Ltd. Applied Chemicals International Pty. Ltd. Applied Chemicals International Pty. Ltd. The Brulin Corporation Acheson Colloids Co. Local Purchase Local Purchase EM Science LabCem Inc.
C04-233 Cleaner, Alkaline Deruster Applied 5-840 C04-234 Cleaner, Alkaline permanganate Applied 5-770 C04-235 Acid, Inhibited phosphoric Applied 2-690 C04-236 Cleaner, Acid Descaler Applied 2-751 C04-237 Cleaner, Mild Alkaline Brulin 815 GD C04-238 Acid, Anhydrous Citric
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. C04-239 Cleaner, Acid Descaler Cee-Bee J-3 C04-240 Cleaner, Acid Descaler Ardrox 1873A C04-241 Chemical Ammonium Bifluoride Flakes C04-242 Chemical Additive, Inhibitor Rodine 31A C04-243 Cleaner, Powdered Precision Alconox C04-244 Remover, Plating Enstrip EN-86 C04-245 Remover, Paint/Carbon Androx 2302 and Additives 2302S, 2302-AA, 2302-SA NOTE: The additives listed are used for Ardrox 2302 solution control per S1187 C04-246 Remover, Plating Enstrip S C04-247 Remover, Carbon Ardrox 1618 C04-248 Chemical Additive, Inhibitor NOTE: For use with Hydrofluoric Acid Rhodine 51 C04-249 Cleaner, Exterior Surface Ardrox 6025 C04-250 Cleaner, Carbon Removal Gel Cee-Bee Alko McGean-Rohco, Inc., Cee-Bee Division Chemetall Plc Henkel Surface Technologies Oakite Products Inc., Div. of Chemetall Enthone, Inc. Oakite Products Inc., Div. of Chemetall Enthone, Inc. Alconox, Inc. Henkel Surface Technologies Mallinckrodt Baker, Inc. Oakite Products Inc., Div. of Chemetall McGean-Rohco, Inc., Cee-Bee Division Consumable Name / Remarks Acid, Anhydrous Citric Supplier Local Purchase
EFFECTIVITY: ALL
70-80-04
Table 1. Consumables Table (Cont) Ref No. Consumable Name / Remarks Turco 5805 Supplier Turco Products, Inc. Subsidiary of Henkel Surface Technologies Petroferm Inc. Fine Organics Corp. CRC Industries, Inc CRC Industries, Inc McGean-Rohco, Inc., Cee-Bee Division Arrow Chemicals Ltd. Ecolink, Inc. Caig Laborotories, Inc. Caig Laborotories, Inc. Caig Laborotories, Inc.
C04-251 Cleaner, Solvent Bioact 105 Precision Cleaner C04-252 Cleaner, Electrical Contact Envirosolv 655 C04-253 Cleaner, Electrical Contact CRC Super Degreaser C04-254 Cleaner, Electrical Contact CRC Precision Cleaner Plus C04-255 Cleaner, Acid Descaler Cee-Bee P-109B C04-256 Solvent, General Supersolve AS C04-257 Cleaner, Electrical Contact Eco Spray C04-258 Electrical Contact Cleaner / Lubricant Pro Gold GX100L Pro Gold GX5L C04-259 Electrical Contact Cleaner CaiKleen TNX Tarnish Remover C04-260 Solvent, General MagChem Skysol MagChem
EFFECTIVITY: ALL
70-80-04
INSPECTION AND MARKING COMPOUNDS - CONSUMABLE PRODUCTS INSPECTION AND MARKING COMPOUNDS TASK 70-80-05-800-016 1. Consumable Products Inspection and Marking Compounds SUBTASK 70-80-05-99G-016 A. Ref No. General. Consumable Name / Remarks Compound, Gear Marking, No. 10 Yellow C05-002 Ink, Marking Dykem (Steel Blue Layout Fluid, Transparent Blue Staining Color) C05-003 Marking Pens LN9051 Red P/N 44404, Black D50TF8, Action Marker Nuclear Grade NOTE: NOTE: NOTE: NOTE: Felt Tip: No. 33 Fine Tip No. 44 Medium Tip No. 55 Broad Tip ITW Mark-Tex Ratioplast GmbH ITW Mark-Tex ITW-Dykem Co. Supplier Prescott and Co., Ltd.
C05-001 Compound, Gear Marking
P/N 44729, White D50TF8, Action Marker Nuclear Grade NOTE: NOTE: NOTE: NOTE: Felt Tip: No. 33 Fine Tip No. 44 Medium Tip No. 55 Broad Tip
P/N 55608, # 55 Valve Action Marker, # Y-608 Black Washout, High Purity Prismacolor Verithin Silver Pencil T.E.C. Marker (Black) C05-004 Ink, Stamp Pad Marco S-1141 (Black) Deleted
EFFECTIVITY: ALL
ITW Mark-Tex
Sanford Corp. Sanford Corp.
70-80-05
CONSUMABLE PRODUCTS INSPECTION AND MARKING COMPOUNDS Page 1 Dec 01/03
Ref No.
Consumable Name / Remarks P/N 80404, Q-404 High Purity Ink, Nuclear Grade NOTE: When using a rubber stamp with Q-404 ink, use a linen or cloth pad (Do Not use a foam Pad). Rubber stamp must be BunaN (Black) not natural rubber (red).
Supplier ITW Mark-Tex
C05-005 Liquid, Leak (Bubble) Test (ASTM E515) Leak-Tec 16-OX C05-006 Fluid, Calibrating (MIL-PRF-7024) Fluid, Calibrating, MIL-PRF7024 C05-007 Fluorescent Penetrant Kit Kit ZA-HR Obsolete: Repair requirement no longer exist C05-008 Phosphor Thermographic No. 1807 Deleted: Contains Cadmium C05-009 Polyvinyl Alcohol Partial Film No. 10 C05-010 Ink Marking Epoxy (White) (GE Spec. F50TF6 Class A) No. 6893 Liquid Epoxy Ink (White) No. 6896, Stamp Pad Ink, (White) C05-011 Tape, Teflon 0.0035 in. (0.089 mm) Max Thick Part No. 011200 Obsolete: Repair requirement no longer exist C05-012 Temperature Marking Tempilstik 1100 deg. F. Tempilstik 1150 deg. F. Tempilstik 1200 deg. F. Tempilstik 1250 deg. F.
EFFECTIVITY: ALL
American Gas and Chemical Company, Ltd. Local Purchase
Rexco Chemical Co. Markem Corp. Markem Corp.
Tempil Inc. / Division of ITW Tempil Inc. / Division of ITW Tempil Inc. / Division of ITW Tempil Inc. / Division of ITW
70-80-05
Ref No.
Consumable Name / Remarks Tempilstik 400 deg. F. Tempilstik 600 deg. F.
Supplier Tempil Inc. / Division of ITW Tempil Inc. / Division of ITW Lectroetch Co. Lectroetch Co. Monode Marking Products Inc. Lectroetch Co. Lectroetch Co.
C05-013 Solutions, Electroetch 250A C05-014 Solutions, Electroetch 250A Nuclear Grade C05-015 Marking, Electrolyte, Monode MSC-1 C05-016 Electrolytic Cleaners Formula 3 Cleaner C05-017 Electrolytic Cleaners Formula 3 Cleaner, Nuclear Grade C05-018 Marking, Electrolyte Monode MSC-3 C05-019 Stencils Blue (Long Life) LSG C05-020 Marking Ink Dykem Hi Spot Blue (No. 107) C05-021 Solvent Dykem Remover and Thinner (No. 138) C05-022 Penetrant ZL-2C ZL2A Obsolete: Replaced by ZL-2C C05-023 Penetrant ZL-22A Obsolete: Replaced by ZL-27A ZL-27A C05-024 Penetrant ZL-30A Obsolete: Replaced by ZL-37 ZL-37 C05-025 Penetrant ITW Magnaflux ITW Magnaflux ITW Magnaflux ITW-Dykem Co. ITW-Dykem Co. Monode Marking Products Inc. Lectroetch Co. Monode Marking Products Inc.
EFFECTIVITY: ALL
70-80-05
Ref No.
Consumable Name / Remarks ZL-54 Obsolete: Replaced by ZL-60D ZL-60D
Supplier
ITW Magnaflux
C05-026 Penetrant ZL-60B Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-027 Penetrant P21 Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-028 Penetrant P40BGE Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-029 Penetrant P41 Obsolete: Replaced by P41H1 P41H1 Turco Products, Inc. Subsidiary of Henkel Surface Technologies
C05-030 Penetrant WP-100 Obsolete: Replaced by WP-100 LSBD or WP-100H WP-100 LSBD Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies
WP-100H
C05-031 Penetrant
EFFECTIVITY: ALL
70-80-05
Ref No.
Consumable Name / Remarks WP169 Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound
Supplier
C05-032 Penetrant WP-1B Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-033 Penetrant WP-170 Obsolete: Replaced by WP170LSBD WP-170LSBD Turco Products, Inc. Subsidiary of Henkel Surface Technologies
C05-034 Penetrant P148A Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-035 Penetrant P149 Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-036 Penetrant P134 Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound
EFFECTIVITY: ALL
70-80-05
Ref No. C05-037 Penetrant
Consumable Name / Remarks P136 Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound
Supplier
C05-038 Penetrant FP-22B C05-039 Penetrant FP30A Obsolete: Replaced by RC-65 RC-65 C05-040 Penetrant HM440 Obsolete C05-041 Penetrant P5TF4 Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-042 Penetrant 985P1 Obsolete: Replaced by 985P12 985P12 C05-043 Penetrant 985P14 985P3 Obsolete: Replaced by 985P14 C05-044 Penetrant 970P10 Obsolete: Replaced by P134D Ardrox P134D C05-045 Penetrant
EFFECTIVITY: ALL
Sherwin, Inc.
Sherwin, Inc.
Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall
Oakite Products Inc., Div. of Chemetall
70-80-05
Ref No.
Consumable Name / Remarks 970P5 Obsolete: Replaced by P133D Ardrox P133D
Supplier
C05-046 Penetrant 985P13 985P2 Obsolete: Replaced by 985P13 C05-047 Penetrant OD-1700A Penetrant C05-048 Penetrant OD-2800-II Penetrant C05-050 Penetrant OD-2800-I Penetrant C05-051 Emulsifier and Solvent ZE4B Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-052 Emulsifier and Solvent ZE4A Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-053 Emulsifier and Solvent ZR-10A Deleted: Replaced by ZR-10B NOTE: Contains EPA Banned Compound ZR-10B C05-054Emulsifier and Solvent E4 ITW Magnaflux Marktec Corp. Marktec Corp. Marktec Corp.
EFFECTIVITY: ALL
70-80-05
Ref No.
Consumable Name / Remarks Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound
Supplier
C05-055 Emulsifier and Solvent E41 Turco Products, Inc. Subsidiary of Henkel Surface Technologies
C05-056 Emulsifier E157A Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-057 Emulsifier ER-83A ER82 Obsolete: Replaced by ER-83A C05-058 Emulsifier 9PR3 C05-059 Emulsifier 9PR12 9PR4 Obsolete: Replaced by 9PR12 C05-060 Emulsifier OD-1700B C05-061 Developer ZP-14A ZP-4A Obsolete: Replaced by ZP-4B or ZP-14A ZP-4B C05-062 Developer ZP-13A ITW Magnaflux ITW Magnaflux Marktec Corp. Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Sherwin, Inc.
EFFECTIVITY: ALL
70-80-05
Ref No.
Consumable Name / Remarks Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound
Supplier
C05-063 Developer ZP-5 Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-064 Developer SKD-S Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-065 Developer SKD-NF Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-066 Developer ZP-9 Deleted: Replaced by ZP-9F NOTE: Contains EPA Banned Compound ZP-9F C05-067 Developer DD2A Turco Products, Inc. Subsidiary of Henkel Surface Technologies ITW Magnaflux
C05-068 Developer WD Deleted: Repair requirement no longer exist

EFFECTIVITY: ALL
70-80-05
Ref No.
Consumable Name / Remarks NOTE: Contains EPA Banned Compound
Supplier
C05-069 Developer NAD-NF Deleted: Replaced by NAD-SB NAD-SB Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies
C05-070 Developer NAD
C05-071 Developer D493A Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-072 Developer D492A Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-073 Developer D495A Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-074 Developer D499A Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound
EFFECTIVITY: ALL
70-80-05
Ref No. C05-075 Developer
Consumable Name / Remarks D499C Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound
Supplier
C05-076 Developer D-90G D90 Obsolete: Replaced by D-90G C05-077 Developer D110 Deleted: Repair requirement no longer exist NOTE: Contains EPA Banned Compound C05-078 Developer D-100 C05-079 Developer D-104 D-106 D101-NF Obsolete: Replaced by D-104 or D-106 C05-080 Developer D-1 Obsolete C05-081 Developer 9D3 Obsolete: Replaced by 9D4A 9D4A C05-082 Developer 9D1B 9D6 Obsolete: Replaced by 9D1B
EFFECTIVITY: ALL
Sherwin, Inc.
Sherwin, Inc. Sherwin, Inc. Sherwin, Inc.
70-80-05
Ref No. C05-083 Developer
Consumable Name / Remarks 9D71 Obsolete: Replaced by 9D76 9D76
Supplier
Oakite Products Inc., Div. of Chemetall Marktec Corp. Marktec Corp.
C05-084 Developer DN-600P C05-085 Developer DN-900D C05-086 Oil-Base, red magnetic particles, Magnaflux Powder No. 9C Deleted: Replaced by C05-088 C05-087 Suspension Fluid (AMS 3160) AMS 3160 ES-6 Facto Pure No. 30, or equivalent Obsolete: Replaced by AMS 3160 Oil, AMS 3160 Suspension Fluid C05-088 Magnaglo Powder 14 A Powder Ardrox 8800 No. 853-40 Powder Obsolete: Replaced by Ardrox 8800 SY8000 A/1 Powder Obsolete: Replaced by Ardrox 8800 C05-089 Suspension Fluid Suspension Fluid Obsolete: Replaced by C05-087 C05-090 Liquid Water Conditioner WA-4 C05-091Glycerin O-G-491 Local Purchase ITW Magnaflux ITW Magnaflux Oakite Products Inc., Div. of Chemetall Local Purchase Dynamation Research, Inc. Eldorado Chemical Co., Inc.
EFFECTIVITY: ALL
70-80-05
Consumable Name / Remarks ZL22C Obsolete: Replaced by C05-023
Supplier
C05-093 Penetrant F-6A-SP/1 C05-094 Emulsifier F-6E-W/1 C05-095 Developer F-5D/1 C05-096 Developer F-4S (NT) /1 C05-097 Developer F-6A/1 C05-098 Emulsifier F-5E-SP/1 C05-099 Emulsifier F-4A-C/1 C05-100 Developer ZL7 Obsolete: See specific repair C05-101 Penetrant P60H Turco Products, Inc. Subsidiary of Henkel Surface Technologies Eishin Kagaku Co., Inc. Eishin Kagaku Co., Inc. Eishin Kagaku Co., Inc. Eishin Kagaku Co., Inc. Eishin Kagaku Co., Inc. Eishin Kagaku Co., Inc. Eishin Kagaku Co., Inc.
C05-102 Aircraft Marker Aircraft Marker Obsolete: Replaced by C05-003 C05-103 Tape, Reflective No. 580-10 C05-104 Ink Marker Ink Marker Deleted: Replaced by C05-003 C05-105 Ink Marker Ink Marker Deleted: Replaced by C05-003 C05-106 Electrolyte 3M Company
EFFECTIVITY: ALL
70-80-05
Ref No. C05-107 Electrolyte
Consumable Name / Remarks Monode C-10, Electrolyte Monode A-10, Electrolyte
Supplier Monode Marking Products Inc. Monode Marking Products Inc. Monode Marking Products Inc. Monode Marking Products Inc. Eastman Kodak Co.
C05-108 Electrolyte Monode T-10 (NC), Electrolyte C05-109 Neutralizer Monode APC, Neutralizer C05-110 Wetting Agent Photo-Flo 200, Catalog No. 146 4502-4 Fl oz. NOTE: Photo-Flo 600 or 2100 may be substituted for Photo-Flo 200 for large tank applications with proper adjustments for concentration (see S1169) Photo-Flo 200, Catalog No. 146 4510-16 Fl oz. NOTE: Photo-Flo 600 or 2100 may be substituted for Photo-Flo 200 for large tank applications with proper adjustments for concentration (see S1169) Photo-Flo 2100, Catalog No. 141 8904-1 gallon Photo-Flo 600, Catalog No. 146 4528-1 gallon C05-111 Chalk, Marking White (Extruded) A-A-318 Dustless Chalk P/N 31144 C05-112 Comparator, 10X Optical MA-81-34-37, Inch Scale, 3/4 inch, in 0.005 intervals MA-81-34-42, LENSCOPE Magnifier, 10X, lens and storage case C05-113 Inspection System, Honeycomb
EFFECTIVITY: ALL
Eastman Kodak Co.
Eastman Kodak Co. Eastman Kodak Co.
Dixon Ticonderoga Co. Paul N. Gardner Company, Inc. Paul N. Gardner Company, Inc.
70-80-05
Ref No.
Consumable Name / Remarks P/N 4013518-290
Supplier Noble Tool Corp. Noble Tool Corp. Sherwin, Inc.
C05-114 Optical Refractor, Honeycomb Inspection System P/N 4013518-319 C05-115 Penetrant RC-77
EFFECTIVITY: ALL
70-80-05
EFFECTIVITY: ALL
70-80-05
WELD, BRAZE - CONSUMABLE PRODUCTS WELD, BRAZE TASK 70-80-06-800-017 1. Consumable Products Weld, Braze SUBTASK 70-80-06-99G-017 A. Ref No. General. Consumable Name / Remarks B50TF142 Obsolete: Duplicate Entry, Replaced by C06-012 C06-002 Braze Alloy, Powder Ni-Si-B Coast Metal 50 Obsolete Nicrobraz 135 Vitta-Braz 1779 NOTE: AMS 4779 C06-003 Powder, Nickel-Aluminum 2101 Vitta-Braz 1013 C06-004 Braze Alloy Gold Nickel AMS 4787 / BAu-4 Wesgo Metals, A Division Morgan Technical Ceramics, Inc. The Westaim Corporation Vitta Corporation Wall-Colmonoy Corp. Vitta Corporation Supplier
C06-001 Braze Alloy, Powder Nickel-Chromium-Silicon-Boron
C06-005 Braze Alloy, Ag-Cu-Zn-Ni AMS 4772 / GBAg-13 Obsolete Braze 541 C06-006 Braze Alloy Gold-Nickel-Palladium AMS 4786 Palniro 7 Wesgo Metals, A Division Morgan Technical Ceramics, Inc. Lucas-Milhaupt Inc.
C06-007 Braze Alloy Powder Ni-Cr-Si-Mn J8300 Obsolete C06-008 Weld Electrode
EFFECTIVITY: ALL
70-80-06
CONSUMABLE PRODUCTS WELD, BRAZE Page 1 Dec 01/03
Ref No.
Consumable Name / Remarks 4643 AL
Supplier United States Welding
C06-009 Coating, Alloy-Cobalt Base Coast Metal 64 Obsolete PMET 994 C06-010 Flux, Braze AMS 3411 C06-011 Braze Alloy BS-1 Obsolete C06-012 Braze Alloy, Powder Nickel-Chromium-Silicon-Boron Amdry 103 PAC 1424 Vitta-Braz 1142 C06-013 Braze Alloy Powder Ni-Si-B (AMS 4778) Coast Metal 52 Obsolete: Replaced by NI-298 NOTE: Product Numbering change at supplier NI-298 Nicrobraz 130 Vitta-Braz 1778 C06-014 Braze Alloy Powder Ni-Si-B (AMS 4777) Coast Metal 53 Obsolete: Replaced by NI-3623 NOTE: Product Numbering change at supplier LM Nicrobraz NI-362-3 Vitta-Braz 1777 C06-015 Braze Alloy Amdry 100 C Vitta-Braz 1782 C06-016 Lithobraze BT Sulzer Metco, Inc. Vitta Corporation Wall-Colmonoy Corp. Praxair / TAFA Indianapolis Vitta Corporation Praxair / TAFA Indianapolis Wall-Colmonoy Corp. Vitta Corporation Sulzer Metco, Inc. Powder Alloy Corp. Vitta Corporation Local Purchase Polymet Corp.
EFFECTIVITY: ALL
70-80-06
Ref No. C06-017 Tape, Braze
Consumable Name / Remarks Lithobraze BT Vitta-Braz 1782, Braze Tape
Supplier Lucas-Milhaupt Inc. Vitta Corporation Astrolite Alloys Division of Astro Cosmos Metallurgical, Inc. Vitta Corporation HTG Metal Methods Wesgo Metals, A Division Morgan Technical Ceramics, Inc. Wesgo Metals, A Division Morgan Technical Ceramics, Inc. Wesgo Metals, A Division Morgan Technical Ceramics, Inc. Unifrax Corporation Polymet Corp. Stellite Coatings Deloro Stellite, Inc. O.M.G Americas Sulzer Metco, Inc. Wesgo Metals, A Division Morgan Technical Ceramics, Inc.
C06-018 Wire, Weld Weld Wire, 6-2-4-2 Ti
C06-019 Binder Braz-Binder Gel Grade ST Type 215 C06-020 Braze Alloy Foil AMS 4778 (0.001 - 0.003 in. Thick) AMS 4779 (0.001 - 0.003 in. Thick) C06-021 Braze Alloy Foil AU-6
C06-022 Ceramic Fiber Insulation Silica-Alumina Fiberfrax C06-023 Weld Electrode PMET 980 Tribaloy 800 C06-024 Braze Alloy Nickel Powder Class B AN325 C06-025 Braze Alloy Ni-Pd-Cr-B Ni-Pd-Cr-B
NOTE: Class D (foil) only C06-026 Braze Alloy Tape (AMS 4778) AMS 4778 / Acrylic Binder 0.037 in. thick x 0.75 in. Wide Vitta-Braz 1778
EFFECTIVITY: ALL
Sulzer Metco, Inc. Vitta Corporation
70-80-06
Ref No. C06-027 Metal Powder
Consumable Name / Remarks NI-334 Nickel Braze Alloy Vitta-Braz 1090
Supplier Praxair / TAFA Indianapolis Sulzer Metco, Inc. Vitta Corporation Wall-Colmonoy Corp. Sulzer Metco, Inc. Golden Empire Corp. Polymet Corp. Dynamet Powder Products Praxair / TAFA Indianapolis Sulzer Metco, Inc. Polymet Corp. Praxair / TAFA Indianapolis AlliedSignal Amorphous Metals Praxair / TAFA Indianapolis Polymet Corp. Wall-Colmonoy Corp. United States Welding Aerospace International Materials (AIM)
C06-028 Blasting Grit, Nichrome Base Nicroblast Grit C06-029 Braze Alloy Ni, 15.0 Cr, 3.5 B AMI 775 C06-030 Flux, Welding Solar Flux, Type I C06-031 Weld Wire 0.040 in. Dia PMET 842 C06-032 Alloy Powder G183 NI-183 Rene 80 C06-033 Weld Wire PMET 880 C06-034 Braze Filler Powder, HS-188 CO-273-5 C06-035 Braze Foil MBF50A C06-036 Weld Powder R142 NI-365-3 C06-037 Weld Wire PMET 822 C06-038 Flux, High Temperature Braze (AMS 3417) Nicrobraz Flux C06-039 Weld Wire Turbaloy 220 C06-040 Weld Wire Class A C06-041 Braze Alloy Foil (AMS 4777)
EFFECTIVITY: ALL
70-80-06
Ref No.
Consumable Name / Remarks Braze Alloy Foil (AMS 4777)
Supplier Wesgo Metals, A Division Morgan Technical Ceramics, Inc. Honeywell Amorphous Metals
METGLAS MBF 20
EFFECTIVITY: ALL
70-80-06
EFFECTIVITY: ALL
70-80-06
THERMAL SPRAY - CONSUMABLE PRODUCTS THERMAL SPRAY TASK 70-80-07-800-018 1. Consumable Products - Thermal Spray Materials SUBTASK 70-80-07-99G-018 A. Ref No. C07-001 Molybdenum Powder Amdry 313X Bay State PP-21 Metco 63 NS MO-102 C07-002 Weld Wire (AMS 4395) Magnesium Alloy Wire (AMS 4395) C07-003 Aluminum Oxide Powder ALO-159 Amperit 742.298 Amperit 742.298 Bay State PP-32 Metco 101B-NS Norton 112 Praxair / TAFA Indianapolis H.C. Starck GmbH and Co KG H.C. Starck Inc. Bay State Surface Technologies, Inc. Sulzer Metco, Inc. Ceramic Grains and Powder Division Norton Company / Division of Saint Gobain Powder Alloy Corp. Lucas-Milhaupt Inc. Powder Alloy Corp. Powder Alloy Corp. Sulzer Metco, Inc. Sulzer Metco, Inc. Timminco Corp. Sulzer Metco, Inc. Bay State Surface Technologies, Inc. Sulzer Metco, Inc. Praxair / TAFA Indianapolis General. Consumable Name / Remarks Supplier
PAC 701B C07-004 Silver Alloy Wire BR 300 (NT) PAC A13 C07-005 Molybdenum Wire PAC 4 Spraybond C07-006 Nickel-Iron-Chromium Wire Metcoloy 33 C07-007 Tungsten Carbide 12% Cobalt Aggregate
EFFECTIVITY: ALL
70-80-07
CONSUMABLE PRODUCTS THERMAL SPRAY Page 1 Dec 01/03
Ref No.
Consumable Name / Remarks 1342VM (Class A) Bay State PP-75 (Class A and B) Metco 72F-NS (Class A) PAC 127 (Class A and B) WC-114 (Class A and B)
Supplier Praxair / TAFA Indianapolis Bay State Surface Technologies, Inc. Sulzer Metco, Inc. Powder Alloy Corp. Praxair / TAFA Indianapolis H.C. Starck GmbH and Co KG H.C. Starck Inc. Praxair / TAFA Indianapolis Sulzer Metco, Inc. Powder Alloy Corp.
C07-008 Chromium Carbide Ni-Cr-Co- Matrix Amperit 591.294 Amperit 591.294 CRC-109 Metco 430NS PAC 133 C07-009 Metal Powder, 75% Tungsten Carbide Self-Bonding Blend Metco 438 NS Obsolete: Repair requirement no longer exist C07-010 50% Tungsten Carbide Self-Bonding Blend Metco 439NS C07-011 Nickel-Aluminum Composite Powder Amperit 286.295 Amperit 286.295 Metco 404 Obsolete: Replaced by Metco 404NS Metco 404NS NI-108 C07-012 Nickel-Chromium Powder AI-1015 Obsolete AI-1017 Obsolete Bay State PP-64 Bay State PP-65 Metco 43C-NS Metco 43F-NS
EFFECTIVITY: ALL
Sulzer Metco, Inc. H.C. Starck GmbH and Co KG H.C. Starck Inc.
Sulzer Metco, Inc. Praxair / TAFA Indianapolis
Bay State Surface Technologies, Inc. Bay State Surface Technologies, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc.
70-80-07
Ref No.
Consumable Name / Remarks NI-107 PAC 98C-1 PAC 98F
Supplier Praxair / TAFA Indianapolis Powder Alloy Corp. Powder Alloy Corp. Praxair / TAFA Indianapolis Sulzer Metco, Inc. Powder Alloy Corp. Westaim Corp.
C07-013 Copper-Nickel Powder CU-103 Metco 57NS PAC 12 C07-01475:25 Nickel-Graphite Powder 75:25 Nickel Graphite Powder AI-1052-1 Obsolete Bay State PP-11A Metco 307NS-3 NI-120 PAC 1058B C07-01585:15 Nickel-Graphite Powder 85:15 Nickel Graphite Powder AI-1052-2 Obsolete Bay State PP-10A Metco 308NS-3 NI-115 PAC 1059B TAFA 1608M Obsolete C07-016 Nickel-Aluminum Composite Powder AI-1037 Amdry 956 Amperit 281.287 Amperit 281.287 Amperit 282.296 Amperit 282.296 Metco 450 Obsolete: Replaced by Metco 450NS
EFFECTIVITY: ALL
Bay State Surface Technologies, Inc. Sulzer Metco, Inc. Praxair / TAFA Indianapolis Powder Alloy Corp. Westaim Corp.
Bay State Surface Technologies, Inc. Sulzer Metco, Inc. Praxair / TAFA Indianapolis Powder Alloy Corp.
Praxair / TAFA Indianapolis Sulzer Metco, Inc. H.C. Starck GmbH and Co KG H.C. Starck Inc. H.C. Starck GmbH and Co KG H.C. Starck Inc.
70-80-07
Ref No.
Consumable Name / Remarks Metco 450NS Metco 480NS NI-109 NI-185 PAC 906 TAFA 1266M (Class A) Obsolete Thermotech 18995 Obsolete
Supplier Sulzer Metco, Inc. Sulzer Metco, Inc. Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Powder Alloy Corp.
C07-017 Aluminum Powder AI-1020 Obsolete: Replaced by AL-104 AL-104 Bay State PP-20 Metco 54NS-1 PAC 19SP C07-018 Alumina/Nickel-Aluminum Powder ALO-273 Obsolete Metco 101B-NS and Metco 404NS Blend C07-019 Nickel-Aluminum Composite Wire Metco 405NS C07-020 Copper-Nickel-Indium Powder Ai-1058A Obsolete Amdry 500C CU-102 Glidden PS72 Obsolete: No Longer Available Metco 58NS PAC 658C Vertex VPC-72C C07-021 Nickel-Silicon-Boron Powder Coast Metals 52
EFFECTIVITY: ALL
Praxair / TAFA Indianapolis Bay State Surface Technologies, Inc. Sulzer Metco, Inc. Powder Alloy Corp.
Sulzer Metco, Inc.
Sulzer Metco, Inc.
Sulzer Metco, Inc. Powder Alloy Corp. Special Metals Corporation, Powder Division
70-80-07
Ref No.
Consumable Name / Remarks Obsolete: Replaced by NI-298 Coast Metals 64 Obsolete: Replaced by NI-298 PAC 65
Supplier
Powder Alloy Corp. Praxair / TAFA Indianapolis Sulzer Metco, Inc. H.C. Starck GmbH and Co KG H.C. Starck Inc.
C07-022 Aluminum-Nickel Chromium Composite Powder 1243M Amdry 960 Amperit 299.297 Amperit 299.297 Metco 443 Obsolete: Replaced by Metco 443NS Metco 443NS NI-122 PAC 908C C07-023 Aluminum Bronze Alloy Thermal Spray Powder CU-104-5 Metco 51F-NS Metco 51NS PAC 16FC C07-024 Aluminum Bronze Alloy Wire (MIL-W-6712 Type II) Metco Sprabronze AA C07-025 Cobalt-Molybdenum-Chromium-Silicon Powder CO-109 Metco 66F-NS Tribaloy T-400 C07-026 Chromium Carbide-Nickel-Aluminide Composite Powder Metco 70-CNS and Metco 404NS Blend C07-027 75% Chromium Carbide; 25% Nickel Chromium Powder AI-1005 Obsolete AI-1007 Obsolete CRC-106 CRC-108
EFFECTIVITY: ALL
Sulzer Metco, Inc. Praxair / TAFA Indianapolis Powder Alloy Corp. Praxair / TAFA Indianapolis Sulzer Metco, Inc. Sulzer Metco, Inc. Powder Alloy Corp. Sulzer Metco, Inc. Praxair / TAFA Indianapolis Sulzer Metco, Inc. Stellite Coatings Deloro Stellite, Inc. Sulzer Metco, Inc.
Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis

70-80-07
Ref No.
Consumable Name / Remarks Metco 81NS Metco 81VF-NS PAC 130 PAC 131
Supplier Sulzer Metco, Inc. Sulzer Metco, Inc. Powder Alloy Corp. Powder Alloy Corp. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc.
C07-028 Aluminum Wire AMS 4180 Metco Aluminum Wire C07-029 Powder, Magnesium Zirconate Amdry 333 Metco 210NS-1G ZRO-103 Obsolete: Replaced by ZRO218 ZRO-218 C07-030 Magnesium Zirconate-Nickel Aluminum Composite Powder Metco 421NS-1 Obsolete ZRO-105 Obsolete C07-031 Cobalt-Molybdenum-Chromium-Silicon Powder CO-111 Metco 68F-NS-1 Tribaloy T-800 C07-032 Nickel Chromium Aluminum Yttrium Powder Amdry 962 Amperit 413.284 Amperit 413.284 NI-164/NI-211 PAC 9620AM C07-033 Zirconium Oxide-Yttrium Oxide Composite Powder Preferred Alternative is C07035 Amperit 821.285 Obsolete: No Longer Available Metco 202NS C07-034 Nickel Aluminum-Molybdenum Composite Powder Sulzer Metco, Inc. Sulzer Metco, Inc. H.C. Starck GmbH and Co KG H.C. Starck Inc. Praxair / TAFA Indianapolis Powder Alloy Corp. Praxair / TAFA Indianapolis Sulzer Metco, Inc. Stellite Coatings Deloro Stellite, Inc. Praxair / TAFA Indianapolis
EFFECTIVITY: ALL
70-80-07
Ref No.
Consumable Name / Remarks Metco 447NS NI-453
Supplier Sulzer Metco, Inc. Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis
C07-035 Zirconium Oxide-Yttrium Oxide Composite Powder 1485I AI-1075 Amperit 827.293 Obsolete: Replaced by Amperit 827.774 Amperit 827.774 Amperit 827.774 Metco 204NS Metco 204NS-G PAC 2008P Zirspra 8 w/o YS (-200, +325) ZRO-113/114 ZrO-8%Y203 (-200, +325) C07-036 Copper-Nickel-Indium Amdry 500 CU-101-1 C07-037 Aluminum Silicon Polyester Powder AL-202 Obsolete AL-228 Amdry 2010 Metco 601NS PAC 905-3 Westaim 1601 C07-038 Inco 718 Powder Amdry 718 Cl B NI-202-1 PAC 718B C07-039 Aluminum Oxide Powder ALO-105-1 Metco 101SF C07-040 Powder, 17% Tungsten Carbide Cobalt Praxair / TAFA Indianapolis Sulzer Metco, Inc. Sulzer Metco, Inc. Praxair / TAFA Indianapolis Powder Alloy Corp. Praxair / TAFA Indianapolis Sulzer Metco, Inc. Sulzer Metco, Inc. Powder Alloy Corp. Westaim Corp. Sulzer Metco, Inc. Praxair / TAFA Indianapolis H.C. Starck GmbH and Co KG H.C. Starck Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Powder Alloy Corp. Zircoa Products Praxair / TAFA Indianapolis Zircoa Products
EFFECTIVITY: ALL
70-80-07
Ref No.
Consumable Name / Remarks Deloro Stellite JK117SP NOTE: For Jetkote System HVOF Metco 73F-NS-1 NOTE: For DJ System HVOF WC-128 Obsolete: Replaced by WC-559 WC-559 WC-619 Obsolete: Replaced by WC-559
Supplier Stellite Coatings Deloro Stellite, Inc.
Sulzer Metco, Inc.
Praxair / TAFA Indianapolis
C07-041 Inconel 718 Powder HVOF Application AE-7227 Obsolete Amdry 1718 NI-202-3 NOTE: For Jetkote HVOF System PAC 718F C07-042 Nickel-Aluminum Wire 75 B PMET 885 Sulzer Metco 8400 C07-043 Nickel-Chromium-Aluminum Wire 73 MXC PMET 886 Sulzer Metco 8443 C07-044 Aluminum Wire 99% Pure Minimum 0.0625 in. (1.59 mm) Diameter O1T C07-045 Not issued, Reserved for 70-49-41 Not issued, Reserved for 7049-41 C07-046 Not issued, Reserved for 70-49-42 Not issued, Reserved for 7049-42
EFFECTIVITY: ALL
Powder Alloy Corp. Praxair / TAFA Concord Polymet Corp. Sulzer Metco, Inc. Praxair / TAFA Concord Polymet Corp. Sulzer Metco, Inc.
Praxair / TAFA Concord
70-80-07
Ref No.
Supplier
C07-047 Cobalt-Molybdenum-Chrome-Silicon Powder, HVOF Application CO-111 Diamalloy 3001 JK 558 C07-048 Metal Powder CO-273-5 NOTE: Alloy Type HS-188 C07-049 Alloy 718 Wire 78T PMET 818 Sulzer Metco 8718 C07-050 Nickel-Chromium-Silicon-Iron Powder (Metcolloy 33) Sulzer Metco 4538 NOTE: Product ID numbering change at Supplier. NOTE: Sulzer Metco 4538 is the powder equivalent to Metcoloy 33 (C07006) XPT-183 Obsolete: Replaced by Sulzer Metco 4538 C07-051 Copper-Zinc-Silver Pre-alloyed Wire 0.0625 in. (1.59 mm) diameter 30S C07-052 Alloy Powder Rene 80 NI-183 C07-053 Alloy Powder Rene 80 NI-183-4 C07-054 Copper-Nickel-Indium Wire 0.0625 in. (1.587 mm) diameter 58T C07-055 Molybdenum Wire TAFA 13T C07-056 Aluminum Bronze Alloy Wire (Aluminum 6.0 - 11.0, Iron 1.5 Max.)
EFFECTIVITY: ALL
Praxair / TAFA Indianapolis Sulzer Metco, Inc. Stellite Coatings Deloro Stellite, Inc. Praxair / TAFA Indianapolis
Praxair / TAFA Concord Polymet Corp. Sulzer Metco, Inc. Sulzer Metco, Inc.
Praxair / TAFA Concord Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis
Praxair / TAFA Concord Praxair / TAFA Concord
70-80-07
Ref No.
Consumable Name / Remarks TAFA 10T
Supplier Praxair / TAFA Concord
EFFECTIVITY: ALL
70-80-07
MISCELLANEOUS - CONSUMABLE PRODUCTS MISCELLANEOUS TASK 70-80-10-800-019 1. Consumable Products - Miscellaneous SUBTASK 70-80-10-99G-019 A. Ref No. General. Consumable Name / Remarks Desiccant (MIL-D-3464, Type I) C10-002 Wax Strips Wax Strips-Preformed with adhesive back 1/2 x 1-1/4 thickness C10-003 Fabric, Glass (SAE-AMS-C-9084, Type VIII or VIIIA) Fabric, Style No. 1581 C10-004 Grinding Wheel Grinding Wheel 23A80-L8V C10-005 Fireproof Cotton Fireproof Cotton Obsolete: Repair requirement no longer exist C10-006 Tubing Tubing, Non-Toxic Vinyl Plastic C10-007 Powder, Aluminum Powder, Aluminum (Fed. Spec. A-A-341) C10-008 Honeycomb Core, Phenolic Reinforced Polyamid Fiber HRH-10-3/8-3.0 (Specify 3/8 in. Thickness and Desired Length and Width) C10-009 Paper, Greaseproof (MIL-B-121 Type II, Grade A, Class 2 (Kraft)) PK 22C C10-010 Abrasive Cloth Scotch Brite Pads No. 7447 (6.0 x 9.5 in.) UPC# 048011-04029 3M Company Ludlow Corp., Packaging Div. Hexcel Corporation Local Purchase Local Purchase Norton Company / Division of Saint Gobain Hexcel Corporation Freeman Mfg. and Supply Co. Supplier Local Purchase
C10-001 Desiccant (MIL-D-3464, Type I)
EFFECTIVITY: ALL
70-80-10
CONSUMABLE PRODUCTS MISCELLANEOUS Page 1 Dec 01/03
Ref No. C10-011 Release Agent
Consumable Name / Remarks Alternative: C10-013 143DF NOTE: Contains Class 2 ODC 143V NOTE: Contains no Class 1 or Class 2 ODC MS-143N Obsolete: Material contained ODC, Replaced by 143DF
Supplier
Miller Stephenson Chemical Co.
Miller Stephenson Chemical Co.
C10-012 Tape, Masking, High Temperature Bron # BRP 1864-8R-GE D/W 410 D/W 497 NOTE: For air plasma applications. D/W 498 NOTE: For normal HVOF applications. D/W 500 NOTE: For Electric Arc (like #497 with added adhesive). D/W 501 NOTE: For thicker HVOF coatings (tape is 0.002 - 0.004 1n. thicker than the #498 tape) Fiberglass Tape 23816 Fluorglas 2905-7 Tape #9710 Fluorglas 2975-8R Furon Tape Division / Division of Saint Gobain Furon Tape Division / Division of Saint Gobain Furon Tape Division / Division of Saint Gobain
Bron Tapes DeWal Industries DeWal Industries
DeWal Industries
DeWal Industries
DeWal Industries
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks Metal Tape 26020
Supplier Furon Tape Division / Division of Saint Gobain
C10-013 Release Agent Alternative: C10-011 MS-122B NOTE: Material contains no Class 1 or Class 2 ODC MS-122DF NOTE: Contains Class 2 ODC MS-122N/C02 Fluorocarbon Obsolete: Contained ODC Replaced by MS-122DF MS-122V NOTE: Material contains no Class 1 or Class 2 ODC C10-014 Maskant Maskant, Turco No. 537 Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Wall-Colmonoy Corp. Miller Stephenson Chemical Co. Miller Stephenson Chemical Co. Miller Stephenson Chemical Co.
Turcoform Mask 540-R
C10-015 Braze Stop-Off Braze Stop-Off, Nicrobraz Green NOTE: Type II (water based) is Environmentally preferred product C10-016 Braze Stop-Off Braze Stop-Off, Nicrobraz Red, Type II C10-017 Binder, Organic Marex Wall-Colmonoy Corp.
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks Obsolete
Supplier
C10-018 Abrasive, Grit, Aluminum Oxide, 50 Micron No. 3 P/N AP123 White, 50 Micron Obsolete: Replaced by No. 3 P/ N AP123 C10-019 Release Agent Release Agent, RAM225 C10-020 Braze Stop-Off Braze Stop-Off, Type 110 (White) C10-021 Tape, Plastic NT-580, Red Patco #110-50 Shurtape PC623 Vinyl Tape, No. 44 Cat No. 6130 (Yellow) Obsolete C10-022 Additive, Fumed-Silica Viscosity Control Agent Cab-O-Sil Obsolete: Replaced by Cab-OSil TS-720 Cab-O-Sil TS-720 C10-023 Quartz Pins Quartz Pins C10-024 Cup Wheel Grinding Cup Wheel Grinding, 32A60J5VBE C10-025Abrasive Wheel Grinding Wheel, A24QBFCW1/ 4 Type 27 C10-026 Grinding Wheel Grinding Wheel, 32A460K5VBE C10-027 Binder Binder, Type 105 C10-028 Seal, Conical Seal, Conical, VSF1015-N-3 Fairchild Fasteners Direct HTG Metal Methods Norton Company / Division of Saint Gobain Carborundum Co. Norton Company / Division of Saint Gobain Industrial Quartz Cabot Corporation BGR, INC. Patco Corp. Shurtape HTG Metal Methods Lily Industries Inc. S.S. White Technologies
EFFECTIVITY: ALL
70-80-10
Ref No. C10-029 Seal, Conical
Consumable Name / Remarks Seal, Conical, VSF1015-N-4
Supplier Fairchild Fasteners Direct Unisorb Installation Technologies
C10-030 Vibration Dampening Material Vibration Dampening Material, Unisorb HB-1/2 (Sheet 1/2 in. x 3 ft. x 5 ft.) C10-031 Polyimide Paper-Dense Laminate Nomex 410 (Sizes 0.024, and, 0.030 in. available) Nomex 411, (Sizes 0.028/0.025 x 1.175/1.145 x 30.0 in.) C10-032 Tape, Masking Tape, Masking, Tuck No. 69 Obsolete: Replaced by C10-021 C10-033 Matrix, Low Melting Alloy ASARCO C58 Obsolete: Replaced by CerroLow 136 CerroLow 136 C10-034 Epoxy, Two Part, Tooling, Liquid Devcon Plastic Steel, Liquid B (P/N 10210: resin plus catalyst kit) C10-035 Release Agent Devcon Release Agent #19600 C10-036 Abrasive Wheel, Rubberized Abrasive Wheel, Spec. No. 808M C10-037 Abrasive Wheel, Light Deburring Light Deburring Wheel, Grade 5, Code 6B Scotch Brite C10-038 Grinding Wheel Grinding Wheel, A70-0-10BB C10-039 Tape, Plastic, High Shrink A16B39D Alternative: C10-135 Hi-Shrink Tape, 0.002x1 in. C10-040 Tape, Teflon Dunstone Company Inc. Radiac Abrasives 3M Company Precision Abrasives and Tools ITW Devcon ITW Devcon Cerro Metal Products Co. Alloy Dept. Essex Group Inc. IWI Operations Essex Group Inc. IWI Operations
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks Scotch Brand 5490, Teflon 1 x 0.002 in. thick
Supplier 3M Company
C10-041 Impression Material Alternative: C10-126, C10-129, or C10-181 Facsimile C10-042 Abrasive, Grit, Blast Media 1250 Novaculite C10-043 Abrasive Wheel, Rubberized Cratex 8-C C10-044 Abrasive Wheel, Rubberized Rubber Wheel 1 x 0.030 x 1/16 A240, U2RR860 C10-045 Carbide Cutter Burr BC-0 1/8 Dia Cut EDP # 54873 C10-046 Foil Chromel C Foil, Tophet C (HAI-NICR 60) Obsolete: Replaced by Chromel C C10-047 Grinding Wheel Grinding Wheel, Electrolytic, A80-150-DM347 DIMI Brass Bond C10-048 Cloth, Bleeder-Osnaberg NOTE: C10-134 may be usd as one way alternative for C10048. C10-048 may not be used as an alternative for C10134 Cloth, Bleeder-Osnaberg NOTE: Must specify Tight Weave - J113410 or Loose Weave J198310 Cloth, Bleeder-Osnaberg Canvas Specialties Miltix-Morgan Fabrics Tyrolit North America Inc. Hoskins Mfg. Co Bassett Rotary Tool Co. Radiac Abrasives Precision Abrasives and Tools Vapor Blast Mfg. Co. Flexbar Machine Corp.
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks Aluminum Oxide Grit, 180 Mesh
Supplier USF / Surface Preparation
C10-049 Abrasive, Grit, Aluminum Oxide
C10-050 Honeycomb Nomex Honeycomb HRH-10 (0.1875 in cell, 3/16 in. thick) C10-051 Film, Release, Perforated Alternative: C10-132 E3760-P1-(0.002) E3760-P2-(0.001) C10-052 Sealant GSNO 213T, 1/8 in. x 1/2 in. x 25 ft. Obsolete: Replaced by C10-138 C10-053 Bagging Bagging, Green Plastic Material Vac-Pac Obsolete: Replaced by C10-137 C10-054 Gun, Heat Gun, Heat C10-055 Heat Blankets, Controllers and Lamps Heat Blankets, Controllers and Hot Bonders C10-056 Tape, Pressure Sensitive Alternative: C10-136 Vac Pack, E3760-PS4 C10-057 Sealant Hi Temp Nylon Vacuum Bag Obsolete: Replaced by C10-137 C10-058 Abrasive Wheel No. W215, Grit A90R V. Grade O C10-059 Abrasive Wheel Cratex 79F C10-060 Brush Unit, Vonnegut SH-1030-2 in 32 Brush Vonnegut Head with long trim brush G and P Machinery Corp. Precision Abrasives and Tools Norton Company / Division of Saint Gobain Richmond Aircraft Prod. BH Thermal Corp. Grainger Parts Richmond Aircraft Prod. Richmond Aircraft Prod. Hexcel Corporation
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks NOTE: Specify arbor hole size for head
Supplier
C10-061 Brush, Replacement, Type SH-306 SH-306 2 in. long trim brushes NOTE: Use with C10-060, SH1030-2 C10-062 Abrasive Cloth 320 Grit, 2 X 16 in LDG, S/C, WP 1/4 in. Shred C10-063 Tape, Specialty Duct TESA 53793 Waterproof Cloth Number 91B Obsolete: Replaced by TESA 53793 C10-064 Protective Hand Cream Co. 406 Obsolete: Replaced by Ply-2 Ply-2 NOTE: Specify tubes or jars C10-065 Grinding Wheel 150R100B99-1/8 (Grinding Wheel, 6 in x 1/8 in x 1 1/4 in.) 1A1-120-66 Obsolete: Replaced by 150R100B99-1/8 D150-45Q Obsolete: Replaced by 150R100B99-1/8 C10-066 Wear Strip Nylatron GS Wear Strip Nylatron GS, 0.938 in. wide, 0.074 in. thick C10-067 Tape, Platers Scotch No. 470, Tape C10-068 Gun, Sealant Gun, Sealant, Semco Model 250-A6, P/N 250065 PRC-Desoto International Inc. 3M Company Penn-Fibre and Specialty Co. Norton Company / Division of Saint Gobain The Milburn Co. Tesa Tape Inc. (TTI) G and P Machinery Corp. G and P Machinery Corp.
EFFECTIVITY: ALL
70-80-10
Ref No. C10-069 Grinding Wheel
Consumable Name / Remarks 57A80L8V, 8.0 in. OD x .500 in. x 1.25 in. ID Norton 19A80L8V, 0.5 in. width x 1.25 in. ID x 8.0 in. OD Obsolete: Replaced by 57A80L8V, 8.0 in. OD x .500 in. x 1.25 in. ID
Supplier Norton Company / Division of Saint Gobain
C10-070 Tape, Glass Fiber Permacel P21 Scotch No. 27 TESA 4616 Obsolete: Replaced by Scotch No. 27, Tape Class Cloth Tuck No. 51 Obsolete: Replaced by Scotch No. 27, Tape Class Cloth C10-071 Safety Wire, 0.020 or 0.032 in. dia. AMS 5685, (305 Stainless Steel), Safety Wire AMS 5687, (Inconel 600) Safety Wire AMS 5689, (321 Stainless Steel) Safety Wire AMS 5690, (316 Stainless Steel) Safety Wire C10-072 BrightBoy Stick BrightBoy Stick Holder, 801-X NOTE: Use with BrightBoy Stick, ST-90-ALO-801R BrightBoy Stick, ST-90-ALO801-R NOTE: Used with 801-X Holder ST-180-ALO-801R, BrightBoy Stick with Holder Obsolete: Replaced by ST-90ALO-801-R Precision Abrasives and Tools Precision Abrasives and Tools Honeywell Hardware Products Group Honeywell Hardware Products Group Honeywell Hardware Products Group Honeywell Hardware Products Group Permacel 3M Company
EFFECTIVITY: ALL
70-80-10
Ref No. C10-073 Abrasive Disk
Consumable Name / Remarks PSA 2 in. dia., 120 S/C
Supplier Field Abrasive Mfg. Co. Inc. Lapmaster International
C10-074 Abrasive, Diamond Compound Diamond Compound Grade No. 45 Heavy Duty C10-075 Coolant, Machining Trim Sol VHP E210 C10-076 Grinding Wheel 32A60K8VBE C10-077 Grinding Wheel 39C80H12V C10-078 Fabric, Peel Ply No. 1 Fabric, Peel Ply No. 1 Obsolete: Replaced by C10-131 C10-079 Cellulose, Acetate PN11340, (Replicating Tape 5 mil thick) C10-080 Abrasive, Polishing Paste, Diamond (Strong Grade) Polishing Paste, Diamond, 15 micron Polishing Paste, Diamond, 3 micron Polishing Paste, Diamond, 6 Micron C10-081 Thinner (Strong Grade) Thinner (Strong Grade) C10-082 Abrasive, Aluminum Oxide, Slurry 0.3 micron Micropolish 40636006 or 406363128 C10-083 Abrasive, Aluminum Oxide, Slurry 0.05 micron Micropolish 406365006 C10-084 Cable Wrap Flexite Spiral Cut Cable Wrap (Teflon 1/4 in OD x 0.03 thick x 0.375 pitch) C10-085 Tape, Glass Cloth
EFFECTIVITY: ALL
Master Chemical Co. Master Chemical Co. Norton Company / Division of Saint Gobain Norton Company / Division of Saint Gobain
Ernest F. Fullam, Inc.
Lapmaster International Lapmaster International Lapmaster International
Lapmaster International Buehler Limited
Buehler Limited Markel Corp.
70-80-10
Ref No.
Consumable Name / Remarks Scotch No. 27, Tape, Glass Cloth Obsolete: Replaced by C10-070
Supplier
C10-086 Cloth, Carbon Fiber, Graphitized Panex 30, SW08 1.5 in. wide C10-087 Gun, Paint Spray Model EGA-503 (Devilbiss) NOTE: EGA used for touch up. Use F fluid tip and 290 air cap. JGA-510 (Devilbiss) NOTE: JGA used for full repair. Use FX fluid tip and 758 or 704 air cap. C10-088 Tape, Glass Fiberglass Tape, Style 573 Obsolete: Replaced by C10-003 C10-089 Abrasive Wheel, Cutoff No. 3, Cutoff Wheel, 1.0 in. x 0.040 in., (25.4 mm x 1.92 mm) C10-090 Polygard Protector MP9000-0500 (0.5 in width) MP9000-1000 (1.0 in width) MP9000-1500 (1.5 in width) MP9000-2000 (2.0 in width) C10-091 Cartridge Heater Chromalox Cartridge Heater Cat. No. CIR 3031 (3.0 in. x 0.5 in. dia) C10-092 Abrasive Brush Brush No. 22299 (320 grit) with adapter No. 1A NOTE: Need to specify shaft size for the adapter. C10-093 Filler, Phenolic Micro-balloons Type BJ0-0930 The M.F. Cachat Co.
Zoltek ITW Industrial Finishing
ITW Industrial Finishing
Precision Abrasives and Tools
APW Zero Cases APW Zero Cases APW Zero Cases APW Zero Cases Chromalox
Osborn International
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks NOTE: Also used in C01-060 Type BJ0-0930
Supplier
Asia Pacific Microspheres (Manufacturer) McMaster Carr
C10-094 Cloth, Wire Mesh Cloth, Wire Mesh, Cat. No. 9226T29 NOTE: Material is 316 Stainless Steel, mesh spacing 8x8 for each sq. in., wire size is 0.035 in. (0.89 mm) dia. C10-095 Perforated Steel Perforated Steel, Cat. No. 9255T631 NOTE: Material, Low alloy steel, 30x120 in. Hole size is 0.125 in. (3.18 mm) dia., 16 gauge thickness Perforated Steel, Cat. No. 9358T14 NOTE: Material, 304 Stainless Steel, Hole size is 0.125 in. (3.18 mm) dia., 16 gauge thickness C10-096 Compound, Polishing 240 grit aluminum oxide. Greaseless #240 C10-097 Brushes, Wire Brushes, Wire, 0.003 in. (0.08 mm) C10-098 Dip Seal Type 2 Dip Seal Type 2, Code DS 58-7 C10-099 Wax, Paraffin ADAWAX 165 Obsolete: Replaced by HM4899 Wax, Paraffin, HM4899
EFFECTIVITY: ALL
McMaster Carr
McMaster Carr
Wm. Buchanan Supply Co.
Osborn International
Dip Seal Plastic Inc.
H.B. Fuller Co.

70-80-10
Ref No. C10-100 Seal, Aluminum
Consumable Name / Remarks Seal. Aluminum No. A-1
Supplier American Casting and Mfg. Co. Sermatech International Inc.
C10-101 Applicator Applicator, Coating (Part No. 97301) Small C10-102 Tape, Masking Tape, Masking, No. 218 Fineline C10-103 Tape, Adhesive Dots Tape, Adhesive Dots (various sizes for masking) C10-104 Burr, 1/8 in. Spherical Carbide Cat. No. 010 0083-20, (Burr, 1/8 in. Spherical Carbide) C10-105 Abrasive, Sandpaper, Roll 120 Grit, Aluminum Oxide, Sandpaper Roll C10-106 Burr, 1/4 in. Spherical Carbide Cat. No. 048-1033-20 (Burr, 1/4 in. Spherical Carbide) C10-107 Cork Stoppers Cat. No. 9566K23 (or equivalent) Cork Stoppers, 15/ 16 in. dia. large end C10-108 Brush, Disposable, Natural Bristle Cat. No. 7237T4 (or equivalent) Disposable Brush Natural Bristle Cat. No. 7798T2 (or equivalent) Disposable Brush Natural Bristle C10-109 Wax, Utility Red 091-1578 (Wax, Utility) C10-110 Almen Test Strips Almen A Almen Strips, Type A (0.0500.052 in.) Almen Strips, Type A (0.0500.052 in.) Associated Spring Barnes Group Inc. Electronics Inc. Metal Improvement Co. Patterson Dental Supply McMaster Carr McMaster Carr Greenfield Industries Local Purchase Greenfield Industries 3M Company 3M Company
McMaster Carr
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks TC330 1-1/4 x 9/16 in. (3M Number)
Supplier 3M Company
C10-111 Rotary Flap Peen Assembly
C10-112 Fabric, High Strength Woven Graphite Fabric, High Strength Woven Graphite 12.5x12.5 tows/in. W322 C10-113 Honeycomb Core, Phenolic Reinforced Polyamide Fiber HRH-10-1/8-3.0 NOTE: Specify 1/2 in Thickness and Desired Length and Width NOTE: 0.125 in. (3.18 mm) cell x 0.5 in. (13 mm) Thick. Density is 3 lb/ ft3 C10-114 Nylon Brushes Abrasive Coated, 320 Grit 38154-4 (Unimaster) 4.0 in. OD, 5/8 in. ID Obsolete: Replaced by Cat. No. 22259 320 Grit Cat. No. 22259, 320 Grit C10-115 Abrasive, Grit, Blast Media Novaculite 200 C10-116 Filler, Graphite Fibers, Milled Thornel Mat VMD Obsolete: Replaced by Thornel Mat VMX-11 Thornel Mat VMX-11 C10-117 Abrasive, Wheel Unitized wheel, level cut, 0.75 in x 0.125 in. x 0.125 in. Grade 5A, Fine C10-118 Wire Mesh, Aluminum (Mesh 200x600) Wire Mesh, Aluminum, 0.0024 in. dia. x 0.0018 in. dia. Wire, 48.0 in. wide x 12.0 ft. long C10-119 Wire Mesh, 304L Stainless Steel, (Mesh 200/600) SEFAR America 3M Company BP Amoco Polymers Inc. Vapor Blast Mfg. Co. Osborn International Hexcel Corporation Cytec Engineered Materials Inc.
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks Wire Mesh, 304L Stainless Steel, Twill Dutch Weave, (Wire Diameters: Warp: 0.0024 in. Shute: 0.0018 In.) Wire Mesh, 304L Stainless Steel,Twill Dutch Weave, (Wire Diameters: Warp: 0.0024 in. Shute: 0.0018 In.) Wire Mesh, 304L Stainless Steel,Twill Dutch Weave, (Wire Diameters: Warp: 0.0024 in. Shute: 0.0018 In.)
Supplier GDC / City Wire Cloth
SEFAR America
Gerard Daniel Company
C10-120 Abrasive Paper, Aluminum Oxide 320 Grit, Abrasive Paper, Aluminum Oxide C10-121 Abrasive Paper, Silicon Carbide Wet/Dry 320 Grit, Abrasive Paper, Silicon Carbide Wet/Dry C10-122 Cloth, Glass (AMS3824A, MIL-Y-1140) Style 120, Finish 538 NOTE: Must Specify Width C10-123 Primer Primer Obsolete: Repair requirement no longer exist C10-124 Tape S-1255 Thermoset Adhesive Tape S1044 Tape Obsolete: Replaced by 1255 C10-125 Tape, Silicone Self-Adhering (A-A-59163 Type I), 0.020 in. thick nominal 920-07 (0.75 in. wide) 920-10 (1.0 in. wide) MIL Style A-A-59163 Type I (0.5 in. or 1.0 in wide) MOX-Tape 620-.5 (0.5 in. wide) Tape, Silicone Self-Adhering Arlon Inc., Silicone Technologies Division Arlon Inc., Silicone Technologies Division Marian Inc. Flexfab D & B Industrial Tyco Electronics / Raychem Interconnect BGF Industries Local Purchase Local Purchase
EFFECTIVITY: ALL
70-80-10
Ref No. C10-126 Impression Material
Consumable Name / Remarks Alternative: C10-041, C10-129, and C10-181 No. 16130, Repro-rubber, Quicksetting Putty (1 3/4 lb.) No. 16131, Repro-rubber, Quicksetting Putty (7 lb.)
Supplier
Flexbar Machine Corp. Flexbar Machine Corp.
C10-127 Chafe Guard, Tube Size 0.500/0.675, Hose Size -8/-10 2681-11 (Chafe Guard) 95340 (Chafe Guard) C10-128 Plastic Sheet, Polyethylene Plastic Sheet, Polyethylene (1.5 mil thickness or greater) C10-129 Impression Material Alternatives: C10-041, C10-126, or C10-181 RTV3110 NOTE: Use with Catalyst 4 C10-130 Cloth, Glass Fiber, Preimpregnated E773FR/120 MXB 7740/120 C10-131 Peel Ply, Style 52006/51789, SRB Peel Ply, Style 52006/51789, SRB C10-132 Film, Polymer FEP Perforated, 0.001 in (0.03 mm) Thick A4000P3 NOTE: 48 or 56 in. width A5000P3 C10-133 Film, Polymer FEP, Un-perforated, 0.001 in. (0.03 mm) thick A4000 NOTE: 48 or 56 in. width A5000 C10-134 Cloth, Breather/Bleeder
EFFECTIVITY: ALL
Parker-Hannifin Corp., Stratoflex Division Titeflex, Inc. Local Purchase
Dow Corning Corp.
Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Precision Fabrics Group Inc.
Airtech International Inc.
Richmond Aircraft Prod.
70-80-10
Ref No.
Consumable Name / Remarks Airweave N10 RC-3000-10
Supplier Airtech International Inc. Richmond Aircraft Prod. Richmond Aircraft Prod. Airtech International Inc.
C10-135 Tape, Shrink #2 Tape, Shrink #2 C10-136 Tape, Pressure Sensitive Flash-Breaker 2 NOTE: 1 or 2 in. width Tape, Flash-Breaker, No. 855, 0.002 in. Thick C10-137 Film, Vacuum Bag Vac-Pak, HS-8171 WL 6400 NOTE: 0.001 or 0.002 in. width C10-138 Tape, Sealant, Vacuum Bag GS-213 NOTE: 0.5 or 0.75 in width SM 5144 Tape, Sealant, Vacuum Bag C10-139 Gloves Gloves, White Cotton Disposable C10-140 Gloves Gloves, Film Latex or Nylon/ Polyethylene Disposable C10-141 Abrasive Paper 120 Grit, SiC, wet/dry, abrasive Paper 180 Grit, SiC, wet/dry, Abrasive Paper C10-142 Film, Polyester, (Mylar), 0.002-0.004 in thick Film, Polyester, (Mylar), 0.0020.004 in thick C10-143 Safety Cable Assembly (321 Stainless Steel AS 4536, AS 3510) 0.032 in. dia. Daniels Mfg. Corp. Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Richmond Aircraft Prod. Airtech International Inc. Richmond Aircraft Prod. Airtech International Inc. 3M Company
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks 0.032 in. dia. Kit K30B18
Supplier Bergen Cable Technologies, Inc.
C10-144 Ferrule, Safety Cable, J1286P01 (321 Stainless Steel AS 4536, AS 3510) F10-02 F30B C10-145 Safety Cable, J1285P01 (321 Stainless Steel AS 4536, AS 3510) 0.032 in. dia. A10-218 NOTE: Cable with Swaged ferrule attached. C30B18 NOTE: Cable with Swaged ferrule attached. C10-146 Test Block, Safety Cable CTK202 Obsolete: Replaced by JRC 202 JRC 202 Obsolete SCT-TB1 TB 101 C10-147 Tester, Safety Cable MPT-200A MPT-200A-SC MPT-200ASC Obsolete: Replaced by MPT200A-SC SCT-ET1 Obsolete: Replaced by MPT200A-SC C10-148 Crimping Tool, Safety Cable (0.032 in dia wire) CTK8V32A Bergen Cable Technologies, Inc. Daniels Mfg. Corp. Daniels Mfg. Corp. Bergen Cable Technologies, Inc. Bergen Cable Technologies, Inc. Daniels Mfg. Corp. Daniels Mfg. Corp. Bergen Cable Technologies, Inc.
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks Obsolete: Replaced by JRC8V32C JRC8V32C NOTE: For use with Task 7011-04-400-008, Safety Cable Method 2 (Snap-On Tool) M303 NOTE: 3.0 in. (76.2 mm) extension for use with TASK 70-11-02-400006, Safety Cable Procedure Method 1. M307 NOTE: 7.0 in. (177.8 mm) extension for use with TASK 70-11-03-400007, Safety Cable Procedure Method 1. (Bergen Tool) SCT323 NOTE: 3.0 in. (76.2 mm) extension for use with TASK 70-11-05-400009, Safety Cable Procedure Method 3. (Daniels (DMC) Tool) SCT327 NOTE: 7.0 in. (177.8 mm) extension for use with TASK 70-11-05-400006, Safety Cable Procedure Method 3. (Daniels (DMC) Tool)
Supplier
Snap-On Special Products
Bergen Cable Technologies, Inc.
Bergen Cable Technologies, Inc.
Daniels Mfg. Corp.
Daniels Mfg. Corp.
C10-149 Wire Cutter, Flush Side Cushioned Wire Cutter, Flush Side Cushioned C10-150 Tool, Safetywire Local Purchase
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks Tool, Safetywire
Supplier Local Purchase
C10-151 Tape, Silicone, Fiberglass Supported (MIL-I-22444), 0.02 Thick, Nominal RL-6000-SA Series SB01020 (1 in. wide) SB00520 (0.5 in. wide) C10-152 Fastener, Self-Locking 0.301 Nylon tie wraps 1/4 in. wide x 13.38 in. long Fastener, Self-Locking 0.301 Nylon tie wraps 1/4 in. wide x 13.38 in long TY-RAP P/N TY27M C10-153 Tape, Silicone Glass Cloth, Thermo-Setting Adhesive Polyken 292 Obsolete C10-154 Beeswax Beeswax C10-155 Shims, Metal Shims Metal, RFI 1795-1 (0.004 in. Thick) Shims Metal, RFI 1795-2 (0.005 in. Thick) Shims Metal, RFI 1795-3 (0.006 in. Thick) Shims Metal, RFI 1795-4 (0.007 in. Thick) Shims Metal, RFI 1795-5 (0.008 in. Thick) Shims Metal, RFI 1795-6 (0.009 in. Thick) C10-156 Wax, Laser Beam Stopping Freeman Sheet Wax #165 Regular Plain NOTE: Specify thickness 0.001, 0.010, 0.015, 0.020, or 0.025 in. SW 12 Wax Billet, Flat, In Broken Chunks Part No. 499A04 C10-157 Tape, Glass Cloth
EFFECTIVITY: ALL
Kirkhill-TA Co. Flexfab Flexfab
Local Purchase
Thomas and Betts Corp.
Local Purchase Laminated Shim Co. Laminated Shim Co. Laminated Shim Co. Laminated Shim Co. Laminated Shim Co. Laminated Shim Co.
Freeman Mfg. and Supply Co.
Kindt-Collins Co.
70-80-10
Ref No.
Consumable Name / Remarks 3807 Mystik 7000 Permacel P-212 Scotch No. 69
Supplier Furon Tape Division / Division of Saint Gobain Furon Tape Division / Division of Saint Gobain Permacel 3M Company MTU Maintenance GmbH MTU Maintenance GmbH MTU Maintenance GmbH MTU Maintenance GmbH MTU Maintenance GmbH Patterson Dental Supply Patterson Dental Supply Patterson Dental Supply Patterson Dental Supply
C10-158 Silicone Rubber Masking Ring Set 31-400-1352 31-400-1353 31-400-1354 31-400-1355 31-400-1356 C10-159 Reamers, Root Canal Stainless Steel Size No. 25, Reamers, Root Canal Stainless Steel Size No. 50, Reamers, Root Canal Stainless Steel Size No. 70, Reamers, Root Canal Stainless Steel Size No. 75, Reamers, Root Canal Stainless Steel C10-160 Aeroquip AE272, Flexwrap Fire Sleeve Size -4 Aeroquip AE272, Flexwrap Fire Sleeve Size -4 C10-161 Aeroquip AE272, Flexwrap Fire Sleeve Size -6 Aeroquip AE272, Flexwrap Fire Sleeve Size -6 C10-162 Aeroquip AE272, Flexwrap Fire Sleeve Size -9 Aeroquip AE272, Flexwrap Fire Sleeve Size -9 C10-163 Aeroquip AE272, Flexwrap Fire Sleeve Size -11 Aeroquip AE272, Flexwrap Fire Sleeve Size -11 C10-164 Flex-hones, 120 grit Silicon Carbide BC 6.4mm (0.250) NOTE: Bolt Hole Size: 0.245 in.-0.255 in. Flex Hone (Part No.: BC 6.4mm (0.250 in.) Brush Research Mfg. Co. Inc. Aeroquip E.F.G. Aerospace Group Aeroquip E.F.G. Aerospace Group Aeroquip E.F.G. Aerospace Group Aeroquip E.F.G. Aerospace Group
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks BC 6.8mm (0.315) NOTE: Bolt Hole Size: 0.295 in.-0.302 in. Flex Hone (Part No.: BC6.8mm (0.315 in.)
Supplier Brush Research Mfg. Co. Inc.
C10-165 Flex-hones, 120 grit Silicon Carbide
C10-166 Flex-hones, 120 grit Silicon Carbide Flex-hones, 120 grit Silicon Carbide Obsolete: Replaced by C10-165 C10-167 Flex-hones, 120 grit Silicon Carbide Flex-hones, 120 grit Silicon Carbide Obsolete: Replaced by C10-165 C10-168 Flex-hones, 120 grit Silicon Carbide BC 9mm (0.354) NOTE: Bolt Hole Size: 0.329 in. - 0.338 in. Flex Hone. Part No. BC 9mm (0.354 in) C10-169 Flex-hones, 120 grit Silicon Carbide Flex-hones, 120 grit Silicon Carbide Obsolete: Replaced by C10-168 C10-170 Flex-hones, 120 grit Silicon Carbide Flex-hones, 120 grit Silicon Carbide Obsolete: Replaced by C10-168 C10-171 Flex-hones, 120 grit Silicon Carbide Flex-hones, 120 grit Silicon Carbide Obsolete: Replaced by C10-168 C10-172 Flex-hones, 120 grit Silicon Carbide BC 10mm (0.394) NOTE: Bolt Hole Size: 0.396 in. - 0.403 in. Flex Hone. Part No. BC 10mm (0.394 in) Brush Research Mfg. Co. Inc. Brush Research Mfg. Co. Inc.
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks Brush, Wire Stainless Steel (0.003 - 0.005 in. dia wires)
C10-173 Brush, Wire Stainless Steel (0.003 - 0.005 in. dia wires)
C10-174 Aeroquip AE272 Flexwrap Fire Sleeve Size -3 Aeroquip AE272 Flexwrap Fire Sleeve Size -3 C10-175 Aeroquip AE272 Flexwrap Fire Sleeve Size -13 Aeroquip AE272 Flexwrap Fire Sleeve Size -13 C10-176 Aeroquip AE272 Flexwrap Fire Sleeve Size -14 Aeroquip AE272 Flexwrap Fire Sleeve Size -14 C10-177 Aeroquip AE272 Flexwrap Fire Sleeve Size -15 Aeroquip AE272 Flexwrap Fire Sleeve Size -15 C10-178C loth, Glass, PTFE Coated (Porous) 200TFP Release Ease 234 TFP NOTE: 38 or 50 in. width C10-179 Cloth, Glass, PTFE Coated (Non-porous) 200TFNP Release Ease 234 TFNP NOTE: 38 or 50 in. width C10-180 Tape, Electrical, Vinyl Scotch 35 NOTE: This Tape contains less than 10 ppm leachable chlorine lead, or sulfur. C10-181 Impression Material Alternative: C10-041, C10-126 or C10-129 Type 1 Red Compound (M.P. 132 deg. F.) Type 1 Red Compound (M.P. 132 deg. F.) Local Purchase Kerr Corp. 3M Company Richmond Aircraft Prod. Airtech International Inc. Richmond Aircraft Prod. Airtech International Inc. Aeroquip E.F.G. Aerospace Group Aeroquip E.F.G. Aerospace Group Aeroquip E.F.G. Aerospace Group Aeroquip E.F.G. Aerospace Group
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks NOTE: Specify Cake 00429 or Stick 00432
Supplier
C10-182 Cloth, Cleaning For Aircraft Structural (SAE-AMS 3819, BMS 15-5) 900-0000 (12 in. x 21 in) Obsolete: Replaced by 9001217 900-0044 (4 in x 8 in) Obsolete Kamen 900-1217 Kamen 900-99 C10-183 Adapter, Light Pipe SX-5 C10-184 Cable, Fiber Optic B248 C10-185 Light Source 170D C10-186 Pipe Light SK10040-0000 C10-187 Abrasive Cloth, Aluminum Oxide (Superflexible) 3M 211K (For grit sizes 80, 100, 120, 150, 180, 220, 240, and 320) 3M 241K (For grit sizes 36, 50 and 60) C10-188 Tape, Vibration Damping Speed Tape Y434 Tape Y434 Tape C10-189 Tape, Paint Adhesion Testing 3M No. 250 C10-190A brasive Paper 400 Grit Silicon Carbide Wet/ Dry C10-191 Abrasive Paper 600 Grit Silicon Carbide Wet/ Dry Local Purchase Local Purchase 3M Company BGR, INC. 3M Company 3M Company Dolan-Jenner Ind. Inc. Dolan-Jenner Ind. Inc. Dolan-Jenner Ind. Inc. Dolan-Jenner Ind. Inc. Kamen Wiping Materials Co., Inc. Kamen Wiping Materials Co., Inc.
3M Company
EFFECTIVITY: ALL
70-80-10
Ref No. C10-192 Release Agent
Consumable Name / Remarks Frekote 44-NC
Supplier Loctite Corp. Tape Works Wall-Colmonoy Corp.
C10-193 Masking Putty Machbloc Blue C10-194 Braze Stop-Off Braze Stop-off, Nicrobraz White, Type II C10-195 Braze Stop-Off Braz-Stop 1YT C10-196 Abrasive Cloth, aluminum Oxide Super-flexible 3M-203E NOTE: Available in USA 3M-241D NOTE: Available in USA 3M-301D NOTE: Available only in Europe C10-197 Glass Beads for Abradable Filler B38/4000 B38/4000 BT11 or MIL 11 NOTE: AMS 2431/6 BT12 or MIL 12 NOTE: AMS 2431/6 Glass Bead Size 11 NOTE: AMS 2431/6 Glass Bead Size 11 Glass Bead Size 12 NOTE: AMS 2431/6 Glass Bead Size 12 S38/4000
EFFECTIVITY: ALL
Vitta Corporation 3M Company
3M Company
3M Company
Consortium International Pharmaceutiques et Chimique 3M Company A and B Deburring Co.
A and B Deburring Co.
Cataphote Inc.
Sovitec France S.A. Cataphote Inc.
Sovitec France S.A. 3M Company

70-80-10
Ref No.
Consumable Name / Remarks Sovitec T 212 NOTE: AMS 2431/6 Sovitec T 212
Supplier Cataphote Inc.
Sovitec France S.A.
C10-198 Plugs, Silicone Rubber for Thermal Spray 55-75 Durometer N6E12156SIL-XXXX NOTE: P/N: XXXX is the diameter of the material (ex: N6E12156SIL-0625) C10-199 Polyester Film Sheet Lumirror Film (Release Agent) C10-200 Abrasive Wheel, Cut Off Allison VA1202 MRA C10-201 Cloth, Polishing Microcloth C10-202 Abrasive, Polishing Paste, Diamond 1 Micron C10-203 Abrasive, Belt, Aluminum Oxide 100 Mesh, Belt, Aluminum Oxide C10-204 Abrasive, Belt, Aluminum Oxide 180-240 Mesh, Belt, Aluminum Oxide C10-205 Almen Test Strips Almen N Almen Strips, Type N (0.0300.032 in.) Almen Strips, Type N (0.0300.032 in.) C10-206 Tape, Glass, Lacing and Tying (A-A-52083, Size 2) NOTE: Formerly MIL-T43435B 402-3/5X C10-207 Swabs, Lint Free Rayon Tip Breyden Products, Inc. Associated Spring Barnes Group Inc. Metal Improvement Co. Electronics Inc. Local Purchase Local Purchase Lapmaster International Buehler Limited Industrial Services, Inc. TORAY Plastics of America Netherland Rubber Co.
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks 16 inch Comfort Tip Applicators, Scopettes Brand, Stock Number 34-7023-12 NOTE: Packed 100 to a box in two sections of 50
Supplier Birchwood Casey Div., Birchwood Laboratories, Inc.
C10-208 Syringe, Polyethylene, Adhesive Cat. No. 7510A3 NOTE: Obsolete: Replaced by Cat. No. 7510A655 (Syringe) with Cat. No. 6710A21 (14 Gauge SS x 2 in. Needle) Syringe, Polyethylene, Adhesive NOTE: Cat. No. 7510A655 (Syringe) with Cat. No. 6710A21 (14 Gauge SS x 2 in. Needle) C10-209 Tape, Glass Cloth with Thermosetting Silicone Adhesive No. 361 Cloth Tape C10-210 Tape, Aluminum Foil (MIL-T-23397B) No. 425 Aluminum Foil Tape C10-211 Abrasive Cloth (Medium) Scotch Brite Pads No. 7440 (6.0 x 9.5 in.) C10-212 PTFE, (Teflon) Sheet PTFE (Teflon) Mechanical Grade Sheet C10-213 PTFE, (Teflon) Sheet, 25% Glass-Filled PTFE (Teflon) 25% GlassFilled Sheet C10-214 Fluid, Leak Detection Real Cool Snoop Snoop C10-215 Release Agent MS-143V-10.0 C10-216 Tape, Aluminum Foil/Glass Cloth Miller Stephenson Chemical Co. Swagelok Swagelok EPM, Inc. EPM, Inc. 3M Company 3M Company 3M Company McMaster Carr
EFFECTIVITY: ALL
70-80-10
Ref No.
Consumable Name / Remarks No. 363 Aluminum Foil/Glass Cloth Tape
Supplier 3M Company
EFFECTIVITY: ALL
70-80-10
INDEXED BY SUPPLIERS TRADE NAME - CONSUMABLE PRODUCTS INDEXED BY SUPPLIERS TRADE NAME TASK 70-80-20-800-020 1. Consumable Products - Listed By Suppliers Trade Name SUBTASK 70-80-20-99G-020 A. Description # 42 Compound # 43 Compound 1 Micron 10-P2-3 and Catalyst EC-110 (Type III) 100 Mesh, Belt, Aluminum Oxide 120 Grit, Aluminum Oxide, Sandpaper Roll 120 Grit, SiC, wet/dry, abrasive Paper 120 Mesh 1243M 1250 Novaculite 1300L Scotch-Grip Rubber and Gasket Adhesive 1342VM (Class A) 14 A Powder 143DF 143V 1485I General. Supplier Richwood Industries Inc. Richwood Industries Inc. Lapmaster International T. C. Specialties, Inc. Local Purchase Local Purchase Local Purchase Treibacher-Schleifmittel Praxair / TAFA Indianapolis Vapor Blast Mfg. Co. 3M Company Praxair / TAFA Indianapolis ITW Magnaflux Miller Stephenson Chemical Co. Miller Stephenson Chemical Co. Praxair / TAFA Indianapolis Ref No. C04-175 Cleaner, Compound C04-176 Cleaner, Compound C10-202 Polishing Paste, Diamond C03-060 Epoxy Paint C10-203 Belt, Aluminum Oxide C10-105 Sandpaper C10-141 Abrasive Paper C04-114 Abrasive, Grit C07-022 Aluminum-Nickel Chromium Composite Powder C10-042 Grit Blast Media C01-173 Adhesive C07-007 Tungsten Carbide 12% Cobalt Aggregate C05-088 Magnaglo Powder C10-011 Compound Mold Release C10-011 Compound Mold Release C07-035 Zirconium OxideYttrium Oxide Composite Powder C10-065 Grinding Wheel
150R100B99-1/8 (Grinding Wheel, 6 in x 1/8 in x 1 1/4 in.)
Norton Company / Division of Saint Gobain
EFFECTIVITY: ALL
70-80-20
CONSUMABLE PRODUCTS INDEXED BY SUPPLIERs TRADE NAME Page 1 Dec 01/03
Description 16 inch Comfort Tip Applicators, Scopettes Brand, Stock Number 34-7023-12 170D 180 Grit, SiC, wet/dry, Abrasive Paper 180-240 Mesh, Belt, Aluminum Oxide 1870 Scotch Grip Industrial Adhesive 200TFNP 200TFP 2086 Scotchweld Epoxy Adhesive 2101 22-38010 220 Mesh 23T3-105 (Fastcure) 240 grit aluminum oxide. Greaseless #240 24T3-105 (Fastcure) 250A 250A Nuclear Grade 2681-11 (Chafe Guard) GE P/N 3003M28P05 3-10 CS Viscosity 30S 31-400-1352 31-400-1353 31-400-1354
Supplier Birchwood Casey Div., Birchwood Laboratories, Inc. Dolan-Jenner Ind. Inc. Local Purchase Local Purchase 3M Company Richmond Aircraft Prod. Richmond Aircraft Prod. 3M Company The Westaim Corporation Ferro Corp. Treibacher-Schleifmittel Akzo Nobel Aerospace Coatings Wm. Buchanan Supply Co. Akzo Nobel Aerospace Coatings Lectroetch Co. Lectroetch Co. Parker-Hannifin Corp., Stratoflex Division GE Company, Silicone Products Division Praxair / TAFA Concord MTU Maintenance GmbH MTU Maintenance GmbH MTU Maintenance GmbH
Ref No. C10-207 Swabs
C10-185 Light Source C10-141 Abrasive Paper C10-204 Belt, Aluminum Oxide C01-037 Adhesive C10-179 Cloth, Class PTFE Coated (Non-porous) C10-178 Cloth, Glass PTFE Coated (Porous) C01-105 Adhesive C06-003 Powder NickelAluminum C01-102Coloring Pigment C04-113 Abrasive, Grit C03-013 Gray Paint C10-096 Compound, Polishing C03-013 Gray Paint C05-013Solutions C05-014 Solutions C10-127 Chafe Guard C02-022 Silicone C07-051 Copper-Zinc-Silver Pre-alloyed Wire C10-158 Silicone Rubber Masking Ring Set C10-158 Silicone Rubber Masking Ring Set C10-158 Silicone Rubber Masking Ring Set
EFFECTIVITY: ALL
70-80-20
Description 31-400-1355 31-400-1356 3145 RTV 320 Grit, 2 X 16 in LDG, S/C, WP 1/4 in. Shred 320 Grit, Abrasive Paper, Aluminum Oxide 320 Grit, Abrasive Paper, Silicon Carbide Wet/Dry 320 Mesh (USA), 325 Mesh (International), Aluminum Oxide 325 Mesh (International) 32A60K8VBE 36-Grit 3807 39C80H12V 3M 211K (For grit sizes 80, 100, 120, 150, 180, 220, 240, and 320) 3M 2214 Scotchweld Structural Adhesive 3M 241K (For grit sizes 36, 50 and 60) 3M No. 250 3M Shipping Mate Labeling Adhesive 3M Super 77 Spray Adhesive 3M-203E 3M-241D 3M-301D 400 Grit Silicon Carbide Wet/ Dry 402-3/5X
Supplier MTU Maintenance GmbH MTU Maintenance GmbH Dow Corning Corp. G and P Machinery Corp. Local Purchase Local Purchase Treibacher-Schleifmittel
Ref No. C10-158 Silicone Rubber Masking Ring Set C10-158 Silicone Rubber Masking Ring Set C01-172 Sealant C10-062 Abrasive Cloth C10-120 Abrasive Paper C10-121 Abrasive Paper C04-220 Abrasive, Grit
Treibacher-Schleifmittel Norton Company / Division of Saint Gobain Local Purchase Furon Tape Division / Division of Saint Gobain Norton Company / Division of Saint Gobain 3M Company
C04-220 Abrasive, Grit C10-076 Grinding Wheel C04-174 Grit, Aluminum Oxide C10-157 Class Cloth Tape C10-077 Grinding Wheel C10-187 Cloth, Abrasive Aluminum Oxide C01-146 Adhesive C10-187 Cloth, Abrasive Aluminum Oxide C10-189 Tape, Paint Adhesion Testing C01-051 Adhesive C01-027 Adhesive C10-196 Abrasive Cloth C10-196 Abrasive Cloth C10-196 Abrasive Cloth C10-190 Abrasive Paper C10-206 Tape, Glass Lacing and Tying
3M Company 3M Company 3M Company 3M Company 3M Company 3M Company 3M Company 3M Company Local Purchase Breyden Products, Inc.
EFFECTIVITY: ALL
70-80-20
Description 4221-T27875 4222T36231 and Catalyst 0200T126 4224-T12197 and Catalyst 0200T129 4229-T17038 and Catalyst 0200T129 (Gloss) 4229-T27038 and Catalyst 0200T126-Semigloss 4229-T37038 and Catalyst 0200T126 - Lusterless 44-GN-11 463-12-8 and Catalyst CA-116 4643 AL 500 Mesh 515X349-Base, 910X533 Activator 528X310 and Activator 910X464 (Type III) 538C306 and Activator 910X464 (Type II) 57A80L8V, 8.0 in. OD x .500 in. x 1.25 in. ID 58T 60-Grit 600 Grit Silicon Carbide Wet/ Dry 61-860700 (Black) 643-3-9 and Catalyst X-310A 646-58-3695 and Catalyst X-501 646-58-7038 and Catalyst X-501 73 MXC 732 Black Multi-Purpose Sealant 736 Red Heat Resistant Sealant 736L680G01, 0.032 in. dia.
Supplier T. C. Specialties, Inc. T. C. Specialties, Inc. T. C. Specialties, Inc. T. C. Specialties, Inc. T. C. Specialties, Inc. T. C. Specialties, Inc. Deft Inc. T. C. Specialties, Inc. United States Welding Treibacher-Schleifmittel PRC-Desoto International Inc. PRC-Desoto International Inc. PRC-Desoto International Inc. Norton Company / Division of Saint Gobain Praxair / TAFA Concord Local Purchase Local Purchase Ferro Corp., Color Division T. C. Specialties, Inc. T. C. Specialties, Inc. T. C. Specialties, Inc. Praxair / TAFA Concord Dow Corning Corp. Dow Corning Corp. Daniels Mfg. Corp.
Ref No. C03-073 Paint, Epoxy C03-056 Epoxy Paint C03-009 Paint C03-010 Paint C03-010 Paint C03-010 Paint C03-077 Primer, WaterReducible Epoxy C03-005 Primer C06-008 Weld Electrode C04-112 Abrasive, Grit C03-063 Primer, Epoxy C03-060 Epoxy Paint C03-060 Epoxy Paint C10-069 Grinding Wheel C07-054 Copper-Nickel-Indium Wire C04-173 Grit, Aluminum Oxide C10-191 Abrasive Paper C03-023Pigment C03-059 Polyurethane Paint C03-070 Paint, Polyurethane C03-069 Paint, Polyurethane C07-043 Nickel-ChromiumAluminum Wire C01-006 RTV C01-007 RTV C10-143 Safety Cable Assembly
EFFECTIVITY: ALL
70-80-20
Description 736L680G01, 0.032 in. dia. Kit K30B18 74-451-182 75 B 75:25 Nickel Graphite Powder 78T 85:15 Nickel Graphite Powder 86009 90-006 920-07 (0.75 in. wide) 920-10 (1.0 in. wide) 93-006 95340 (Chafe Guard) GE P/N 3003M28P02 985P12 985P13 985P14 9D1B 9D4A 9D76 9PR12 9PR3
Supplier Bergen Cable Technologies, Inc. BF Goodrich Ice Protection Systems Praxair / TAFA Concord Westaim Corp. Praxair / TAFA Concord Westaim Corp. GLYPTAL, INC. Dow Corning Corp. Arlon Inc., Silicone Technologies Division Arlon Inc., Silicone Technologies Division Dow Corning Corp. Titeflex, Inc. Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall
Ref No. C10-143 Safety Cable Assembly C01-185 Polyurethane Sheet C07-042 Nickel-Aluminum Wire C07-014 75:25 Nickel-Graphite Powder C07-049 Alloy 718 Wire C07-015 85:15 Nickel-Graphite Powder C03-030 Aluminum Paint C01-154 RTV C10-125 Tape, Silicone SelfAdhering C10-125 Tape, Silicone SelfAdhering C01-158 RTV C10-127 Chafe Guard C05-042 Penetrant C05-046 Penetrant C05-043 Penetrant C05-082 Developer C05-081 Developer C05-083 Developer C05-059 Emulsifier C05-058 Emulsifier
EFFECTIVITY: ALL
70-80-20
Description Description A10-218 A15D3 Pasa-Jell 107 A4000 A4000P3 A5000 A5000P3 AA5629-1D1A AA5629-1D1A Abrasive Wheel, Spec. No. 808M Acetic Acid, Liguid (50% Concentration) Acheson GP460 Acid, Acetic, (Commercial Grade or Better, A-A-55829 Acid, Anhydrous Citric Acid, Hydrofluoric (70%) Additive 73B (DuBois) Adiprene, L-167 Aeroglaze 9929 Aerokroil (Aerosol) Aeroquip AE272 Flexwrap Fire Sleeve Size -13 Aeroquip AE272 Flexwrap Fire Sleeve Size -14 Aeroquip AE272 Flexwrap Fire Sleeve Size -15 Aeroquip AE272 Flexwrap Fire Sleeve Size -3 Aeroquip AE272, Flexwrap Fire Sleeve Size -11 Aeroquip AE272, Flexwrap Fire Sleeve Size -4
EFFECTIVITY: ALL
Supplier Supplier Daniels Mfg. Corp. PRC-Desoto International Inc. Airtech International Inc. Airtech International Inc. Richmond Aircraft Prod. Richmond Aircraft Prod. Satair A/S PAS Precision Abrasives and Tools LabCem Inc. Acheson Colloids Co. Local Purchase Local Purchase Local Purchase DuBois Chemical Co. Uniroyal Chemical Co. Lord Corp. Chemical Products Group Kano Laboratories Aeroquip E.F.G. Aerospace Group Aeroquip E.F.G. Aerospace Group Aeroquip E.F.G. Aerospace Group Aeroquip E.F.G. Aerospace Group Aeroquip E.F.G. Aerospace Group Aeroquip E.F.G. Aerospace Group
Ref No. Ref No. C10-145 Cable, Safety Cable C04-027 Chemical Surface Treatment C10-133 Film, Polymer FEP, Un-perforated, C10-132 Film, Polymer C10-133 Film, Polymer FEP, Un-perforated, C10-132 Film, Polymer C01-046 Epoxy repair kit C01-046 Epoxy repair kit C10-036 Abrasive Wheel C04-227 Acid C02-058 Graphite C04-097 Acid C04-238 Citric Acid C04-011 Acid C04-013 Chemical Additive C03-027 Elastomer C03-026 Primer C02-053 Penetrating Oil C10-175 Aeroquip AE272 Flexwrap Fire Sleeve Size -13 C10-176 Aeroquip AE272 Flexwrap Fire Sleeve Size -14 C10-177 Aeroquip AE272 Flexwrap Fire Sleeve Size -15 C10-174 Aeroquip AE272 Flexwrap Fire Sleeve Size -3 C10-163 Aeroquip AE272, Flexwrap Fire Sleeve Size -11 C10-160 Aeroquip AE272, Flexwrap Fire Sleeve Size -4
70-80-20
Description Aeroquip AE272, Flexwrap Fire Sleeve Size -6 Aeroquip AE272, Flexwrap Fire Sleeve Size -9 Aeroshell Fluid 2T Aeroshell Grease 17 Aeroshell Grease 7 Aeroshell Grease 7
Supplier Aeroquip E.F.G. Aerospace Group Aeroquip E.F.G. Aerospace Group Equilon Enterprise Equilon Enterprise Equilon Enterprise Shell International Trading Co., International Aviation Division Equilon Enterprise Shell International Trading Co., International Aviation Division 3M Company 3M Company 3M Company 3M Company 3M Company 3M Company 3M Company 3M Company 3M Company 3M Company Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis
Ref No. C10-161 Aeroquip AE272, Flexwrap Fire Sleeve Size -6 C10-162 Aeroquip AE272, Flexwrap Fire Sleeve Size -9 C02-025 Oil, Preservation C02-014 Molybdenum Disulphite C02-016 Grease C02-016 Grease
Aeroshell Turbine Oil 2 Aeroshell Turbine Oil 2
C02-021 Oil, 1010 C02-021 Oil, 1010
AF-15 AF-191K (Class B) AF-191K (Class C) (0.08 wt) AF-3024 AF-3109-2U 0.035 psf AF-32 AF126-2 0.06 psf AF163-2K .085 AF163-2U AF3109-2K 0.085 psf AI-1037, (GE Spec. B50TF56, Class A) AI-1075
C01-137 Adhesive, Film C01-165 Adhesive C01-186 Adhesive C01-132 Adhesive, Foam C01-175 Adhesive C01-184 Adhesive C01-142 Adhesive Film C01-130 Adhesive Film C01-131Adhesive Film C01-128Epoxy Film C07-016 Nickel-Aluminum Composite Powder C07-035 Zirconium OxideYttrium Oxide Composite Powder C10-134 Cloth, Breather/ Bleeder C03-017 Primer C03-018 Paint C03-076 Paint, Flat Black C07-017 Aluminum Powder
Airweave N10 Akzo Nobel 10-P20-13 and Catalyst EC-213 Akzo Nobel 646-58-7925 and Catalyst X-501 Akzo Nobel 666-58-7038 and Catalyst X-503 AL-104
Airtech International Inc. T. C. Specialties, Inc. T. C. Specialties, Inc. T. C. Specialties, Inc. Praxair / TAFA Indianapolis
EFFECTIVITY: ALL
70-80-20
Description AL-228 Alcohol, Denatured Alcohol, Ethyl, Anhydrous, Denatured Alcohol, Methyl Alconox Alko N Salt All Purpose Silicone Spray P/N S00206 Allison VA1202 MRA Almen A Almen N Almen Strips, Type A (0.0500.052 in.) Almen Strips, Type A (0.0500.052 in.) Almen Strips, Type N (0.0300.032 in.) Almen Strips, Type N (0.0300.032 in.) ALO-105-1 ALO-159 Alocrom 1200 Brush Alocrom 1200 DIP Alodine 1132 Alodine 1200S Alodine 1200SRTU Alodine 1201 Alodine No. 1500 ALSEAL 519 Aluminum Oxide Grit, 180 Mesh Amdry 100 C (GE Spec. B50TF81, Class A)
Supplier Praxair / TAFA Indianapolis Local Purchase EM Science Local Purchase Alconox, Inc. Kolene Corp. Krylon Products Group, the Specialty Div. of SherwinWilliams Co. Industrial Services, Inc. Associated Spring Barnes Group Inc. Associated Spring Barnes Group Inc. Electronics Inc. Metal Improvement Co. Metal Improvement Co. Electronics Inc. Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis ICI Paints Division ICI Paints Division Henkel Surface Technologies Henkel Surface Technologies Henkel Surface Technologies Henkel Surface Technologies Henkel Surface Technologies Coatings For Industry Inc. USF / Surface Preparation Sulzer Metco, Inc.
Ref No. C07-037 Aluminum Silicon Polyester Powder C04-014 Alcohol C04-228 Solvent C04-180 Alcohol, Methyl C04-243 Cleaner, Powdered C04-154 Cleaner, Molten Salt C02-080 Lubricant
C10-200 Cut Off Wheel C10-110 Almen Test Strips C10-205 Almen Strips for Shot Peening C10-110 Almen Test Strips C10-110 Almen Test Strips C10-205 Almen Strips for Shot Peening C10-205 Almen Strips for Shot Peening C07-039 Aluminum Oxide Powder C07-003 Aluminum Oxide Powder C03-084 Coating C03-083 Coating C03-092 Coating C03-006 Coating C03-081 Coating C03-082 Coating C03-008 Conversion Coating C03-091 Paint C10-049 Aluminum Oxide Grit C06-015 Braze Alloy
EFFECTIVITY: ALL
70-80-20
Description Amdry 103 Amdry 1718 Amdry 2010 Amdry 313X Amdry 333 Amdry 500 Amdry 500C Amdry 718 Cl B Amdry 956, (GE Spec. B50TF56, Class A) Amdry 960 Amdry 962 AMI 775 AMMO-301 (20/40), Plastic Blast Media (MIL-P-85891, Type II, Grade A, 3.5 Mohs Hardness) Ammonium Bifluoride Flakes Ammonium Chloride, Crystal Certified or Reagent Grade Ammonium Hydroxide, Reagent Grade Amperit 281.287, (GE Spec. B50TF56, Class B) Amperit 281.287, (GE Spec. B50TF56, Class B) Amperit 282.296, (GE Spec. B50TF56, Class A) Amperit 282.296, (GE Spec. B50TF56, Class A) Amperit 286.295 Amperit 286.295
Supplier Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Select-Tech, Inc.
Ref No. C06-012 Braze Alloy, Powder C07-041 Inconel 718 Powder HVOF Application C07-037 Aluminum Silicon Polyester Powder C07-001 Molybdenum Powder C07-029 Powder, Magnesium Zirconate C07-036 Copper-Nickel-Indium C07-020 Copper-Nickel-Indium Powder C07-038 Inco 718 Powder C07-016 Nickel-Aluminum Composite Powder C07-022 Aluminum-Nickel Chromium Composite Powder C07-032 Nickel Chromium Aluminum Yttrium Powder C06-029 Braze Alloy C04-153 Abrasive, Plastic
Mallinckrodt Baker, Inc. Local Purchase Local Purchase H.C. Starck GmbH and Co KG H.C. Starck Inc. H.C. Starck Inc. H.C. Starck GmbH and Co KG H.C. Starck GmbH and Co KG H.C. Starck Inc.
C04-241 Chemical C04-133 Chemical C04-134 Chemical C07-016 Nickel-Aluminum Composite Powder C07-016 Nickel-Aluminum Composite Powder C07-016 Nickel-Aluminum Composite Powder C07-016 Nickel-Aluminum Composite Powder C07-011 Nickel-Aluminum Composite Powder C07-011 Nickel-Aluminum Composite Powder
EFFECTIVITY: ALL
70-80-20
Description Amperit 299.297 Amperit 299.297 Amperit 413.284 Amperit 413.284 Amperit 591.294 Amperit 591.294 Amperit 742.298 Amperit 742.298 Amperit 827.774
Supplier H.C. Starck GmbH and Co KG H.C. Starck Inc. H.C. Starck Inc. H.C. Starck GmbH and Co KG H.C. Starck Inc. H.C. Starck GmbH and Co KG H.C. Starck Inc. H.C. Starck GmbH and Co KG H.C. Starck GmbH and Co KG
Ref No. C07-022 Aluminum-Nickel Chromium Composite Powder C07-022 Aluminum-Nickel Chromium Composite Powder C07-032 Nickel Chromium Aluminum Yttrium Powder C07-032 Nickel Chromium Aluminum Yttrium Powder C07-008 Chromium Carbide NiCr-C0- Matrix C07-008 Chromium Carbide NiCr-C0- Matrix C07-003 Aluminum Oxide Powder C07-003 Aluminum Oxide Powder C07-035 Zirconium OxideYttrium Oxide Composite Powder C07-035 Zirconium OxideYttrium Oxide Composite Powder C05-087 Suspension Fluid C06-010 Flux C06-020 Braze Alloy Foil
Amperit 827.774
H.C. Starck Inc.
AMS 3160 AMS 3411 AMS 4778 (0.001 - 0.003 in. Thick) AMS 4778 / Acrylic Binder 0.037 in. thick x 0.75 in. Wide AMS 4779 (0.001 - 0.003 in. Thick) AMS 4787 / BAu-4
Dynamation Research, Inc. Local Purchase Wesgo Metals, A Division Morgan Technical Ceramics, Inc. Sulzer Metco, Inc. Wesgo Metals, A Division Morgan Technical Ceramics, Inc. Wesgo Metals, A Division Morgan Technical Ceramics, Inc. Honeywell Hardware Products Group Honeywell Hardware Products Group Honeywell Hardware Products Group Honeywell Hardware Products Group
C06-026 Braze Alloy Tape C06-020 Braze Alloy Foil
C06-004 Braze Alloy Gold Nickel C10-071 Safety Wire C10-071 Safety Wire C10-071 Safety Wire C10-071 Safety Wire
AMS 5685, (305 Stainless Steel), Safety Wire AMS 5687, (Inconel 600) Safety Wire AMS 5689, (321 Stainless Steel) Safety Wire AMS 5690, (316 Stainless Steel) Safety Wire
EFFECTIVITY: ALL
70-80-20
Description Ancamine-Z Curing Agent Anchorlube G-771 Androx 2302 and Additives 2302S, 2302-AA, 2302-SA Applicator, Coating (Part No. 97301) Small Applied 2-690 Applied 2-751 Applied 5-770 Applied 5-840 Aquasorb
Supplier Air Products and Chemicals Inc. Anchor Chemical Company Oakite Products Inc., Div. of Chemetall Sermatech International Inc. Applied Chemicals International Pty. Ltd. Applied Chemicals International Pty. Ltd. Applied Chemicals International Pty. Ltd. Applied Chemicals International Pty. Ltd. Turco Products, Inc. Subsidiary of Henkel Surface Technologies Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall
Ref No. C01-039 Catalyst C02-081 Lubricant C04-245 Remover, Paint/ Carbon C10-101 Applicator C04-235 Acid, Inhibited phosphoric C04-236 Cleaner, Acid descaler C04-234 Cleaner, Alkaline permanganate C04-233 Alkaline Deruster C02-064 Oil
Ardrox 1064-K Ardrox 1218 (Inhibited Phosphoric Acid) Ardrox 1618 Ardrox 163 Ardrox 1630 Ardrox 1635 Ardrox 185 Ardrox 185L Ardrox 1871 Ardrox 1873 Ardrox 1873A Ardrox 188 and Additives 188LC/188LP
C04-160 Solvent, General C04-121 Acid C04-247 Remover, Carbon C04-169 Cleaner, Compound C04-081 Cleaner, Compound C04-074 Cleaner, Acid Descaler C04-052 Cleaner, Heavy Duty Alkaline C04-052 Cleaner, Heavy Duty Alkaline C04-067 Cleaner, Acid Descaler C04-066 Cleaner, Acid Descaler C04-240 Cleaner, Acid C04-058 Cleaner, Alkaline Permanganate
EFFECTIVITY: ALL
70-80-20
Description Ardrox 188RFU and additives 188LC/188LP Ardrox 1900B Ardrox 2204 Ardrox 311 Ardrox 321-N Ardrox 3962 Ardrox 552 Ardrox 6025 Ardrox 6077 Ardrox 6085 Ardrox 631 Ardrox 6333 Ardrox 6333A Ardrox 6366 Ardrox 6367 Ardrox 6368 Ardrox 690 Ardrox 690-I Ardrox 8800 Ardrox Base Oil HF Ardrox P133D
Supplier Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Chemetall Plc Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall Oakite Products Inc., Div. of Chemetall
Ref No. C04-058 Cleaner, Alkaline Permanganate C04-210 Cleaner, Compound C04-147 Remover, Silicone Rubber C02-063 Oil C03-071 Coating C02-064 Oil C04-224 Solvent C04-249 Cleaner, Exterior Surface C04-204 Cleaner, Compound C04-209 Cleaner, Mild Alkaline C04-064 Cleaner, Mild Alkaline C04-163 Cleaner, Mild Alkaline C04-163 Cleaner, Mild Alkaline C04-140 Cleaner, Gas Path C04-140 Cleaner, Gas Path C04-140 Cleaner, Gas Path C04-062 Remover, Paint/ Carbon C04-124 Chemical Additive Inhibitor C05-088 Magnaglo Powder C04-181 Suspension Fluid C05-045 Penetrant
EFFECTIVITY: ALL
70-80-20
Description Ardrox P134D ARP 2 Agent ASC 2-N (Aluminide Coating) AU-6
Supplier Oakite Products Inc., Div. of Chemetall MacDermid, Inc. Alloy Surfaces Co., Inc. Wesgo Metals, A Division Morgan Technical Ceramics, Inc.
Ref No. C05-044 Penetrant C04-222 Surfactant C04-158 Remover, Coating C06-021 Braze Alloy Foil
Description B and B 3100 (Type I) B and B TC-100 (Type II) B248 B38/4000 B38/4000 B50TF307, Class A Barco Bond MB-165 Bay State PP-10A Bay State PP-11A Bay State PP-20 Bay State PP-21 Bay State PP-32 Bay State PP-64 (GE Spec. B50TF40 Class B Fine) Bay State PP-65 (GE Spec. B50TF40 Class A Coarse) Bay State PP-75 (Class A and B) BC 10mm (0.394) BC 6.4mm (0.250) BC 6.8mm (0.315)
Supplier B and B Tritech Inc. B and B Tritech Inc. Dolan-Jenner Ind. Inc. 3M Company Consortium International Pharmaceutiques et Chimique Aerospace International Materials (AIM) Astro Chemical Co., Inc. Bay State Surface Technologies, Inc. Bay State Surface Technologies, Inc. Bay State Surface Technologies, Inc. Bay State Surface Technologies, Inc. Bay State Surface Technologies, Inc. Bay State Surface Technologies, Inc. Bay State Surface Technologies, Inc. Bay State Surface Technologies, Inc. Brush Research Mfg. Co. Inc. Brush Research Mfg. Co. Inc. Brush Research Mfg. Co. Inc.
Ref No. C04-140 Cleaner, Gas Path C04-140 Cleaner, Gas Path C10-184 Cable, Fiber Optic C10-197 Hollow Glass Beads C10-197 Hollow Glass Beads C06-040 C01-028 Adhesive C07-015 85:15 Nickel-Graphite Powder C07-014 75:25 Nickel-Graphite Powder C07-017 Aluminum Powder C07-001 Molybdenum Powder C07-003 Aluminum Oxide Powder C07-012 Nickel-Chromium Powder C07-012 Nickel-Chromium Powder C07-007 Tungsten Carbide 12% Cobalt Aggregate C10-172 Flex-hones, 120 grit Silicon Carbide C10-164 Flex-hones, 120 grit Silicon Carbide C10-165 Flex-hones, 120 grit Silicon Carbide
EFFECTIVITY: ALL
70-80-20
Description BC 9mm (0.354) BCS No. 08-PB BCS No. 08-PC BCS No. 11L84 Beeswax Binder, Type 105 Bio-T-Max Bioact 105 Precision Cleaner Blue (Long Life) Blue Gold Industrial Cleaner BR 300 (NT) BR 6747-1 BR-127 BR-154 BR-34B-32 Primer Brayco 460 Brayco 483 Brayco 599 Braycoat 120 Braycoat 655 Braz-Binder Gel Grade ST Braz-Stop 1YT Braze 541 Braze Alloy Foil (AMS 4777)
Supplier Brush Research Mfg. Co. Inc. B.C.S Company, Inc. B.C.S Company, Inc. B.C.S Company, Inc. Local Purchase HTG Metal Methods BioChem Systems, Div. of Golden Tech. Petroferm Inc. Monode Marking Products Inc. Modern Chemical, Inc. Lucas-Milhaupt Inc. Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Castrol Industrial North American Inc. Castrol Industrial North American Inc. Castrol Industrial North American Inc. Castrol Industrial North American Inc. Castrol Industrial North American Inc. Vitta Corporation Vitta Corporation Lucas-Milhaupt Inc. Wesgo Metals, A Division Morgan Technical Ceramics, Inc. Wall-Colmonoy Corp.
Ref No. C10-168 Flex-hones, 120 grit Silicon Carbide C04-144 Abrasive, Tumbling C04-145 Abrasive, Tumbling C04-146 Cleaner, Compound C10-154 Beeswax C10-027 Binder, Aerobraze C04-207 Cleaner, Compound C04-251 Solvent Cleaner C05-019 Stencils C04-164 Cleaner, Mild Alkaline C07-004 Silver Alloy Wire C03-086 Primer C03-007 Primer C01-166 Primer, High Temperature C01-098 Adhesive C02-021 Oil, 1010 C02-025 Oil, Preservation C02-051 Corrosion Inhibitor C02-054 Neutralizer C02-001 Anti-Seize Compound C06-019 Binder C10-195 Braze Stop-Off C06-005 Braze Alloy C06-041 Braze Foil
Braze Stop-Off, Nicrobraz Green
C10-015 Braze Stop-Off
EFFECTIVITY: ALL
70-80-20
Description Braze Stop-Off, Nicrobraz Red, Type II Braze Stop-off, Nicrobraz White, Type II Braze Stop-Off, Type 110 (White) BrightBoy Stick Holder, 801-X BrightBoy Stick, ST-90-ALO801-R Brisol-ox Brolite AA-59107 Bron # BRP 1864-8R-GE Brulin 815 GD Brush No. 22299 (320 grit) with adapter No. 1A Brush, Wire Stainless Steel (0.003 - 0.005 in. dia wires) Brushes, Wire, 0.003 in. (0.08 mm) BT11 or MIL 11 BT12 or MIL 12 Burr BC-0 1/8 Dia Cut EDP # 54873
Supplier Wall-Colmonoy Corp. Wall-Colmonoy Corp. HTG Metal Methods Precision Abrasives and Tools Precision Abrasives and Tools Labinal Division, Systeme Aeronautique Kop-Coat, Inc. (Vernon, CA) Bron Tapes The Brulin Corporation Osborn International Local Purchase Osborn International A and B Deburring Co. A and B Deburring Co. Bassett Rotary Tool Co.
Ref No. C10-016 Braze Stop-Off C10-194 Braze Stop-Off C10-020 Braze Stop-Off C10-072 BrightBoy Stick C10-072 BrightBoy Stick C02-070 Grease C04-024 Solvent, General C10-012 Tape, Masking High Temperature C04-237 Cleaner C10-092 Abrasive Brush C10-173 Brush, Wire Stainless Steel C10-097 Brushes, Wire C10-197 Hollow Glass Beads C10-197 Hollow Glass Beads C10-045 Carbide Cutter
Description C-1102 (Liquid) C30B18 CA-5 Pronto Instant Adhesive Cab-O-Sil TS-720 CaiKleen TNX Tarnish Remover Cal Lube 7030 Calcium Carbonate, Powder Certified or Reagent Grade
Supplier DuBois Chemical Co. Bergen Cable Technologies, Inc. 3M Company Cabot Corporation Caig Laborotories, Inc. Calvary Chemical Corp. Local Purchase
Ref No. C04-045 Cleaner, Compound C10-145 Cable, Safety Cable C01-109 Adhesive C10-022 Filler, Fumed-Silica Viscosity Control Agent C04-259 Electrical Contact Cleaner C02-079 Lubricant C04-135 Chemical
EFFECTIVITY: ALL
70-80-20
Description Castrol EASE AI Cat. No. 010 0083-20, (Burr, 1/8 in. Spherical Carbide) Cat. No. 048-1033-20 (Burr, 1/4 in. Spherical Carbide) Cat. No. 22259, 320 Grit Cat. No. 7237T4 (or equivalent) Disposable Brush Natural Bristle Cat. No. 7798T2 (or equivalent) Disposable Brush Natural Bristle Cat. No. 9566K23 (or equivalent) Cork Stoppers, 15/ 16 in. dia. large end Catalyst 147B Caustic Soda, Liquid (50% Concentration) Caytur 21 Caytur 21 CCW14 CCW14 CCW14, Conditioned Cut Wire Steel Shot (GE Spec. D50TF11 Class B) CCW20 CCW20 CCW20, Conditioned Cut Wire Steel Shot (GE Spec. D50TF11 Class B) CCW31, Conditioned Cut Wire Steel Shot (GE Spec. D50F11CLB) CCW31, Conditioned Cut Wire Steel Shot (GE Spec. D50F11CLB) CCW31, Conditioned Cut Wire Steel Shot (GE Spec. D50F11CLB)
Supplier Castrol Industrial North American Inc. Greenfield Industries Greenfield Industries Osborn International McMaster Carr
Ref No. C02-016 Grease C10-104 Burr, 1/8 in. C10-106 Burr C10-114 Nylon Brushes Abrasive Coated C10-108 Brush
McMaster Carr
C10-108 Brush
McMaster Carr
C10-107 Cork Stoppers
Rhone-Poulenc Olin Corporation Uniroyal Chemical Co. Omni Specialty Corp. Premier Shot Company KME Josef Frohn
C01-169 Silicone C04-226 Cleaner C03-028 Curing Agent C03-028 Curing Agent C04-166 Abrasive, Peening C04-166 Abrasive, Peening C04-166 Abrasive, Peening
KME Josef Frohn Premier Shot Company
C04-167 Abrasive, Peening C04-167 Abrasive, Peening C04-167 Abrasive, Peening
KME
C04-178 Abrasive, Peening
Josef Frohn
Premier Shot Company
EFFECTIVITY: ALL
70-80-20
Description Cee-Bee A-202 Cee-Bee A-477 and Additives: Additive A, Additive O Cee-Bee A-7X7 Cee-Bee Alko Cee-Bee C-105 HF Cee-Bee C-46 Cee-Bee C-623 Cee-Bee J-19 Cee-Bee J-19L Cee-Bee J-3 Cee-Bee J-84A Cee-Bee J-84AL Cee-Bee J-88 Cee-Bee J-88A Cee-Bee J-88L Cee-Bee No. B-55 Cee-Bee P-109B Cee-Bee R-43C Cee-Bee WDO Cellosolve Acetate Ceral 114
Supplier McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division Local Purchase Gebruder M. und M. Morant GMBH
Ref No. C04-022 Remover, Epoxy C04-194 Remover, Paint/ Carbon C04-165Cleaner, Mild Alkaline C04-250 Cleaner, Carbon Removal Gel C04-148 Remover, Silicone Rubber C04-039 Cleaner, Heavy Duty C04-143 Acid C04-142 Cleaner, Acid Descaler C04-142 Cleaner, Acid Descaler C04-239 Cleaner C04-049 Cleaner, Heavy Duty Alkaline C04-049 Cleaner, Heavy Duty Alkaline C04-055 Cleaner, Alkaline Permanganate C04-055 Cleaner, Alkaline Permanganate C04-055 Cleaner, Alkaline Permanganate C04-023 Cleaner, Acid Descaler C04-255 Cleaner, Acid Descaler C04-060 Remover, Paint/ Carbon C02-064 Oil C04-230 Chemical C03-093 Paint, Inorganic, Aluminum
EFFECTIVITY: ALL
70-80-20
Description CerroLow 136 Chemglaz 11, White A276 Chromalox Cartridge Heater Cat. No. CIR 3031 (3.0 in. x 0.5 in. dia) Chromel C Chromic Acid Cimperial 1070 Citrikleen HD Class 3 AMS 3079 Class B AN325 Class B Unical 8661810 Cloth, Bleeder-Osnaberg Cloth, Bleeder-Osnaberg Cloth, Wire Mesh, Cat. No. 9226T29 CO-109 CO-111 CO-111 CO-273-5 CO-273-5 Coconut Oil, Coco 20 Coconut Oil, Misty Coco-15 Compound Carbon Removal (Fed. Spec. P-C-111b) Compound, Gear Marking, No. 10 Yellow Conapoxy AD-10 Conathane TU 901 Corrosol 853 (Inhibited Phosphoric Acid) Corrotherm CT33M
Supplier Cerro Metal Products Co. Alloy Dept. Lord Corp. Chemical Products Group Chromalox
Ref No. C10-033 Matrix, Low Melting Alloy C03-004 Paint C10-091 Cartridge Heater
Hoskins Mfg. Co Local Purchase Cincinnati Milacron Local Purchase Local Purchase O.M.G Americas Creanova Canvas Specialties Miltix-Morgan Fabrics McMaster Carr Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Phillips Supply Co. Phillips Supply Co. Local Purchase Prescott and Co., Ltd. Conap, Inc. Conap, Inc. PPG Industries, Inc. Corro Therm Inc.
C10-046 Foil C04-094 Acid C02-047 Cutting Fluid C04-045 Cleaner, Compound C02-024 Preservative Film C06-024 Braze Alloy Nickel Powder C03-019 Yellow Coloring C10-048 Cloth, BleederOsnaburg C10-048 Cloth, BleederOsnaburg C10-094 Cloth, Wire Mesh C07-025 Cobalt-MolybdenumChromium-Silicon Powder C07-031 Cobalt-MolybdenumChromium-Silicon Powder C07-047 Cobalt-MolybdenumChrome-Silicon Powder C07-048 Metal Powder C06-034 Braze Filler Powder C04-028 Cleaner C04-028 Cleaner C04-006 Remover, Paint/ Carbon C05-001 Compound, Gear Marking C01-100 Epoxy C03-058 Casting Resin C04-122 Acid C03-055 Aluminum Paint
EFFECTIVITY: ALL
70-80-20
Description Cosmoline 1104 Cratex 79F Cratex 8-C CRC Precision Cleaner Plus CRC Super Degreaser CRC-106 (GE Spec. B50TF137, Class A) CRC-108 (GE Spec. B50TF137, Class B) CRC-109 Cream Hardener CT-404 CU-101-1 CU-102 CU-103 CU-104-5 Cup Wheel Grinding, 32A60J5VBE CYCOM 919 GFK 3070 PW T300 Fiber Weavestyle 3K
Supplier Houghton International Precision Abrasives and Tools Precision Abrasives and Tools CRC Industries, Inc CRC Industries, Inc Praxair / TAFA Indianapolis
Ref No. C02-054 Neutralizer C10-059 Abrasive Wheel C10-043 Rubberized Abrasive C04-254 Cleaner, Electrical Contact C04-253 Cleaner, Electrical Contact C07-027 75% Chromium Carbide; 25% Nickel Chromium Powder C07-027 75% Chromium Carbide; 25% Nickel Chromium Powder C07-008 Chromium Carbide NiCr-C0- Matrix C01-002 Catalyst C03-040 Coating C07-036 Copper-Nickel-Indium C07-020 Copper-Nickel-Indium Powder C07-013 Copper-Nickel Powder C07-023 Aluminum Bronze Alloy Thermal Spray Powder C10-024 Cup Wheel Grinding C01-127 Epoxy Material
Praxair / TAFA Indianapolis
Praxair / TAFA Indianapolis Fibre Glass Evercoat Co. Corro Therm Inc. Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Norton Company / Division of Saint Gobain Cytec Engineered Materials Inc.
Description D-100 D-104 D-106 D-90G D/W 410 D/W 497 D/W 498
Supplier Sherwin, Inc. Sherwin, Inc. Sherwin, Inc. Sherwin, Inc. DeWal Industries DeWal Industries DeWal Industries
Ref No. C05-078 Developer C05-079 Developer C05-079 Developer C05-076 Developer C10-012 Tape, Masking High Temperature C10-012 Tape, Masking High Temperature C10-012 Tape, Masking High Temperature
EFFECTIVITY: ALL
70-80-20
Description D/W 500 D/W 501 D117 D180 D85 TER Dag 2404 Dag Dispersion No. 154 Dag Dispersion No. 200 Dag Dispersion No. 213 Daraclean 282 Daraclean 282GF DD2A
Supplier DeWal Industries DeWal Industries Mohawk Fabric Co. Inc. Acheson Colloids Co. Acheson Colloids Co. Acheson Colloids Co. Acheson Colloids Co. Acheson Colloids Co. Acheson Colloids Co. ITW Magnaflux ITW Magnaflux Turco Products, Inc. Subsidiary of Henkel Surface Technologies Deft Inc. Kleer-Flo Co. Stellite Coatings Deloro Stellite, Inc. Local Purchase from Dental Supplier ITW Magnaflux Turco Products, Inc. Subsidiary of Henkel Surface Technologies Local Purchase ITW Devcon
Ref No. C10-012 Tape, Masking High Temperature C10-012 Tape, Masking High Temperature C01-126 Netting C02-066 Lubricant C02-068 Lubricant C02-039 Penetrating Oil C02-028 Graphite Coating C02-029 Graphite Coating C02-030 Graphite Coating C04-168 Cleaner, Mild Alkaline Water Based C04-168 Cleaner, Mild Alkaline Water Based C05-067 Developer
Deft 44-W-7 Degreasol 99-R Deloro Stellite JK117SP Dental Cement Kit (Liquid/ Catalyst and Powder) Deodorized, High Flash Point Kerosene, Carrier II Deodorized, High Flash Point Kerosene, Turco 6809 Desiccant (MIL-D-3464, Type I) Devcon Plastic Steel, Liquid B (P/N 10210: resin plus catalyst kit) Devcon Release Agent #19600 Diamalloy-3001 Diammonium EDTA Diamond Compound Grade No. 45 Heavy Duty Diethylenetriamine (High Purity Grade)
EFFECTIVITY: ALL
C03-079 Primer C04-171 Solvent, General C07-040 Powder, 17% Tungsten Carbide Cobalt C01-083 Adhesive C04-181 Suspension Fluid C04-181 Suspension Fluid
C10-001 Desiccant C10-034 Plastic Steel
ITW Devcon Sulzer Metco, Inc. Dow Chemical Co. Lapmaster International Fisher Scientific Co.
C10-035 Release Agent C07-047 Cobalt-MolybdenumChrome-Silicon Powder C04-169 Cleaner, Compound C10-074 Diamond Compound C01-024 Catalyst
70-80-20
Description Diethylenetriamine (High Purity Grade) Diethylenetriamine (High Purity Grade), Product Code: 803274 Diethylenetriamine (High Purity Grade), Product Code: H768 or 3356 Dimethyl Sulfoxide (DMSO) Dimethyl Sulfoxide (DMSO) Dimethyl Sulfoxide (DMSO) Dimethyl Sulfoxide (DMSO) Dip Seal Type 2, Code DS 58-7 Dixon No. 635 DN-600P DN-900D Dow Corning 1200 Primer Red or Clear Dow Corning 730 Solvent Resistant Sealant Dow Corning1 33 Extreme Low Temperature Grease Dustless Chalk P/N 31144 Dykem (Steel Blue Layout Fluid, Transparent Blue Staining Color) Dykem Hi Spot Blue (No. 107) Dykem Remover and Thinner (No. 138)
Supplier Union Carbide Corp. Merck KGaA
Ref No. C01-024 Catalyst C01-024 Catalyst
C01-024 Catalyst
Mallinckrodt, Inc. JT Baker Inc. Pechiney World Trade Inc. Aldrich Chemical Co., Inc. Dip Seal Plastic Inc. Dixon Ticonderoga Marktec Corp. Marktec Corp. Dow Corning Corp. Dow Corning Corp. Dow Corning Corp. Dixon Ticonderoga Co. ITW-Dykem Co.
C04-095 Chemical C04-095 Chemical C04-095 Chemical C04-095 Chemical C10-098 Dip Seal Type 2 C02-011 Graphite C05-084 Developer C05-085 Developer C01-014 Silicone Adhesive C01-153 RTV C02-062 Grease C05-111 Chalk C05-002 Ink, Marking
ITW-Dykem Co. ITW-Dykem Co.
C05-020 Dykem Hi Spot Blue C05-021 Dykem Remover and Thinner
Description E3760-P1-(0.002) E3760-P2-(0.001) E41
Supplier Richmond Aircraft Prod. Richmond Aircraft Prod. Turco Products, Inc. Subsidiary of Henkel Surface Technologies Cytec Engineered Materials Inc.
Ref No. C10-051 Film, Release, Perforated C10-051 Film, Release, Perforated C05-055 Emulsifier and Solvent
E773FR/120
C10-130 Cloth, Glass Fiber
EFFECTIVITY: ALL
70-80-20
Description EA 9628NW .085 psf EA 9628UNS EA 9689.08 (Class E) EA 9689.08 (Class E) EA 9689.10 PSF GK (Class D) EA 9689.10 PSF GK (Class D) EC 2174 EC 3500 B/A EC 3901 EC 3964 EC 612 (Ribbon form only) EC-3439 EC-3524 B/A EC-3917 EC-847 Eco Spray EGA-503 (Devilbiss) Elastolock 2710 Part A & Part B Eldorado AC-111 Eldorado AC-183 Eldorado ED-306LF Eldorado HTP-1150 and Additive ATP 1150A Eldorado HTP-1150L and Additive HTP-1150A Eldorado HTP-1190 Eldorado HTP-1190L EN-79 Nickel Stripper Part A and Part B Enstrip A (Powder) Enstrip EN-86 Enstrip GT 317 Enstrip L-90
EFFECTIVITY: ALL
Supplier Loctite Aerospace Loctite Aerospace Watkins & Associates Loctite Aerospace Loctite Aerospace Watkins & Associates 3M Company 3M Company 3M Company 3M Company Accumetric, LLC 3M Company 3M Company 3M Company 3M Company Ecolink, Inc. ITW Industrial Finishing SIA Adhesives, Inc. Eldorado Chemical Co., Inc. Eldorado Chemical Co., Inc. Eldorado Chemical Co., Inc. Eldorado Chemical Co., Inc. Eldorado Chemical Co., Inc. Eldorado Chemical Co., Inc. Eldorado Chemical Co., Inc. Enthone, Inc. Enthone, Inc. Enthone, Inc. Enthone, Inc. Enthone, Inc.
Ref No. C01-130 Adhesive Film C01-131 Adhesive Film C01-136 Adhesive Film C01-136 Adhesive Film C01-136 Adhesive Film C01-136 Adhesive Film C01-138 Primer C01-071 Compound, Potting C01-141 Metal Adhesive C01-134 Adhesive C01-013 Potting Compound C01-183 Compound C01-125 Adhesive C01-166 Primer, High Temperature C01-093 Adhesive C04-257 Cleaner, Electrical Contact C10-087 Gun, Paint Spray C01-181 Epoxy Adhesive C04-216 Cleaner, Acid Descaler C04-217 Acid C04-218 Cleaner, Heavy Duty Alkaline C04-212 Cleaner, Mild Alkaline C04-213 Cleaner, Mild Alkaline C04-214 Cleaner, Alkaline Permanganate C04-215 Cleaner, Alkaline Permanganate C04-155 Remover, Plating C04-082 Remover, Plating C04-244 Remover, Plating C04-156 Remover, Plating C04-008 Remover, Coating
70-80-20
Description Enstrip Q516 Enstrip Regenerator Enstrip S Enstrip T-L (Concentrated Power) Envirosolv 655 Epibond 1210A / 9610 Epibond 8543 (Parts C/B) Epocast 1636 A/B EPON 828 EPON 828 EPON 828 Epoxylite, 6203 ER-83A ES-6 Everlube 810 (Concentrate) Everlube 811 or MIL-L-81329 equivalent Everlube ESNA 382 EY 4014 A and B
Supplier Enthone, Inc. Enthone, Inc. Enthone, Inc. Enthone, Inc. Fine Organics Corp. Vantico Vantico Vantico Shell Chemical Co. Miller Stephenson Chemical Co. E. V. Roberts and Associates Epoxylite Corp. Sherwin, Inc. Eldorado Chemical Co., Inc. E/M E/M E/M Fiber-Resin Corp.
Ref No. C04-092 Remover, Plating C04-157 Chemical Additive C04-246 Remover, Plating C04-083 Remover, Plating C04-252 Cleaner, Electrical Contact C01-074 Adhesive C01-117 Adhesive C01-070 Potting Compound C01-017 Epoxy C01-017 Epoxy C01-017 Epoxy C01-077 Sealing Compound C05-057 Emulsifier C05-087 Suspension Fluid C02-049 Lubricant C02-005 Lubricant C02-006 Lubricant C01-078 Adhesive
Description F-4A-C/1 F-4S (NT) /1 F-5D/1 F-5E-SP/1 F-6A-SP/1 F-6A/1 F-6E-W/1 F10-02 F30B F7-16C 0.44 in (11.2 mm) cylinder fine cut
Supplier Eishin Kagaku Co., Inc. Eishin Kagaku Co., Inc. Eishin Kagaku Co., Inc. Eishin Kagaku Co., Inc. Eishin Kagaku Co., Inc. Eishin Kagaku Co., Inc. Eishin Kagaku Co., Inc. Daniels Mfg. Corp. Bergen Cable Technologies, Inc. A and B Deburring Co.
Ref No. C05-099 Emulsifier C05-096 Developer C05-095 Developer C05-098 Emulsifier C05-093 Penetrant C05-097 Developer C05-094 Emulsifier C10-144 Ferrule, Safety Cable C10-144 Ferrule, Safety Cable C04-159 Abrasive, Tumbling
EFFECTIVITY: ALL
70-80-20
Description F7-16C 0.44 in (11.2 mm) cylinder fine cut Fabric, High Strength Woven Graphite 12.5x12.5 tows/in. W322 Fabric, Style No. 1581 Facsimile Fascat 2003 Fastener, Self-Locking 0.301 Nylon tie wraps 1/4 in. wide x 13.38 in long FE 2640 Ferlon Ferric Chloride (Commercial Grade or Better) Ferrocoat 364AC Ferrocoat 366 Fiberglass Tape 23816 Film, Polyester, (Mylar), 0.0020.004 in thick Flame Control No. 11 Flame Control No. 170 Flame Control No. 190 Top Coat Flash-Breaker 2 Flexite Spiral Cut Cable Wrap (Teflon 1/4 in OD x 0.03 thick x 0.375 pitch) Flexobond 329 Kit Fluid, Calibrating, MIL-PRF7024 Fluorglas 2905-7 Tape #9710 Fluorglas 2975-8R FM 300M .08 psf
Supplier Sweco Inc. Cytec Engineered Materials Inc. Hexcel Corporation Flexbar Machine Corp. Atofina Chemicals Local Purchase
Ref No. C04-159 Abrasive, Tumbling C10-112 Fabric, High Strength Woven Graphit C10-003 Fabric Glass C10-041 Impression Material C01-005 Catalyst C10-152 Fastener, Self-Locking
Bollore Henkel Surface Technologies Local Purchase Quaker Chemical Corp. Quaker Chemical Corp. Furon Tape Division / Division of Saint Gobain Local Purchase Flame Control Coating Inc. Flame Control Coating Inc. Flame Control Coating Inc. Airtech International Inc. Markel Corp.
C03-073 Paint, Epoxy C04-050 Cleaner, Heavy Duty Alkaline C04-098 Chemical C02-055 Preservative C02-055 Preservative C10-012 Tape, Masking High Temperature C10-142 Film, Polyester C04-107 Remover, Paint/ Carbon C03-024 Panit C03-025 Paint C10-136 Tape, Flash-Breaker C10-084 Cable Wrap
Bacon Industries Local Purchase Furon Tape Division / Division of Saint Gobain Furon Tape Division / Division of Saint Gobain Cytec Engineered Materials Inc.
C01-095 Elastomer C05-006 Fluid, Calibrating C10-012 Tape, Masking High Temperature C10-012 Tape, Masking High Temperature C01-182 Adhesive
EFFECTIVITY: ALL
70-80-20
Description FM 350 NA S .09 psf FM-1000 .03 psf 0.005 in. to 0.007 in. thick FM-123-5 .06 psf FM-34B-32 Adhesive (Supported or Unsupported) FM-96 FM-96U FM350U NA .06 psf FM410-1 FM490A Foam, Urethane, 2 in. (51 mm) thick Formkote T-50 Formula 3 Cleaner Formula 3 Cleaner, Nuclear Grade FP-22B Freeman Sheet Wax #165 Regular Plain Frekote 44-NC Fruit Stones (Pits) FRV 1106
Supplier Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Local Purchase E/M Lectroetch Co. Lectroetch Co. Sherwin, Inc. Freeman Mfg. and Supply Co. Loctite Corp. Local Purchase GE Company, Silicone Products Division
Ref No. C01-165 Adhesive C01-103 Film C01-066 Epoxy Film C01-098 Adhesive C01-111 Adhesive Film C01-112 Adhesive Film C01-139 Adhesive Film C01-132 Adhesive, Foam C01-132 Adhesive, Foam C01-025 Urethane C02-035 Anti-Seize Graphite C05-016 Electrolytc Cleaners C05-017 Electrolytc Cleaners C05-038 Penetrant C10-156 Wax, Laser Beam Stopping C10-192 Mold Release C04-117 Abrasive, Other C01-153 RTV
Description G183 GE PN 9193M42 (Red) GE01-2 KIT Glass Bead Size 11 Glass Bead Size 11 Glass Bead Size 12
EFFECTIVITY: ALL
Supplier Dynamet Powder Products Parkway Products, Inc. Polycraft Products, Inc. Cataphote Inc. Sovitec France S.A. Cataphote Inc.
Ref No. C06-032 Alloy Powder C03-015 Paint C01-180 Seal Kit C10-197 Hollow Glass Beads C10-197 Hollow Glass Beads C10-197 Hollow Glass Beads
70-80-20
Description Glass Bead Size 12 Gloves, Film Latex or Nylon/ Polyethylene Disposable Gloves, White Cotton Disposable Glyptal 1201 Grade 50-55 Porous PTFE Grinding Wheel 23A80-L8V Grinding Wheel, 32A460K5VBE Grinding Wheel, A24QBFCW1/ 4 Type 27 Grinding Wheel, A70-0-10BB Grinding Wheel, Electrolytic, A80-150-DM347 DIMI Brass Bond Grip Cement Kit No. 675570 GS-213 Gun, Heat Gun, Sealant, Semco Model 250-A6, P/N 250065
Supplier Sovitec France S.A. Local Purchase Local Purchase GLYPTAL, INC. Fluoro Plastics Inc. Norton Company / Division of Saint Gobain Norton Company / Division of Saint Gobain Carborundum Co. Radiac Abrasives Tyrolit North America Inc.
Ref No. C10-197 Hollow Glass Beads C10-140 Gloves C10-139 Gloves C01-038 Varnish C01-113 Teflon Sheet C10-004 Grinding Wheel C10-026 Grinding Wheel C10-025 Grinding Wheel C10-038 Grinding Wheel C10-047 Grinding Wheel
Dentsply/Caulk Division Airtech International Inc. Grainger Parts PRC-Desoto International Inc.
C01-083 Adhesive C10-138 Tape, Sealant, Vacuum Bag C10-054 Gun, Heat C10-068 Gun, Sealant
Description Hampene Diammonium EDTA Heat Blankets, Controllers and Hot Bonders Hi-Shrink Tape, 0.002x1 in. HRH-10-1/8-3.0 HRH-10-3/8-3.0 (Specify 3/8 in. Thickness and Desired Length and Width) HT424 Supported Film (0.135 psf) HT424 Two Part Primer HT424 Two Part Thixotropic Paste
EFFECTIVITY: ALL
Supplier Hampshire Chemical Corp. BH Thermal Corp. Dunstone Company Inc. Hexcel Corporation Hexcel Corporation
Ref No. C04-169 Cleaner, Compound C10-055 Heat Blankets, Controllers and Lamps C10-039 Plastic Tape, High Shrink C10-113 Honeycomb Core C10-008 Honeycomb Cor, Phenolic Reinforced Polyamid Fiber C01-054 Adhesive C01-099 Primer C01-053 Adhesive
Cytec Engineered Materials Inc. Cytec Engineered Materials Inc. Cytec Engineered Materials Inc.
70-80-20
Description HT424 Two Part Thixotropic Paste Hydrochloric Acid, 22 degrees Be O-H-765 Hydrochloric Acid, Reagent Grade Hydrocol Jet Hydrofluoric Acid (48%) O-H795 Hysol EA 901NA/B-1 Hysol EA 9205 Hysol EA 934NA Hysol EA 9394 Hysol EA 9394/C2 Hysol EA 9395 Hysol EA 9396 Hysol EA 9396/C2 Hysol EA 956 Hysol EA 960F Hysol EA 9689.06 psf Hysol EA 9689.09 psf Hysol EA 9689.09 psf Hysol EA 9890 Hysol EA 9891RP
Supplier Cytec Eur. Local Purchase Local Purchase Delta Petroleum Inc. Local Purchase Loctite Aerospace Loctite Aerospace Loctite Aerospace Loctite Aerospace Loctite Aerospace Loctite Aerospace Loctite Aerospace Loctite Aerospace Loctite Aerospace Loctite Aerospace Loctite Aerospace Loctite Aerospace Watkins & Associates Loctite Aerospace Loctite Aerospace
Ref No. C01-053 Adhesive C04-071 Acid C04-136 Hydrochloeic Acid C02-021 Oil, 1010 C04-126 Acid C01-010 Adhesive C01-166 Primer, High Temperature C01-011 Adhesive C01-155 Adhesive C01-156 Adhesive C01-174 Adhesive C01-147 Adhesive C01-157 Adhesive C01-106 Epoxy C01-129 Adhesive C01-139 Adhesive Film C01-165 Adhesive C01-165 Adhesive C01-162 Abradable Seal Material C01-161 Abradable Seal Material
Description IC-9 Immunol 1228 Intex 8201 (Liquid) Iridite 14-2 Isobutyl Alcohol Isoparaffinic Solvents CE-SX94, GB-SX-94, and L-SX-94
Supplier Argent Ltd. Harry Miller Corp. McGean-Rohco, Inc., Cee-Bee Division MacDermid, Inc. Local Purchase Selig Chemical Industries, Inc. Div. of National Services Industries, Inc.
Ref No. C02-073 Oil C02-056 Inhibitor C04-044 Cleaner, Compound C03-064 Conversion Coating C04-151 Solvent, General C04-199 Solvent, General
EFFECTIVITY: ALL
70-80-20
Description Isopropyl Alcohol
Ref No. C04-035 Solvent, General
Description Jet Clean B
Supplier Turco Products, Inc. Subsidiary of Henkel Surface Technologies DuBois Chemical Co. ITW Industrial Finishing Stellite Coatings Deloro Stellite, Inc. Snap-On Special Products
Ref No. C04-078 Cleaner, Compound
Jettacin JGA-510 (Devilbiss) JK 558 JRC8V32C
C04-172 Solvent, General C10-087 Gun, Paint Spray C07-047 Cobalt-MolybdenumChrome-Silicon Powder C10-148 Crimping Tool
Description Kamen 900-1217 Kamen 900-99 Kerosene, Deodorized (VV-K220) Kolene 1 Kolene DGS Kop-Coat Reducer, T-1329-66 (Type II Epoxy) Kroil (Liquid) Krylon 1358
Supplier Kamen Wiping Materials Co., Inc. Kamen Wiping Materials Co., Inc. Local Purchase Kolene Corp. Kolene Corp. Kop-Coat, Inc. Kano Laboratories Krylon Products Group, the Specialty Div. of SherwinWilliams Co. Krylon Products Group, the Specialty Div. of SherwinWilliams Co. Krylon Products Group, the Specialty Div. of SherwinWilliams Co. Krylon Products Group, the Specialty Div. of SherwinWilliams Co. Krylon Products Group, the Specialty Div. of SherwinWilliams Co.
Ref No. C10-182 Cloth, Cleaning C10-182 Cloth, Cleaning C04-125 Solvent, General C04-103 Cleaner, Molten Salt C04-091 Cleaner, Molten Salt C04-029 Paint Thinner C02-053 Penetrating Oil C03-074 Primer, Gray
Krylon 1601
C03-075 Paint, Gloss Black
Krylon No. 1303
C03-068 Coating, Clear
Krylon No. K1302
C01-034 Acrylic Cement
Krylon No. S-500
C01-034 Acrylic Cement
EFFECTIVITY: ALL
70-80-20
Description L1 Liquid Wrench, Industrial Grade LDC Plating Solutions Leak-Tec 16-OX Light Deburring Wheel, Grade 5, Code 6B Scotch Brite Lithobraze BT LM Nicrobraz LN9051 Red Loctite 088 Loctite 19269 Loctite 21348 Loctite 242 Loctite 271 Loctite 277 Loctite 290 Loctite 430 Loctite 567 Loctite 592 Loctite 609 Loctite 620 Loctite 638 Loctite 640 Loctite 680 Loctite 7090 P/N 12695 Loctite C 200 Solid Loctite C5A Copper Loctite Primer T 7471 Loctite Superbonder 496 LPS-1 LPS-LST LSG Lumirror Film (Release Agent)
Supplier Radiator Specialty Co. Liquid Development Company (LDC) American Gas and Chemical Company, Ltd. 3M Company Lucas-Milhaupt Inc. Wall-Colmonoy Corp. Ratioplast GmbH Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. Loctite Corp. LPS Laboratories, Inc. LPS Laboratories, Inc. Lectroetch Co. TORAY Plastics of America
Ref No. C02-026 Penetrating Oil C03-051 Brush Plating C05-005 Liquid, Leak (Bubble) Test (ASTM E515) C10-037 Light Deburring Wheel C06-016 Lithobrage BT C06-014 Braze Alloy Powder C05-003 Marking Pens C01-187 Sealant C01-040 Primer C01-040 Primer C01-143 Locking Agent C01-048 Locking Agent C01-055 Sealant C01-012 Locking Agent C01-118 Adhesive C01-084 Adhesive C01-084 Adhesive C01-110 Retaining Compound C01-114 Compound C01-041 Locking Agent C01-149 Retaining Compound C01-041 Locking Agent C01-160 Primer C02-046 Lubricant C02-032 Anti-Seize Compound C01-090 Primer C01-057 Adhesive C02-053 Penetrating Oil C02-053 Penetrating Oil C05-019 Stencils C10-199 Polyester Film Sheet
EFFECTIVITY: ALL
70-80-20
Description M-Everlube 211-G M-PYPROL M303 M307 M6725-1 M8800 MA 109C (Type II) MA 110RTU (Type II) MA-25 Ablative Coating Parts A, B, & C MA-529 WCG (P/N 1153M28P01) MA-529 WCG (P/N 1153M28P02) MA-81-34-37, Inch Scale, 3/4 inch, in 0.005 intervals MA-81-34-42, LENSCOPE Magnifier, 10X, lens and storage case MA557 Machbloc Blue MagChem Aerodet MagChem AP-9186 MagChem AP-954 MagChem AP-988 MagChem Corrotek MagChem DG-Kleen MagChem Evasol MagChem HDL-202 and Additive Deox MagChem HDP-2524
Supplier LPS Laboratories, Inc. ISP Technologies, Inc. Bergen Cable Technologies, Inc. Bergen Cable Technologies, Inc. Cytec Engineered Materials Inc. Dow Corning Corp. JAD Chemical Co. JAD Chemical Co. Lockheed Martin Space Systems Company - Michoud Operations SIA Adhesives, Inc. SIA Adhesives, Inc. Paul N. Gardner Company, Inc. Paul N. Gardner Company, Inc.
Ref No. C02-014 Molybdenum Disulphite C04-090 Solvent, General C10-148 Crimping Tool C10-148 Crimping Tool C01-067 Primer C02-045 Lubricant C04-140 Cleaner, Gas Path C04-140 Cleaner, Gas Path C01-015 Ablative Silicone
C01-188 Adhesive, Aluminum Filled Epoxy Film C01-188 Adhesive, Aluminum Filled Epoxy Film C05-112 Comparator C05-112 Comparator
SIA Adhesives, Inc. Tape Works MagChem MagChem MagChem MagChem MagChem MagChem MagChem MagChem MagChem
C01-132 Adhesive, Foam C10-193 Masking Putty C04-191 Cleaner, Compound C04-189 Cleaner, Acid Descaler C04-190 Cleaner, Acid Descaler C04-183 Cleaner, Acid Descaler C02-072 Corrosion Inhibitor C04-184 Cleaner, Mild Alkaline C04-205 Cleaner, Compound C04-182 Cleaner, Heavy Duty Alkaline C04-188 Cleaner, Alkaline Permanganate
EFFECTIVITY: ALL
70-80-20
Description MagChem HDP-2888 MagChem Kemstrip-596 and additives: OLS-96, A-96, and S96 Skysol MagChem Soluwax MagChem Teksol Magnesium Alloy Wire (AMS 4395) Magnesium Hydroxide plus Water Maskant, Turco No. 537
Supplier MagChem MagChem
Ref No. C04-187 Cleaner, Heavy Duty Alkaline C04-185 Remover, Paint/ Carbon C04-260 Solvent,eneral C04-186 Cleaner, Mild Alkaline C04-197 Solvent, General C07-002 Weld Wire C02-061 Anti-Seize Compound C10-014 Maskant
MagChem MagChem MagChem Timminco Corp. Local Purchase Turco Products, Inc. Subsidiary of Henkel Surface Technologies MaxiBlast, Inc.
MB-2 (20/30), Plastic Blast Media (MIL-P-85891, Type II, Grade A, 3.5 Mohs Hardness) MB-3 (30/40), Plastic Blast Media (MIL-P-85891, Type II, Grade A, 3.5 Mohs Hardness) MBF50A Meta Nitrobenzenesulfonic Acid - Sodium Salt Metal Tape 26020 Metal-Set A4 Part A and B Metco 101B-NS Metco 101B-NS and Metco 404NS Blend Metco 101SF Metco 202NS
MaxiBlast, Inc.
AlliedSignal Amorphous Metals Local Purchase Furon Tape Division / Division of Saint Gobain Smooth-On Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc.
C06-035 Braze Foil C04-096 Chemical C10-012 Tape, Masking High Temperature C01-021 Adhesive C07-003 Aluminum Oxide Powder C07-018 Alumina/NickelAluminum Powder C07-039 Aluminum Oxide Powder C07-033 Zirconium OxideYttrium Oxide Composite Powder C07-035 Zirconium OxideYttrium Oxide Composite Powder C07-035 Zirconium OxideYttrium Oxide Composite Powder
Metco 204NS
Sulzer Metco, Inc.
Metco 204NS-G
Sulzer Metco, Inc.
EFFECTIVITY: ALL
70-80-20
Description Metco 210NS-1G Metco 307NS-3 Metco 308NS-3 Metco 404NS Metco 405NS Metco 430NS Metco 439NS Metco 43C-NS (GE Spec. B50TF40 Class A Coarse) Metco 43F-NS (GE Spec. B50TF40 Class B Fine) Metco 443NS Metco 447NS
Supplier Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc.
Ref No. C07-029 Powder, Magnesium Zirconate C07-014 75:25 Nickel-Graphite Powder C07-015 85:15 Nickel-Graphite Powder C07-011 Nickel-Aluminum Composite Powder C07-019 Nickel-Aluminum Composite Wire C07-008 Chromium Carbide NiCr-C0- Matrix C07-010 50% Tungsten Carbide Self-Bonding Blend C07-012 Nickel-Chromium Powder C07-012 Nickel-Chromium Powder C07-022 Aluminum-Nickel Chromium Composite Powder C07-034 Nickel AluminumMolybdenum Composite Powder C07-016 Nickel-Aluminum Composite Powder C07-016 Nickel-Aluminum Composite Powder C07-023 Aluminum Bronze Alloy Thermal Spray Powder C07-023 Aluminum Bronze Alloy Thermal Spray Powder C07-017 Aluminum Powder C07-013 Copper-Nickel Powder C07-020 Copper-Nickel-Indium Powder C07-037 Aluminum Silicon Polyester Powder C07-001 Molybdenum Powder C07-025 Cobalt-MolybdenumChromium-Silicon Powder C07-031 Cobalt-MolybdenumChromium-Silicon Powder
Metco 450NS, (GE Spec. B50TF56, Class A) Metco 480NS, (GE Spec. B50TF56, Class B) Metco 51F-NS Metco 51NS Metco 54NS-1 Metco 57NS Metco 58NS Metco 601NS Metco 63 NS Metco 66F-NS Metco 68F-NS-1
Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc.
EFFECTIVITY: ALL
70-80-20
Description Metco 70-CNS and Metco 404NS Blend Metco 72F-NS (Class A) Metco 73F-NS-1 Metco 81NS (GE Spec. B50TF137, Class B) Metco 81VF-NS (GE Spec. B50TF137, Class A) Metco Aluminum Wire Metco Sprabronze AA Metcoloy 33 Metcoseal AP Metcoseal APT Metex Strip Aid METGLAS MBF 20 Methylthymol Blue Fisher Reagent AC-414940010 Metrolux MIBK (Methyl Isobutyl Ketone) Microcloth Microfinish Micropolish 40636006 or 406363128 Micropolish 406365006 MIL Style A-A-59163 Type I (0.5 in. or 1.0 in wide) MIL-C-22750 MIL-PRF-6085 MIL-R-9300, Type I Milk-of-Magnesia (unflavored) Milled Cat. No. 731ED 1/16 in. or 1/8 in. long
EFFECTIVITY: ALL
Supplier Sulzer Metco, Inc.
Ref No. C07-026 Chromium CarbideNickel-Aluminide Composite Powder C07-007 Tungsten Carbide 12% Cobalt Aggregate C07-040 Powder, 17% Tungsten Carbide Cobalt C07-027 75% Chromium Carbide; 25% Nickel Chromium Powder C07-027 75% Chromium Carbide; 25% Nickel Chromium Powder C07-028 Aluminum Wire C07-024 Aluminum Bronze Alloy Wire C07-006 Nickel-Iron-Chromium Wire C01-030 Sealer C01-031 Thinner C04-085 Remover, Coating C06-041 Braze Foil C04-138 Chemical C04-111 Chemical Additive, Antirust C04-170 Solvent, General C10-201 Cloth, Polishing C02-040 Lubricant C10-082 Aluminum Oxide C10-083 Aluminum Oxide, Slurry 0.05 micron C10-125 Tape, Silicone SelfAdhering C03-056 Epoxy Paint C02-050 Preservation Oil C01-026 Epoxy Resin C02-061 Anti-Seize Compound C01-108 Fiber Glass
Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc.
Sulzer Metco, Inc.
Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. MacDermid, Inc. Honeywell Amorphous Metals Fisher Scientific Co. Vapor Blast Mfg. Co. Local Purchase Buehler Limited Champions Choice, Inc. Buehler Limited Buehler Limited Marian Inc. Local Purchase Local Purchase Local Purchase Local Purchase Owens-Corning Fiberglass Corporation
70-80-20
Description Mineral Spirits (ASTM D-235 Type II, Class C) MO-102 Molydag 254 Molykote 33 Molykote 3400A Molykote D 321 R Molykote D 321 R Molykote D 321 R Molykote G-n Paste (USA), (GE Spec. A50TF313, Class C) Molykote M-77 Molykote Type Z Molykote U-n (Available in Europe Only) Monode A-10, Electrolyte Monode APC, Neutralizer Monode C-10, Electrolyte Monode MSC-1 Monode MSC-3 Monode T-10 (NC), Electrolyte MOX-Tape 620-.5 (0.5 in. wide) MP9000-0500 (0.5 in width) MP9000-1000 (1.0 in width) MP9000-1500 (1.5 in width) MP9000-2000 (2.0 in width) MPT-200A MPT-200A-SC MS-111 Stripper MS-122B MS-122DF MS-122V
Supplier Local Purchase Praxair / TAFA Indianapolis Acheson Colloids Co. Dow Corning Corp. Dow Corning Corp. Dow Corning Europe SA Dow Corning France SA Fournier Aerospace International Materials (AIM) Dow Corning Corp. Dow Corning Corp. Dow Corning Corp. (France) Monode Marking Products Inc. Monode Marking Products Inc. Monode Marking Products Inc. Monode Marking Products Inc. Monode Marking Products Inc. Monode Marking Products Inc. Flexfab APW Zero Cases APW Zero Cases APW Zero Cases APW Zero Cases Bergen Cable Technologies, Inc. Daniels Mfg. Corp. Miller Stephenson Chemical Co. Miller Stephenson Chemical Co. Miller Stephenson Chemical Co. Miller Stephenson Chemical Co.
Ref No. C04-002 Solvent C07-001 Molybdenum Powder C02-027 Lubricant C02-062 Lubricant C02-057 Lubricant C02-003 Lubricant C02-003 Lubricant C02-003 Lubricant C02-078 Lubricant C02-069 Lubricant C02-009 Lubricant C02-069 Lubricant C05-107 Electrolyte C05-109 Neutralizer C05-106 Electrolyte C05-015 Monode MSC-1 C05-018 Monode MSC-3 C05-108 Electrolyte C10-125 Tape, Silicone SelfAdhering C10-090 Polygard Protector C10-090 Polygard Protector C10-090 Polygard Protector C10-090 Polygard Protector C10-147 Tester, Safety Cable C10-147 Tester, Safety Cable C04-088 Remover, Paint/ Carbon C10-013 Compound, Release Agent C10-013 Compound, Release Agent C10-013 Compound, Release Agent
EFFECTIVITY: ALL
70-80-20
Description MS-143V-10.0 Multicut Plastic Media Type 2UREA 20/40 mesh MV-30 MXB 7740/120 Mystik 7000
Supplier Miller Stephenson Chemical Co. Poly-Pacific International Inc. Sunnen Products Co. Cytec Engineered Materials Inc. Furon Tape Division / Division of Saint Gobain
Ref No. C10-215 Release Agent C04-153 Abrasive, Plastic C02-073 Oil C10-130 Cloth, Glass Fiber C10-157 Class Cloth Tape
Description N6E12156SIL-XXXX NAD
Supplier Netherland Rubber Co. Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Local Purchase Bostik, Inc. (Domestic Sales) Bostik, Inc. (Domestic Sales) Bostik, Inc. (International Sales) Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis
Ref No. C10-198 Plugs C05-070 Developer
NAD-SB
C05-069 Developer
Napth, Fed. Spec. (TT-N-95 Type II) Never-Seez Pure Nickel Special Grade Never-Seez Regular Grade Never-Seez Regular Grade NI-107 (GE Spec. B50TF40 Class A Coarse) NI-108 NI-109, (GE Spec. B50TF56, Class A) NI-115 NI-120 NI-122 NI-164/NI-211 NI-183
C04-018 Naphtha, C02-071 Anti-Seize C02-060 Anti-Seize Compound C02-060 Anti-Seize Compound C07-012 Nickel-Chromium Powder C07-011 Nickel-Aluminum Composite Powder C07-016 Nickel-Aluminum Composite Powder C07-015 85:15 Nickel-Graphite Powder C07-014 75:25 Nickel-Graphite Powder C07-022 Aluminum-Nickel Chromium Composite Powder C07-032 Nickel Chromium Aluminum Yttrium Powder C07-052 Alloy Powder Rene 80
EFFECTIVITY: ALL
70-80-20
Description NI-183 NI-183-4 NI-185, (GE Spec. B50TF56, Class B) NI-202-1 NI-202-3 NI-298 NI-334 NI-362-3 NI-365-3 (GE Spec. B50TF271 Class B) NI-453 (GE Spec. B50TF166, Class A) Ni-Pd-Cr-B
Supplier Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis
Ref No. C06-032 Alloy Powder C07-053 Alloy Powder Rene 80 C07-016 Nickel-Aluminum Composite Powder C07-038 Inco 718 Powder C07-041 Inconel 718 Powder HVOF Application C06-013 Braze Alloy Powder C06-027 Nickel Braze Alloy C06-014 Braze Alloy Powder C06-036 Weld Powder C07-034 Nickel AluminumMolybdenum Composite Powder C06-025 Braze Alloy
Wesgo Metals, A Division Morgan Technical Ceramics, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Heatbath Corp.
Ni-Pd-Cr-B Nickel Braze Alloy (GE Spec. B50TF90) Nickel Penetrate Salts
C06-025 Braze Alloy C06-027 Nickel Braze Alloy C03-043 Compound, Molten Salt Chemical Surface Treatment C06-028 Blasting Grit C06-013 Braze Alloy Powder C06-002 Braze Alloy C06-038 Flux, High Temperature C01-036 Cement C04-072 Acid C04-109 Chemical Additive, Anti-Solidifying C10-126 Impression Material C10-126 Impression Material C10-018 Grit Blast C10-089 Cutoff Wheel
Nicroblast Grit Nicrobraz 130 Nicrobraz 135 Nicrobraz Flux Nicrobraz No. 320 Nitric Acid (Commercial Grade), 42 degrees Be O-N-350 No-Pack No. 16130, Repro-rubber, Quicksetting Putty (1 3/4 lb.) No. 16131, Repro-rubber, Quicksetting Putty (7 lb.) No. 3 P/N AP123 No. 3, Cutoff Wheel, 1.0 in. x 0.040 in., (25.4 mm x 1.92 mm)
EFFECTIVITY: ALL
Wall-Colmonoy Corp. Wall-Colmonoy Corp. Wall-Colmonoy Corp. Wall-Colmonoy Corp. Wall-Colmonoy Corp. Local Purchase Vapor Blast Mfg. Co. Flexbar Machine Corp. Flexbar Machine Corp. S.S. White Technologies Precision Abrasives and Tools
70-80-20
Description No. 361 Cloth Tape No. 363 Aluminum Foil/Glass Cloth Tape No. 425 Aluminum Foil Tape No. 580-10 No. 6893 Liquid Epoxy Ink (White) No. 6896, Stamp Pad Ink, (White) No. 866 Pigment No. P-89507 / 8 No. T-251-C No. W215, Grit A90R V. Grade O Nomex 410 (Sizes 0.024, and, 0.030 in. available) Nomex 411, (Sizes 0.028/0.025 x 1.175/1.145 x 30.0 in.) Nomex Honeycomb HRH-10 (0.1875 in cell, 3/16 in. thick) Norton 112
Supplier 3M Company 3M Company 3M Company 3M Company Markem Corp. Markem Corp. Creanova Chicago Pneumatic Tool Co. Beck Chemical, Inc. Norton Company / Division of Saint Gobain Essex Group Inc. IWI Operations Essex Group Inc. IWI Operations Hexcel Corporation Ceramic Grains and Powder Division Norton Company / Division of Saint Gobain Vapor Blast Mfg. Co. BGR, INC. Nuvite Chemical Compounds, Corp. Nyco SA
Ref No. C10-209 Tape, Glass Cloth C10-216 Tape, Aluminum Foil/ Glass Cloth C10-210 Tape, Aluminum Foil C05-103 Tape, Reflective C05-010 Ink Marking Epoxy C05-010 Ink Marking Epoxy C03-029 Black Lamp C02-042 Oil C04-042 Remover, Paint/ Cleaner C10-058 Abrasive Wheel C10-031 Polyimide PaperDense Laminate C10-031 Polyimide PaperDense Laminate C10-050 Honeycomb C07-003 Aluminum Oxide Powder C10-115 Grit Blast Media C10-021 Tape, Duct C04-206 Cleaner, Compound C02-001 Anti-Seize Compound
Novaculite 200 NT-580, Red Nu-Gear-SC Nyco GA47
Description O-G-491 O1T Oakite 156 Oakite 157
Supplier Local Purchase Praxair / TAFA Concord Chemetall Oakite Chemetall Oakite
Ref No. C05-091 Glycerine C07-044 Aluminum Wire 99% Pure Minimum C04-037 Remover, Paint/ Carbon C04-037 Remover, Paint/ Carbon
EFFECTIVITY: ALL
70-80-20
Description Oakite Stripper A2 Ocean No. 1522 OD-1700A Penetrant OD-1700B OD-2800-I Penetrant OD-2800-II Penetrant Oil, AMS 3160 Suspension Fluid Oil, Engine Lubricating Oil, Engine Lubricating (MIL-L23699) Oxalic Acid (Commercial Grade or Better)
Supplier Chemetall Oakite Fire Research Lab. Marktec Corp. Marktec Corp. Marktec Corp. Marktec Corp. Local Purchase Local Purchase Local Purchase Local Purchase
Ref No. C04-141 Remover, Paint/ Carbon C03-003 Paint C05-047 Penetrant C05-060 Emulsifier C05-050 Penetrant C05-048 Penetrant C05-087 Suspension Fluid C02-019 Oil C02-023 Oil C04-099 Chemical
Description P-80 P-80 P/N 4013518-290 P/N 4013518-319 P/N 44404, Black D50TF8, Action Marker Nuclear Grade P/N 44729, White D50TF8, Action Marker Nuclear Grade P/N 55608, # 55 Valve Action Marker, # Y-608 Black Washout, High Purity P/N 80404, Q-404 High Purity Ink, Nuclear Grade P41H1
Supplier International Products Corporation (UK) International Products Corporation (USA) Noble Tool Corp. Noble Tool Corp. ITW Mark-Tex ITW Mark-Tex ITW Mark-Tex
Ref No. C02-076 Lubricant, Rubber C02-076 Lubricant, Rubber C05-113 Inspection System C05-114 Optical Refractor C05-003 Marking Pens C05-003 Marking Pens C05-003 Marking Pens
ITW Mark-Tex Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Powder Alloy Corp.
C05-004 Ink, Stamp Pad C05-029 Penetrant
P60H
C05-101 Penetrant
PAC 1058B
C07-014 75:25 Nickel-Graphite Powder
EFFECTIVITY: ALL
70-80-20
Description PAC 1059B PAC 12 PAC 127 (Class A and B) PAC 130 (GE Spec. B50TF137, Class B) PAC 131 (GE Spec. B50TF137, Class A) PAC 133 PAC 1424 PAC 16FC PAC 19SP PAC 2008P
Supplier Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp.
Ref No. C07-015 85:15 Nickel-Graphite Powder C07-013 Copper-Nickel Powder C07-007 Tungsten Carbide 12% Cobalt Aggregate C07-027 75% Chromium Carbide; 25% Nickel Chromium Powder C07-027 75% Chromium Carbide; 25% Nickel Chromium Powder C07-008 Chromium Carbide NiCr-C0- Matrix C06-012 Braze Alloy, Powder C07-023 Aluminum Bronze Alloy Thermal Spray Powder C07-017 Aluminum Powder C07-035 Zirconium OxideYttrium Oxide Composite Powder C07-005 Molybdenum Wire C07-021 Nickel-Silicon-Boron Powder C07-020 Copper-Nickel-Indium Powder C07-003 Aluminum Oxide Powder C07-038 Inco 718 Powder C07-041 Inconel 718 Powder HVOF Application C07-037 Aluminum Silicon Polyester Powder C07-016 Nickel-Aluminum Composite Powder C07-022 Aluminum-Nickel Chromium Composite Powder C07-032 Nickel Chromium Aluminum Yttrium Powder C07-012 Nickel-Chromium Powder C07-012 Nickel-Chromium Powder
Powder Alloy Corp.
Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp.
PAC 4 PAC 65 PAC 658C PAC 701B PAC 718B PAC 718F PAC 905-3 PAC 906, (GE Spec. B50TF56, Class A) PAC 908C PAC 9620AM PAC 98C-1 (GE Spec. B50TF40 Class A Coarse) PAC 98F (GE Spec. B50TF40 Class B Fine)
EFFECTIVITY: ALL
Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp. Powder Alloy Corp.
70-80-20
Description PAC A13 Palniro 7
Supplier Powder Alloy Corp. Wesgo Metals, A Division Morgan Technical Ceramics, Inc. Zoltek Henkel Surface Technologies Rexco Chemical Co. PRC-Desoto International Inc. Accumetric, LLC Patco Corp. Sermatech International Inc. Akzo Nobel Aerospace Coatings Precision Fabrics Group Inc. McMaster Carr McMaster Carr Permabond International Corp. Permacel Permacel W. W. Grainger Local Purchase Chemtech Finishing Systems Local Purchase Eastman Kodak Co. Eastman Kodak Co. Eastman Kodak Co. Eastman Kodak Co. Ludlow Corp., Packaging Div.
Ref No. C07-004 Silver Alloy Wire C06-006 Braze Alloy GoldNickel-Palladium C10-086 Tape, Graphit Cloth C03-046 Acid, Mixture/Solution C05-009 Polyvinyl Alcohol C04-150 Compound, Surface Treatment C04-150 Compound, Surface Treatment C10-021 Tape, Duct C03-022 Cement C03-014 Hardener C10-131 Peel Ply C10-095 Perforated Steel C10-095 Perforated Steel C01-057 Adhesive C10-157 Class Cloth Tape C10-070 Tape, Glass Fiber C01-003 Compound, Sealing C02-008 Petroleum Jelly C04-120 Acid C04-093 Acid C05-110 Wetting Agent C05-110 Wetting Agent C05-110 Wetting Agent C05-110 Wetting Agent C10-009 Paper, Greaseproof
Panex 30, SW08 1.5 in. wide Parcolene 41 Partial Film No. 10 Pasa-Jell 105 Pasa-Jell 105 Patco #110-50 PBX Ceramic Cement PC-216 Peel Ply, Style 52006/51789, SRB Perforated Steel, Cat. No. 9255T631 Perforated Steel, Cat. No. 9358T14 Permabond 910 Permacel P-212 Permacel P21 Permatex, Form-A-Gasket No. 2 Petrolatum VV-P-236 Phos-It (Inhibited Phosphoric Acid) Phosphoric Acid Photo-Flo 200, Catalog No. 146 4502-4 Fl oz. Photo-Flo 200, Catalog No. 146 4510-16 Fl oz. Photo-Flo 2100, Catalog No. 141 8904-1 gallon Photo-Flo 600, Catalog No. 146 4528-1 gallon PK 22C
EFFECTIVITY: ALL
70-80-20
Description Plastic Sheet, Polyethylene (1.5 mil thickness or greater) Plastiseal F Plastisol PP-0274 Plaudit
Supplier Local Purchase Kenneth Industrial Products, Inc. Portland Plastics Turco Products, Inc. Subsidiary of Henkel Surface Technologies Ashland Chemicals The Milburn Co. Polymet Corp. Polymet Corp. Polymet Corp. Polymet Corp. Polymet Corp. Polymet Corp. Polymet Corp. Polymet Corp. Ernest F. Fullam, Inc. Lapmaster International Lapmaster International Lapmaster International U.S. Technology Corp.
Ref No. C10-128 Plastic Sheet, Polyethylene C01-004 Compound, Sealing C01-120 Adhesive C04-078 Cleaner, Compound
Pliobond 20 Ply-2 PMET 818 PMET 822 PMET 842 PMET 880 PMET 885 PMET 886 PMET 980 PMET 994 PN11340, (Replicating Tape 5 mil thick) Polishing Paste, Diamond, 15 micron Polishing Paste, Diamond, 3 micron Polishing Paste, Diamond, 6 Micron PolyPlus 20/40 Mesh, Plastic Blast Media (MIL-P-85891, Type II, Grade A, 3.5 Mohs Hardness) Porous PTFE (NATO Supply Code F0585) Positron Potassium Dichromate O-P-559 Potassium Hydroxide O-P-566 Potassium Nitrate, Crystal Certified or Reagent Grade
C01-072 Adhesive C10-064 Protective Hand Cream C07-049 Alloy 718 Wire C06-037 Weld Wire C06-031 Weld Wire C06-033 Weld Wire C07-042 Nickel-Aluminum Wire C07-043 Nickel-ChromiumAluminum Wire C06-023 Weld Electrode C06-009 Coating, Alloy-Cobalt Base C10-079 Cellulose, Acetate C10-080 Polishing Paste C10-080 Polishing Paste C10-080 Polishing Paste C04-153 Abrasive, Plastic
P. Viennot S. A. Ecolink, Inc. Local Purchase Local Purchase Local Purchase
C01-113 Teflon Sheet C04-198 Solvent, General C04-108 Chemical C04-127 Chemical C04-137 Chemical
EFFECTIVITY: ALL
70-80-20
Description Potassium Permanganate (MIL-P-19970) Powder, Aluminum (Fed. Spec. A-A-341) Powdered Coke PR 1422 PR 1750 B-2 PR-1440 AMS-S-8802 PR-1826 Class B-1/4 PR1440-B-2 Presto-Black BST4 (Dilute Aqueous Acid) Primer - MB Prismacolor Verithin Silver Pencil Pro Gold GX100L Pro Gold GX5L Pro-Seal 501 PS 870-B-2 PSA 2 in. dia., 120 S/C PTFE (Teflon) 25% GlassFilled Sheet PTFE (Teflon) Mechanical Grade Sheet
Supplier Local Purchase Local Purchase J.S. McCormick Co. PRC-Desoto International Inc. PRC-Desoto International Inc. PRC-Desoto International Inc. PRC-Desoto International Inc. PRC-Desoto International Inc. Birchwood Casey Div., Birchwood Laboratories, Inc. Rhone-Poulenc Sanford Corp. Caig Laborotories, Inc. Caig Laborotories, Inc. PRC-Desoto International Inc. PRC-Desoto International Inc. Field Abrasive Mfg. Co. Inc. EPM, Inc. EPM, Inc.
Ref No. C04-118 Chemical C10-007 Powder, Aluminum C04-026 Abrasive C01-062 Sealing Compound C01-073 Sealing Compound C01-062 Sealing Compound C01-190 Sealant C01-115 Adhesive C03-049 Black Oxide Touch-up C01-170 Silicone C05-003 Marking Pens C04-258 Electrical Contact Cleaner / Lubricant C04-258 Electrical Contact Cleaner / Lubricant C01-140 Adhesive C01-115 Adhesive C10-073 Abrasive Disk C10-213 Teflon Sheet C10-212 Teflon Sheet
Description Quartz Pins
Supplier Industrial Quartz
Ref No. C10-023 Quartz Pins
Description R-MC Engine Cleaner, (4070 Type II) R-MC Engine Cleaner, (4072 Type IIRTU) RC Tumbling Nuggets, Size # 10
Supplier ECT Inc. ECT Inc. Richwood Industries Inc.
Ref No. C04-140 Cleaner, Gas Path C04-140 Cleaner, Gas Path C04-177 Abrasive, Tumbling
EFFECTIVITY: ALL
70-80-20
Description RC-3000-10 RC-65 RC-77 Real Cool Snoop Red 091-1578 (Wax, Utility) Release Agent, RAM225 Release Ease 234 TFNP Release Ease 234 TFP Reliabond 380 Rene 80 Resin Pack # 039-080055-685 Rhodine 51 Rice Hulls RL-6000-SA Series Rodine 213 Rodine 31A Rodine XL1090 Royco 22CF Royco 27 Royco 44 Royco 481 Royco 483 Royco 64 Royco 81MS Royco Grease 22 MS
Supplier Richmond Aircraft Prod. Sherwin, Inc. Sherwin, Inc. Swagelok Patterson Dental Supply Lily Industries Inc. Airtech International Inc. Airtech International Inc. Hexcel Corporation Sulzer Metco, Inc. Syon Corporation Henkel Surface Technologies Local Purchase Kirkhill-TA Co. Henkel Surface Technologies Henkel Surface Technologies Henkel Surface Technologies Royal Lubricants Co., Inc. Royal Lubricants Co., Inc. Royal Lubricants Co., Inc. Royal Lubricants Co., Inc. Royal Lubricants Co., Inc. Royal Lubricants Co., Inc. Royal Lubricants Co., Inc. Shell International Trading Co., International Aviation Division Royal Lubricants Co., Inc. Vantico Accumetric, LLC GE Company, Silicone Products Division GE Company, Silicone Products Division
Ref No. C10-134 Cloth, Breather/ Bleeder C05-039 Penetrant C05-115 Penetrant C10-214 Fluid, Leak Detection C10-109 Wax C10-019 Release Agent C10-179 Cloth, Class PTFE Coated (Non-porous) C10-178 Cloth, Glass PTFE Coated (Porous) C01-063 Epoxy C06-032 Alloy Powder C01-060 Epoxy C04-248 Inhibitor C04-116 Abrasive, Other C10-151 Tape, Silicone C04-010 Inhibitor C04-242 Inhibitor C04-010 Inhibitor C02-017 Grease C02-016 Grease C02-001 Anti-Seize Compound C02-021 Oil, 1010 C02-025 Oil, Preservation C02-014 Molybdenum Disulphite C02-020 Oil C02-044 Grease
Royco HF825 RP6402-1 Resin and Hardener RSP-3 Kit RTV 103 (Black) (GE Spec. A15F6A3) RTV 106 (Red) (GE Spec. A15F6B6)
C02-013 Lubricant C01-144 Urethane C01-060 Epoxy C01-006 RTV C01-007 RTV
EFFECTIVITY: ALL
70-80-20
Description RTV 108 (Translucent) RTV 109 (Aluminum) RTV 118 (Translucent) RTV 133 (Black) RTV 147A RTV 148 RTV 157 (Gray) RTV 159 (Red) RTV 167 RTV 560 (Red) RTV 577 (White) RTV 5812 RTV 5813 RTV 60 (Red) RTV 615 (Clear) RTV 630 (Blue) RTV 664 (Blue) RTV 88 (Red) RTV3110 Rubber Cement and Thinner Rubber Wheel 1 x 0.030 x 1/16 A240, U2RR860 Rubber, Silicone Sheet, molded, 0.125 inch (3.2 mm) thick
Supplier GE Company, Silicone Products Division GE Company, Silicone Products Division GE Company, Silicone Products Division GE Company, Silicone Products Division Rhone-Poulenc Rhone-Poulenc GE Company, Silicone Products Division GE Company, Silicone Products Division GE Company, Silicone Products Division GE Company, Silicone Products Division GE Company, Silicone Products Division GE Company, Silicone Products Division GE Company, Silicone Products Division GE Company, Silicone Products Division GE Company, Silicone Products Division GE Company, Silicone Products Division GE Company, Silicone Products Division GE Company, Silicone Products Division Dow Corning Corp. Starkey Chemical Radiac Abrasives Furon Tape Division / Division of Saint Gobain
Ref No. C01-056 Silicone Rubber C01-076 Silicone C01-094 RTV C01-176 RTV C01-168 Silicone C01-167 Silicone C01-122 Adhesive C01-178 RTV C01-172 Sealant C01-008 Silicone C01-049 Potting Compound C01-191 RTV, Silicone Elastomer C01-192 RTV, Silicone Elastomer C01-075 Silicone C01-164 Sealing Compound C01-042 Silicone Rubber C01-086 Silicone C01-150 Silicone Rubber C10-129 RTV, Casting Material C01-050 Rubber Cement C10-044 Rubber Wheel C01-189 Rubber, Silicone Sheet
EFFECTIVITY: ALL
70-80-20
Description Rubber, Silicone, Shore A40 (1/4 in. thick) Rust Lick B
Supplier Local Purchase ITW Magnaflux
Ref No. C01-064 Silicone C04-025 Rust Preventative
Description S-1255 Thermoset Adhesive Tape S1193 S1194 S1195 S2260 Prime Coat S38/4000 SAE 20-20 Sandstrom 27A MoS2 Base and Corrosion Inhibitor (GE Spec. A50TF192 Class B) SB-2 SB00520 (0.5 in. wide) SB01020 (1 in. wide) Scotch 35 Scotch Brand 5490, Teflon 1 x 0.002 in. thick Scotch Brite Pads No. 7440 (6.0 x 9.5 in.) Scotch Brite Pads No. 7447 (6.0 x 9.5 in.) UPC# 048011-04029 Scotch No. 27 Scotch No. 470, Tape Scotch No. 69 Scotch Weld AF-191U 0.50 psf SCT-TB1 SCT323 SCT327 Seal, Conical, VSF1015-N-3 Seal, Conical, VSF1015-N-4 Seal. Aluminum No. A-1
Supplier Tyco Electronics / Raychem Interconnect GLYPTAL, INC. GLYPTAL, INC. GLYPTAL, INC. Dow Corning Corp. 3M Company Local Purchase Sandstrom Products Co.
Ref No. C10-124 Tape C03-034 Paint C03-041 Paint C03-035 Reducer C01-179 Primer C10-197 Hollow Glass Beads C02-038 Oil C02-004 Lubricant
Acheson Colloids Co. Flexfab Flexfab 3M Company 3M Company 3M Company 3M Company 3M Company 3M Company 3M Company 3M Company Daniels Mfg. Corp. Daniels Mfg. Corp. Daniels Mfg. Corp. Fairchild Fasteners Direct Fairchild Fasteners Direct American Casting and Mfg. Co.
C04-231 Solvent C10-151 Tape, Silicone C10-151 Tape, Silicone C10-180 Tape, Electrical C10-040 Tape, Teflon C10-211 Abrasive Cloth C10-010 Scotch Brite Pads C10-070 Tape, Glass Fiber C10-067 Tape, Platers C10-157 Class Cloth Tape C01-139 Adhesive Film C10-146 Test Block C10-148 Crimping Tool C10-148 Crimping Tool C10-028 Seal, Conical C10-029 Seal, Conical C10-100 Seal, Aluminum
EFFECTIVITY: ALL
70-80-20
Description Selective Plating Supplies Series 646-58-6473 Sermalloy J Sermaseal 565 Sermetel 1076HS Sermetel 1636 Sermetel 196 Sermetel 409 Sermetel W Seymour Hi Tech 16-897 SGB/2GX SH-1030-2 in 32 Brush Vonnegut Head with long trim brush SH-306 2 in. long trim brushes Shims Metal, RFI 1795-1 (0.004 in. Thick) Shims Metal, RFI 1795-2 (0.005 in. Thick) Shims Metal, RFI 1795-3 (0.006 in. Thick) Shims Metal, RFI 1795-4 (0.007 in. Thick) Shims Metal, RFI 1795-5 (0.008 in. Thick) Shims Metal, RFI 1795-6 (0.009 in. Thick) Shurtape PC623 Sikkens S 21/8 Silica-Alumina Fiberfrax Size No. 25, Reamers, Root Canal Stainless Steel
Supplier SIFCO Selective Plating-Div., SIFCO Industries Creative Coatings Co. Inc. Sermatech International Inc. Sermatech International Inc. Sermatech International Inc. Sermatech International Inc. Sermatech International Inc. Sermatech International Inc. Sermatech International Inc. Seymour of Sycamore Electrolube G and P Machinery Corp.
Ref No. C03-050 Brush Plating C03-080 Paint C03-047 Coating, High Temperature C03-090 Coating, Solid Film Inorganic Sealant C03-089 Coating, Chromium Oxide Pigmented C03-088 Coating, Aluminum Oxide Pigmented C03-039 Coating C03-012 Color Coating C03-038 Paint C03-085 Primer C02-070 Grease C10-060 Brush Unit
G and P Machinery Corp. Laminated Shim Co. Laminated Shim Co. Laminated Shim Co. Laminated Shim Co. Laminated Shim Co. Laminated Shim Co. Shurtape Akzo Nobel Aerospace Coatings Unifrax Corporation Patterson Dental Supply
C10-061 Brush, Replaceable Type Sh-306 C10-155 Shims, Metal C10-155 Shims, Metal C10-155 Shims, Metal C10-155 Shims, Metal C10-155 Shims, Metal C10-155 Shims, Metal C10-021 Tape, Duct C03-054 Aluminum-Silicone Resin Pain C06-022 Ceramic Fiber Insulation C10-159 Reamers, Root Canal Stainless Steel
EFFECTIVITY: ALL
70-80-20
Description Size No. 50, Reamers, Root Canal Stainless Steel Size No. 70, Reamers, Root Canal Stainless Steel Size No. 75, Reamers, Root Canal Stainless Steel SK10040-0000 Skydrol 500B-4 SkyKleen SM 5144 Snoop Sodium Carbonate (O-S-571) Sodium Cyanide Sodium Dichromate Sodium Hydroxide Sodium Nitrite (1%) Commercial Quality Solar Flux, Type I Solvent, Acetone (Fed. Spec. 0-A-51) Solvent, Hexane Solvent, Methyl-Ethyl-Ketone (ASTM D 740) Solvent, Methyl-Propyl-Ketone Solvent, Stoddard (MIL-PRF 680 Type I, Type II, or Type III) Solvent, Trichloroethylene, Technical (Fed. Spec. O-T-634) Sovitec T 212 Sovitec T 212 Spray Mix Type I Spraybond SQ32L SS4004 (Pink) SS4155 (Blue) SS4155 (Blue)
Supplier Patterson Dental Supply Patterson Dental Supply Patterson Dental Supply Dolan-Jenner Ind. Inc. Solutia Inc. Solutia Inc. Richmond Aircraft Prod. Swagelok Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Golden Empire Corp. Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Local Purchase Sovitec France S.A. Cataphote Inc. Drilube Co. Sulzer Metco, Inc. Marston Lubricants, LTD GE Company, Silicone Products Division General Electric France GE Company, Silicone Products Division
Ref No. C10-159 Reamers, Root Canal Stainless Steel C10-159 Reamers, Root Canal Stainless Steel C10-159 Reamers, Root Canal Stainless Steel C10-186 Pipe Light C02-075 Hydraulic Fluid C04-200 Solvent, General C10-138 Tape, Sealant, Vacuum Bag C10-214 Fluid, Leak Detection C04-123 Chemical C04-086 Remover, Plating C04-229 Chemical C04-084 Chemical C02-056 Inhibitor C06-030 Flux, Welding C04-003 Solvent C04-021 Solvents, General C04-001 Solvent C04-196 Solvent, General C04-002 Solvent C04-004 Solvent C10-197 Hollow Glass Beads C10-197 Hollow Glass Beads C02-010 Lubricant C07-005 Molybdenum Wire C01-145 Jointing Compound C01-159 RTV Primer C01-092 Primer C01-092 Primer
EFFECTIVITY: ALL
70-80-20
Description Steelgard 1301DC Steelgard 1315 STO Style 120, Finish 538 Sulfuric Acid (Commercial Grade 65 deg. Be O-S-809) Sulzer Metco 4538 Sulzer Metco 8400 Sulzer Metco 8443 Sulzer Metco 8718 Super Bee 262 Super Bee 300LF Super Koropon 515-700 Supersolve AS Supertect ST-A Surf-kote LOB-1800G Surfacto SW 12 Wax Billet, Flat, In Broken Chunks Part No. 499A04 Sweco 30 deg. Angle Cut Cylinders B1-4 (1/4 dia. x 11/ 32) Sweco 30 deg. Angle Cut Cylinders B1-4 (1/4 dia. x 11/ 32) Sweco 30 deg. Angle Cut Cylinders B3-16 ( 3/16 dia. x 11/32) Sweco 30 deg. Angle Cut Cylinders B3-16 ( 3/16 dia. x 11/32) SWECO Burnishing No. 1 (Burnishing Soap)
Supplier Harry Miller Corp. Harry Miller Corp. GE Company, Silicone Products Division BGF Industries Local Purchase Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. Sulzer Metco, Inc. McGean-Rohco, Inc., Cee-Bee Division McGean-Rohco, Inc., Cee-Bee Division PRC-Desoto International Inc. Arrow Chemicals Ltd. Roly International Hohman Plating and Mfg., Inc. Vapor Blast Mfg. Co. Kindt-Collins Co.
Ref No. C02-056 Inhibitor C02-048 Preservation Treatment C01-005 Catalyst C10-122 Glass Cloth C04-101 Acid C07-050 Nickel-ChromiumSilicon-Iron Powder C07-042 Nickel-Aluminum Wire C07-043 Nickel-ChromiumAluminum Wire C07-049 Alloy 718 Wire C04-211 Cleaner, Compound C04-221 Cleaner, Mild Alkaline C03-087 Primer C04-256 Hand Wipe Solvent C02-053 Penetrating Oil C02-065 Lubricant C04-110 Chemical Additive, Wetting Agent C10-156 Wax, Laser Beam Stopping C04-130 Abrasive, Tumbling
Sweco Inc.
C04-130 Abrasive, Tumbling
Sweco Inc.
C04-040 Cleaner, Compound
EFFECTIVITY: ALL
70-80-20
Description SWECO F3-8T Sweco XC 11-8t Sweco XC3-16 Sweco XC5-16 SX-5 Sylgard 170 Parts A and B Syringe, Polyethylene, Adhesive
Supplier A and B Deburring Co. A and B Deburring Co. A and B Deburring Co. A and B Deburring Co. Dolan-Jenner Ind. Inc. Dow Corning Corp. McMaster Carr
Ref No. C04-032 Abrasive, Tumbling C04-019 Abrasive, Tumbling C04-020 Abrasive, Tumbling C04-017 Abrasive, Tumbling C10-183 Adapter, Light Pipe C01-151 Silicone Rubber C10-208 Syringe
Description T.E.C. Marker (Black) Tacks, #3 Blued Cut TAFA 10T TAFA 13T Tape, Adhesive Dots (various sizes for masking) Tape, Brown Ceramic Filled TFE, Etched one side (GE PN 3046M82) Tape, Brown Ceramic Filled TFE, Etched one side (GE PN 3046M82) Tape, Flash-Breaker, No. 855, 0.002 in. Thick Tape, Masking, No. 218 Fineline Tape, Shrink #2 Tape, Silicone Self-Adhering (GE PN 3003M70) Tartaric Acid (Commercial Grade or Better) TB 101 TC330 1-1/4 x 9/16 in. (3M Number) Tectyl 275 Tempilstik 1100 deg. F. Tempilstik 1150 deg. F. Tempilstik 1200 deg. F.
EFFECTIVITY: ALL
Supplier Sanford Corp. Holland Manufacturing Co. Praxair / TAFA Concord Praxair / TAFA Concord 3M Company RM Engineered Products, Inc.
Ref No. C05-003 Marking Pens C04-223 Tacks C07-056 Bronze Alloy Wire C07-055 Wire C10-103 Tape, Adhesive Dots C01-097 Tape, Brown Ceramic Filled C01-097 Tape, Brown Ceramic Filled C10-136 Tape, Flash-Breaker C10-102 Tape, Masking C10-135 Tape, Shrink #2 C10-125 Tape, Silicone SelfAdhering C04-100 Acid C10-146 Test Block C10-111 Rotary Flap Peen Assembly C02-054 Neutralizer C05-012 Temperature Marking C05-012 Temperature Marking C05-012 Temperature Marking
Saint-Gobain Performance Plastics 3M Company 3M Company Richmond Aircraft Prod. D & B Industrial Local Purchase Bergen Cable Technologies, Inc. 3M Company Ashland Chemical Inc. Tempil Inc. / Division of ITW Tempil Inc. / Division of ITW Tempil Inc. / Division of ITW
70-80-20
Description Tempilstik 1250 deg. F. Tempilstik 400 deg. F. Tempilstik 600 deg. F. TESA 53793 Tetra-Etch Thinner (Strong Grade) Thornel Mat VMX-11 Tioform LF 22 Tiolube 70 organic solvent base dry film lubricant (GE Spec. A50TF192 Class B) Tiolube 75/75 Water base, dry film lubricant (GE Spec. A50TF192 Class B) TL-29 TL-52 Toluene Industrial Toluene Solvent (Reagent Grade) Tool, Safetywire TR-103B TR-200 TR-48 (Type I Polyurethane) TR-49 (Type II Epoxy) Tri-Flow Superior Lubricant Tribaloy 800 Tribaloy T-400 Tribaloy T-800 Trim Sol Trim Tap NC Trim Tap NC Heavy Triton X-100 Triton X-100 TT-E-527 Color 36231
Supplier Tempil Inc. / Division of ITW Tempil Inc. / Division of ITW Tempil Inc. / Division of ITW Tesa Tape Inc. (TTI) W.L. Gore and Associates, Inc. Lapmaster International BP Amoco Polymers Inc. Lubri-Film Div. Tiodize Co., Inc.
Ref No. C05-012 Temperature Marking C05-012 Temperature Marking C05-012 Temperature Marking C10-063 Masking Tape C04-007 Surface Treatment C10-081 Thinner (Strong Grade) C10-116 Filler, Graphite Fibers C02-035 Anti-Seize Graphite C02-004 Lubricant
Tiodize Co., Inc.
C02-004 Lubricant
T. C. Specialties, Inc. T. C. Specialties, Inc. Local Purchase Local Purchase Local Purchase A and B Deburring Co. A and B Deburring Co. T. C. Specialties, Inc. T. C. Specialties, Inc. Sherwin-Williams, Inc. Stellite Coatings Deloro Stellite, Inc. Stellite Coatings Deloro Stellite, Inc. Stellite Coatings Deloro Stellite, Inc. Master Chemical Co. Master Chemical Co. Master Chemical Co. Van Waters and Roger, Inc. Union Carbide Corp. Creative Coatings Co. Inc.
C03-057 Paint Thinner C03-062 Paint Thinner C04-036 Solvent, General C04-102 Solvent, General C10-150 Tool, Safetywire C04-131 Chemical C04-016 Cleaning Compound C04-029 Paint Thinner C04-029 Paint Thinner C02-077 Oil, Lubricating C06-023 Weld Electrode C07-025 Cobalt-MolybdenumChromium-Silicon Powder C07-031 Cobalt-MolybdenumChromium-Silicon Powder C10-075 Coolant C02-074 Tapping Fluid C02-074 Tapping Fluid C04-015 Wetting Agent C04-015 Wetting Agent C03-036 Paint
EFFECTIVITY: ALL
70-80-20
Description TT-P-1757 Type 1 or 2 Class C (AMS3110) Color Y Tubing, Non-Toxic Vinyl Plastic Tumblex 4TL Turbaloy 220 Turbinade TA-A Turco 2538
Supplier Local Purchase Local Purchase Abrasive Finishing, Inc. United States Welding Roly International Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies
Ref No. C03-001 Primer C10-006 Tubing C04-038 Abrasive, Tumbling C06-039 C02-053 Penetrating Oil C04-059 Remover, Paint/ Carbon C04-128 Cleaner, Heavy Duty Alkaline C04-048 Cleaner, Heavy Duty Alkaline C04-073 Acid
Turco 3976
Turco 4008
Turco 4104
Turco 4181
C04-009 Cleaner
Turco 4181-L
C04-009 Cleaner
Turco 4316
C04-080 Cleaner, Alkaline Permanganate C04-080 Cleaner, Alkaline Permanganate C04-054 Cleaner, Alkaline Permanganate C04-054 Cleaner, Alkaline Permanganate C04-119 Acid
Turco 4316-L
Turco 4338-C
Turco 4338-L
Turco 4409 (Inhibited Phosphoric Acid) Turco 4460-BK
C04-201 Solvent, General
EFFECTIVITY: ALL
70-80-20
Description Turco 4781-7
Supplier Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies
Ref No. C04-053 Cleaner, Heavy Duty Alkaline C04-053 Cleaner, Heavy Duty Alkaline C04-132 Cleaner, Compound
Turco 4781-7L
Turco 4848-92
Turco 5279-A
Turco 5668 and Additives #1, #2, and #3 Turco 5805
C04-105 Remover, Paint/ Carbon C04-250 Cleaner, Carbon Removal Gel C04-140 Cleaner, Gas Path
Turco 5884, (Type I)
Turco 5948 DPM
Turco 5948 DPM Thick
Turco 5948-R
C04-152 Cleaner, Mild Alkaline
Turco 6045
C04-149 Remover, Silicone Rubber C04-203 Solvent, General
Turco 6780
Turco 6783-50 (Type II)
C04-140 Cleaner, Gas Path
Turco 6869
C04-202 Solvent, General
Turco Demask 625
C03-053 Demasking Compound
EFFECTIVITY: ALL
70-80-20
Description Turco IND 79
Supplier Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Thomas and Betts Corp. Kerr Corp. Local Purchase HTG Metal Methods Asia Pacific Microspheres (Manufacturer) The M.F. Cachat Co. Protech Lab Corporation Metcut Research
Ref No. C04-225 Solvent
Turco Liquid Sprayeze NP-LT
C04-193 Cleaner, Mild Alkaline
Turco Maskolene
C03-067 Paint Booth Coating
Turco Scale Gon #5
C04-195 Cleaner, Acid Descaler C04-034 Remover, Paint/ Carbon C04-076 Remover, Paint/ Carbon C04-033 Cleaner, Mild Alkaline
Turco Stripper No. 5351 Thick
Turco Super Carb
Turco Vitro-Klene
Turcoform Mask 540-R
C10-014 Maskant
TY-RAP P/N TY27M Type 1 Red Compound (M.P. 132 deg. F.) Type 1 Red Compound (M.P. 132 deg. F.) Type 215 Type BJ0-0930 Type BJ0-0930 Type FM-1000 0.005 in. to 0.007 in. thick Type FM-1000 0.005 in. to 0.007 in. thick
C10-152 Fastener, Self-Locking C10-181 Compound, Surface Impression C10-181 Compound, Surface Impression C06-019 Binder C10-093 Filler, Phenolic Microballoons C10-093 Filler, Phenolic Microballoons C01-103 Film C01-103 Film
EFFECTIVITY: ALL
70-80-20
Description Ultracal 30 Ultracal All Ultrachem Assembly Fluid No. 1 Unical 7214 Unitized wheel, level cut, 0.75 in x 0.125 in. x 0.125 in. Grade 5A, Fine
Supplier U. S. Gypsum Co. U. S. Gypsum Co. Ultrachem, Inc. Creanova 3M Company
Ref No. C01-124 Plaster, Stable C01-123 Plaster Stable C02-007 Assembly Fluid C03-020 Blue Coloring C10-117 Scotch Brite
Description V-9119 (Tan) Vac Pack, E3760-PS4 Vac-Pak, HS-8171 Valvoline Tectyl 894 (MIL-C16173 Type 3) Versene 220 Versilube G-321 Vertex VPC-72C VHP E210 Vibration Dampening Material, Unisorb HB-1/2 (Sheet 1/2 in. x 3 ft. x 5 ft.) Virgo Molten Salts Vitta-Braz 1013 Vitta-Braz 1090 Vitta-Braz 1142 Vitta-Braz 1777 Vitta-Braz 1778 Vitta-Braz 1778 Vitta-Braz 1779 Vitta-Braz 1782 Vitta-Braz 1782, Braze Tape
Supplier Ferro Color Division Richmond Aircraft Prod. Richmond Aircraft Prod. Ashland Chemical Inc. Dow Chemical Co. Foam Seal/Novagard Special Metals Corporation, Powder Division Master Chemical Co. Unisorb Installation Technologies Kolene Corp. Vitta Corporation Vitta Corporation Vitta Corporation Vitta Corporation Vitta Corporation Vitta Corporation Vitta Corporation Vitta Corporation Vitta Corporation
Ref No. C03-078 Coloring Pigment C10-056 Tape, Flash-breaker, Pressure Sensitive C10-137 Film, Vacuum Bag C02-059 Oil C04-139 Cleaner, Compound C02-031 Silicone C07-020 Copper-Nickel-Indium Powder C10-075 Coolant C10-030 Vibration Dampening Material C04-070 Cleaner, Molten Salt C06-003 Powder NickelAluminum C06-027 Nickel Braze Alloy C06-012 Braze Alloy, Powder C06-014 Braze Alloy Powder C06-013 Braze Alloy Powder C06-026 Braze Alloy Tape C06-002 Braze Alloy C06-015 Braze Alloy C06-017 Tape, Braze
EFFECTIVITY: ALL
70-80-20
Description WA-4 Walnut Shells Wax Strips-Preformed with adhesive back 1/2 x 1-1/4 thickness Wax, Paraffin, HM4899 WC-114 (Class A and B) WC-559 WD-40 Wear Strip Nylatron GS, 0.938 in. wide, 0.074 in. thick Weld Wire, 6-2-4-2 Ti
Supplier ITW Magnaflux Local Purchase Freeman Mfg. and Supply Co.
Ref No. C05-090 Water Conditioner C04-115 Abrasive, Other C10-002 Wax Strips
H.B. Fuller Co. Praxair / TAFA Indianapolis Praxair / TAFA Indianapolis WD-40 Company Penn-Fibre and Specialty Co. Astrolite Alloys Division of Astro Cosmos Metallurgical, Inc. Westaim Corp. Ruger Chemical Co. Witco Corp. Fibre Glass Evercoat Co. Fuchs Lubricants Co. Local Purchase GDC / City Wire Cloth
C10-099 Wax C07-007 Tungsten Carbide 12% Cobalt Aggregate C07-040 Powder, 17% Tungsten Carbide Cobalt C02-018 Penetrating Oil C10-066 Wear Strip Nylatron GS C06-018 Wire, Weld
Westaim 1601 White Fonoline White Fonoline White Star Windsor L-110 Wire Cutter, Flush Side Cushioned Wire Mesh, 304L Stainless Steel, Twill Dutch Weave, (Wire Diameters: Warp: 0.0024 in. Shute: 0.0018 In.) Wire Mesh, 304L Stainless Steel,Twill Dutch Weave, (Wire Diameters: Warp: 0.0024 in. Shute: 0.0018 In.) Wire Mesh, 304L Stainless Steel,Twill Dutch Weave, (Wire Diameters: Warp: 0.0024 in. Shute: 0.0018 In.) Wire Mesh, Aluminum, 0.0024 in. dia. x 0.0018 in. dia. Wire, 48.0 in. wide x 12.0 ft. long WL 6400
C07-037 Aluminum Silicon Polyester Powder C02-033 Petrolatum C02-033 Petrolatum C01-001 Body Filler C02-021 Oil, 1010 C10-149 Wire Cutter C10-119 Wire Mesh, 304L Stainless Steel
Gerard Daniel Company
C10-119 Wire Mesh, 304L Stainless Steel
SEFAR America
C10-119 Wire Mesh, 304L Stainless Steel
SEFAR America
C10-118 Wire Mesh, Aluminum
C10-137 Film, Vacuum Bag
EFFECTIVITY: ALL
70-80-20
Description WP-100 LSBD
Supplier Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies Turco Products, Inc. Subsidiary of Henkel Surface Technologies
WP-100H
C05-030 Penetrant
WP-170LSBD
C05-033 Penetrant
Description X-OFF P/N SFC 1735 (20/40), Plastic Blast Media (MIL-P85891, Type II, Grade A, 3.5 Mohs Hardness)
Supplier MPC Industries, Patent Plastics, Inc.
Ref No. C04-153 Abrasive, Plastic
Description Y434 Tape Y434 Tape
Supplier BGR, INC. 3M Company
Ref No. C10-188 Tape Vibration Damping Speed Tape C10-188 Tape Vibration Damping Speed Tape
Description Z150, Ceramic Peening Media, 0.006 - 0.008 in. (0.15 - 0.29 mm) Z210, Ceramic Peening Media 0.008 -0.016 in. (0.20 -0.41 mm) Z300, Ceramic Peening Media, 0.011 -0.017 in. (0.30 -0.425 mm) ZIP-D-5460NS MoS2 Colloidal Suspension (GE Spec. A50TF192 Class C) Zirspra 8 w/o YS (-200, +325)
Supplier SEPR Ceramic Beads and Powders SEPR Ceramic Beads and Powders SEPR Ceramic Beads and Powders Zip-Chem Products
Ref No. C04-161 Abrasive, Peening
C04-162 Abrasive, Peening C04-179 Abrasive, Peening
C02-004 Lubricant
Zircoa Products
C07-035 Zirconium OxideYttrium Oxide Composite Powder C01-113 Teflon Sheet
Zitex
Norton Performance Plastics Corporation
EFFECTIVITY: ALL
70-80-20
Description ZL-27A ZL-2C ZL-37 ZL-60D ZOK27, (Type II) ZOK27, (Type II) ZOK27-RTU, (Type IIRTU) ZOK27-RTU, (Type IIRTU) ZP-14A ZP-4B ZP-9F ZR-10B ZRO-113/114
Supplier ITW Magnaflux ITW Magnaflux ITW Magnaflux ITW Magnaflux Zokman Products, Inc Airworthy Ltd. Airworthy Ltd. Zokman Products, Inc ITW Magnaflux ITW Magnaflux ITW Magnaflux ITW Magnaflux Praxair / TAFA Indianapolis
Ref No. C05-023 Penetrant C05-022 Penetrant C05-024 Penetrant C05-025 Penetrant C04-140 Cleaner, Gas Path C04-140 Cleaner, Gas Path C04-140 Cleaner, Gas Path C04-140 Cleaner, Gas Path C05-061 Developer C05-061 Developer C05-066 Developer C05-053 Emulsifier and Solvent C07-035 Zirconium OxideYttrium Oxide Composite Powder C07-029 Powder, Magnesium Zirconate C07-035 Zirconium OxideYttrium Oxide Composite Powder
ZRO-218 ZrO-8%Y203 (-200, +325)
Praxair / TAFA Indianapolis Zircoa Products
EFFECTIVITY: ALL
70-80-20
EFFECTIVITY: ALL
70-80-20
INDEXED BY SUPPLIER - CONSUMABLE PRODUCTS INDEXED BY SUPPLIER TASK 70-80-30-800-021 1. Consumable Products - Indexed by Supplier SUBTASK 70-80-30-99G-021 A. Supplier 3M Company General. Trade Name 1300L Scotch-Grip Rubber and Gasket Adhesive 1870 Scotch Grip Industrial Adhesive 2086 Scotchweld Epoxy Adhesive 3M 211K (For grit sizes 80, 100, 120, 150, 180, 220, 240, and 320) 3M 2214 Scotchweld Structural Adhesive 3M 241K (For grit sizes 36, 50 and 60) 3M No. 250 3M Shipping Mate Labeling Adhesive 3M Super 77 Spray Adhesive 3M-203E 3M-241D 3M-301D AF-15 AF-191K (Class B) AF-191K (Class C) (0.08 wt) AF-3024 AF-3109-2U 0.035 psf AF-32 AF126-2 0.06 psf AF163-2K 0.085 AF163-2U Ref No. C01-173 Adhesive C01-037 Adhesive C01-105 Adhesive C10-187 Cloth, Abrasive Aluminum Oxide C01-146 Adhesive C10-187 Cloth, Abrasive Aluminum Oxide C10-189 Tape, Paint Adhesion Testing C01-051 Adhesive C01-027 Adhesive C10-196 Abrasive Cloth C10-196 Abrasive Cloth C10-196 Abrasive Cloth C01-137 Adhesive, Film C01-165 Adhesive C01-186 Adhesive C01-132 Adhesive, Foam C01-175 Adhesive C01-184 Adhesive C01-142 Adhesive Film C01-130 Adhesive Film C01-131 Adhesive Film
CONSUMABLE PRODUCTS INDEXED BY SUPPLIER Page 1 Dec 01/03
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name AF3109-2K 0.085 psf B38/4000 CA-5 Pronto Instant Adhesive EC 2174 EC 3500 B/A EC 3901 EC 3964 EC-3439 EC-3524 B/A EC-3917 EC-847 Light Deburring Wheel, Grade 5, Code 6B Scotch Brite No. 361 Cloth Tape No. 363 Aluminum Foil/Glass Cloth Tape No. 425 Aluminum Foil Tape No. 580-10 S38/4000 Scotch 35 Scotch Brand 5490, Teflon 1 x 0.002 in. thick Scotch Brite Pads No. 7440 (6.0 x 9.5 in.) Scotch Brite Pads No. 7447 (6.0 x 9.5 in.) UPC# 048011-04029 Scotch No. 27 Scotch No. 470, Tape Scotch No. 69 Scotch Weld AF-191U 0.50 psf Tape, Adhesive Dots (various sizes for masking) Tape, Flash-Breaker, No. 855, 0.002 in. Thick Tape, Masking, No. 218 Fineline TC330 1-1/4 x 9/16 in. (3M Number)
Ref No. C01-128 Epoxy Film C10-197 Hollow Glass Beads C01-109 Adhesive C01-138 Primer C01-071 Compound, Potting C01-141 Metal Adhesive C01-134 Adhesive C01-183 Compound C01-125 Adhesive C01-166 Primer, High Temperature C01-093 Adhesive C10-037 Light Deburring Wheel C10-209 Tape, Glass Cloth C10-216 Tape, Aluminum Foil/ Glass Cloth C10-210 Tape, Aluminum Foil C05-103Tape, Reflective C10-197 Hollow Glass Beads C10-180 Tape, Electrical C10-040 Tape, Teflon C10-211 Abrasive Cloth C10-010 Scotch Brite Pads C10-070 Tape, Glass Fiber C10-067 Tape, Platers C10-157 Class Cloth Tape C01-139 Adhesive Film C10-103 Tape, Adhesive Dots C10-136Tape, Flash-Breaker C10-102 Tape, Masking C10-111 Rotary Flap Peen Assembly
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Unitized wheel, level cut, 0.75 in x 0.125 in. x 0.125 in. Grade 5A, Fine Y434 Tape
Ref No. C10-117 Scotch Brite
C10-188 Tape Vibration Damping Speed Tape
Supplier A and B Deburring Co.
Trade Name BT11 or MIL 11 BT12 or MIL 12 F7-16C 0.44 in (11.2 mm) cylinder fine cut Sweco 30 deg. Angle Cut Cylinders B1-4 (1/4 dia. x 11/ 32) Sweco 30 deg. Angle Cut Cylinders B3-16 (3/16 dia. x 11/ 32) SWECO Burnishing No. 1 (Burnishing Soap) SWECO F3-8T Sweco XC 11-8t Sweco XC3-16 Sweco XC5-16 TR-103B TR-200
Ref No. C10-197 Hollow Glass Beads C10-197 Hollow Glass Beads C04-159 Abrasive, Tumbling C04-130 Abrasive, Tumbling
C04-040 Cleaner, Compound C04-032 Abrasive, Tumbling C04-019 Abrasive, Tumbling C04-020 Abrasive, Tumbling C04-017 Abrasive, Tumbling C04-131 Chemical C04-016 Cleaning Compound C04-038 Abrasive, Tumbling C01-013 Potting Compound C04-150 Compound, Surface Treatment C01-060 Epoxy C02-058 Graphite C02-066 Lubricant C02-068 Lubricant C02-039 Penetrating Oil C02-028 Graphite Coating C02-029 Graphite Coating C02-030 Graphite Coating C02-027 Lubricant
Abrasive Finishing, Inc. Accumetric, LLC
Tumblex 4TL EC 612 (Ribbon form only) Pasa-Jell 105 RSP-3 Kit
Acheson Colloids Co.
Acheson GP460 D180 D85 TER Dag 2404 Dag Dispersion No. 154 Dag Dispersion No. 200 Dag Dispersion No. 213 Molydag 254
EFFECTIVITY: ALL
70-80-30
Supplier Aeroquip E.F.G. Aerospace Group
Trade Name SB-2 Aeroquip AE272 Flexwrap Fire Sleeve Size -13 Aeroquip AE272 Flexwrap Fire Sleeve Size -14 Aeroquip AE272 Flexwrap Fire Sleeve Size -15 Aeroquip AE272 Flexwrap Fire Sleeve Size -3 Aeroquip AE272, Flexwrap Fire Sleeve Size -11 Aeroquip AE272, Flexwrap Fire Sleeve Size -4 Aeroquip AE272, Flexwrap Fire Sleeve Size -6 Aeroquip AE272, Flexwrap Fire Sleeve Size -9
Ref No. C04-231 Solvent C10-175 Aeroquip AE272 Flexwrap Fire Sleeve Size -13 C10-176 Aeroquip AE272 Flexwrap Fire Sleeve Size -14 C10-177 Aeroquip AE272 Flexwrap Fire Sleeve Size -15 C10-174 Aeroquip AE272 Flexwrap Fire Sleeve Size -3 C10-163 Aeroquip AE272, Flexwrap Fire Sleeve Size -11 C10-160 Aeroquip AE272, Flexwrap Fire Sleeve Size -4 C10-161 Aeroquip AE272, Flexwrap Fire Sleeve Size -6 C10-162 Aeroquip AE272, Flexwrap Fire Sleeve Size -9 C06-040 C02-078 Lubricant C01-039 Catalyst C10-133 Film, Polymer FEP, Un-perforated, C10-132 Film, Polymer C10-134 Cloth, Breather/ Bleeder C10-136 Tape, Flash-Breaker C10-138 Tape, Sealant, Vacuum Bag C10-179 Cloth, Class PTFE Coated (Non-porous) C10-178 Cloth, Glass PTFE Coated (Porous) C10-137 Film, Vacuum Bag C04-140 Cleaner, Gas Path C04-140 Cleaner, Gas Path C03-013 Gray Paint C03-013 Gray Paint
Aerospace International Materials (AIM)
B50TF307, Class A Molykote G-n Paste (USA), (GE Spec. A50TF313, Class C)
Air Products and Chemicals Inc. Airtech International Inc.
Ancamine-Z Curing Agent A4000 A4000P3 Airweave N10 Flash-Breaker 2 GS-213 Release Ease 234 TFNP Release Ease 234 TFP WL 6400
Airworthy Ltd. Akzo Nobel Aerospace Coatings
ZOK27, (Type II) ZOK27-RTU, (Type IIRTU) 23T3-105 (Fastcure) 24T3-105 (Fastcure)
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name PC-216 Sikkens S 21/8
Ref No. C03-014 Hardener C03-054 Aluminum-Silicone Resin Pain C04-243 Cleaner, Powdered C04-095 Chemical C06-035 Braze Foil C04-158 Remover, Coating C10-100 Seal, Aluminum C05-005 Liquid, Leak (Bubble) Test (ASTM E515) C02-081 Lubricant C04-235 Acid, Inhibited phosphoric C04-236 Cleaner, Acid descaler C04-234 Cleaner, Alkaline permanganate C04-233 Alkaline Deruster C10-090 Polygard Protector C10-090 Polygard Protector C10-090 Polygard Protector C10-090 Polygard Protector C02-073 Oil C10-125 Tape, Silicone SelfAdhering C10-125 Tape, Silicone SelfAdhering C04-256 Hand Wipe Solvent C02-054 Neutralizer C02-059 Oil C01-072 Adhesive C10-093 Filler, Phenolic Microballoons C10-110 Almen Test Strips C10-205 Almen Strips for Shot Peening
Alconox, Inc. Aldrich Chemical Co., Inc. AlliedSignal Amorphous Metals Alloy Surfaces Co., Inc. American Casting and Mfg. Co. American Gas and Chemical Company, Ltd. Anchor Chemical Company Applied Chemicals International Pty. Ltd.
Alconox Dimethyl Sulfoxide (DMSO) MBF50A ASC 2-N (Aluminide Coating) Seal. Aluminum No. A-1 Leak-Tec 16-OX Anchorlube G-771 Applied 2-690 Applied 2-751 Applied 5-770 Applied 5-840
APW Zero Cases
MP9000-0500 (0.5 in width) MP9000-1000 (1.0 in width) MP9000-1500 (1.5 in width) MP9000-2000 (2.0 in width)
Argent Ltd. Arlon Inc., Silicone Technologies Division
IC-9 920-07 (0.75 in. wide) 920-10 (1.0 in. wide)
Arrow Chemicals Ltd. Ashland Chemical Inc.
Supersolve AS Tectyl 275 Valvoline Tectyl 894 (MIL-C16173 Type 3)
Ashland Chemicals Asia Pacific Microspheres (Manufacturer) Associated Spring Barnes Group Inc.
Pliobond 20 Type BJ0-0930 Almen A Almen N
EFFECTIVITY: ALL
70-80-30
Supplier Astro Chemical Co., Inc. Astrolite Alloys Division of Astro Cosmos Metallurgical, Inc. Atofina Chemicals
Trade Name Barco Bond MB-165 Weld Wire, 6-2-4-2 Ti
Ref No. C01-028 Adhesive C06-018 Wire, Weld
Fascat 2003
C01-005 Catalyst
Supplier B and B Tritech Inc. B.C.S Company, Inc.
Trade Name B and B 3100 (Type I) B and B TC-100 (Type II) BCS No. 08-PB BCS No. 08-PC BCS No. 11L84
Ref No. C04-140 Cleaner, Gas Path C04-140 Cleaner, Gas Path C04-144 Abrasive, Tumbling C04-145 Abrasive, Tumbling C04-146 Cleaner, Compound C01-095 Elastomer C10-045 Carbide Cutter C07-015 85:15 Nickel-Graphite Powder C07-014 75:25 Nickel-Graphite Powder C07-017 Aluminum Powder C07-001 Molybdenum Powder C07-003 Aluminum Oxide Powder C07-012 Nickel-Chromium Powder C07-012 Nickel-Chromium Powder C07-007 Tungsten Carbide 12% Cobalt Aggregate C04-042 Remover, Paint/ Cleaner C10-143 Safety Cable Assembly C10-145 Cable, Safety Cable C10-144 Ferrule, Safety Cable C10-148 Crimping Tool C10-148 Crimping Tool C10-147 Tester, Safety Cable
Bacon Industries Bassett Rotary Tool Co. Bay State Surface Technologies, Inc.
Flexobond 329 Kit Burr BC-0 1/8 Dia Cut EDP # 54873 Bay State PP-10A Bay State PP-11A Bay State PP-20 Bay State PP-21 Bay State PP-32 Bay State PP-64 (GE Spec. B50TF40 Class B Fine) Bay State PP-65 (GE Spec. B50TF40 Class A Coarse) Bay State PP-75 (Class A and B)
Beck Chemical, Inc. Bergen Cable Technologies, Inc.
No. T-251-C 736L680G01, 0.032 in. dia. Kit K30B18 C30B18 F30B M303 M307 MPT-200A
EFFECTIVITY: ALL
70-80-30
Supplier BF Goodrich Ice Protection Systems BGF Industries BGR, INC.
Trade Name TB 101 74-451-182 Style 120, Finish 538 NT-580, Red Y434 Tape
Ref No. C10-146 Test Block C01-185 Polyurethane Sheet C10-122 Glass Cloth C10-021 Tape, Duct C10-188 Tape Vibration Damping Speed Tape C10-055 Heat Blankets, Controllers and Lamps C04-207 Cleaner, Compound C10-207 Swabs
BH Thermal Corp. BioChem Systems, Div. of Golden Tech. Birchwood Casey Div., Birchwood Laboratories, Inc.
Heat Blankets, Controllers and Hot Bonders Bio-T-Max 16 inch Comfort Tip Applicators, Scopettes Brand, Stock Number 34-7023-12 Presto-Black BST4 (Dilute Aqueous Acid)
C03-049 Black Oxide Touch-up C03-073 Paint, Epoxy C02-071 Anti-Seize C02-060 Anti-Seize Compound C02-060 Anti-Seize Compound C10-116 Filler, Graphite Fibers C10-206 Tape, Glass Lacing and Tying C10-012 Tape, Masking High Temperature C10-172 Flex-hones, 120 grit Silicon Carbide C10-164 Flex-hones, 120 grit Silicon Carbide C10-165 Flex-hones, 120 grit Silicon Carbide C10-168 Flex-hones, 120 grit Silicon Carbide C10-201 Cloth, Polishing C10-082 Aluminum Oxide C10-083 Aluminum Oxide, Slurry 0.05 micron
Bollore Bostik, Inc. (Domestic Sales)
FE 2640 Never-Seez Pure Nickel Special Grade Never-Seez Regular Grade Never-Seez Regular Grade Thornel Mat VMX-11 402-3/5X Bron # BRP 1864-8R-GE BC 10mm (0.394) BC 6.4mm (0.250) BC 6.8mm (0.315) BC 9mm (0.354)
Bostik, Inc. (International Sales) BP Amoco Polymers Inc. Breyden Products, Inc. Bron Tapes Brush Research Mfg. Co. Inc.
Buehler Limited
Microcloth Micropolish 40636006 or 406363128 Micropolish 406365006
EFFECTIVITY: ALL
70-80-30
Supplier Cabot Corporation Caig Laborotories, Inc.
Trade Name Cab-O-Sil TS-720 CaiKleen TNX Tarnish Remover Pro Gold GX100L Pro Gold GX5L
Ref No. C10-022 Filler, Fumed-Silica Viscosity Control Agent C04-259 Electrical Contact Cleaner C04-258 Electrical Contact Cleaner/ Lubricant C04-258 Electrical Contact Cleaner/ Lubricant C02-079 Lubricant C10-048 Cloth, BleederOsnaburg C10-025 Grinding Wheel C02-021 Oil, 1010 C02-025 Oil, Preservation C02-051 Corrosion Inhibitor C02-054 Neutralizer C02-001 Anti-Seize Compound C02-016 Grease C10-197 Hollow Glass Beads C10-197 Hollow Glass Beads C10-197 Hollow Glass Beads C07-003 Aluminum Oxide Powder C10-033 Matrix, Low Melting Alloy C02-040 Lubricant C04-037 Remover, Paint/ Carbon C04-037 Remover, Paint/ Carbon C04-141 Remover, Paint/ Carbon C04-249 Cleaner, Exterior Surface C04-120 Acid C02-042 Oil
Calvary Chemical Corp. Canvas Specialties Carborundum Co. Castrol Industrial North American Inc.
Cal Lube 7030 Cloth, Bleeder-Osnaberg Grinding Wheel, A24QBFCW1/ 4 Type 27 Brayco 460 Brayco 483 Brayco 599 Braycoat 120 Braycoat 655 Castrol EASE AI
Cataphote Inc.
Glass Bead Size 11 Glass Bead Size 12 Sovitec T 212
Ceramic Grains and Powder Division Norton Company / Division of Saint Gobain Cerro Metal Products Co. Alloy Dept. Champions Choice, Inc. Chemetall Oakite
Norton 112
CerroLow 136 Microfinish Oakite 156 Oakite 157 Oakite Stripper A2
Chemetall Plc Chemtech Finishing Systems Chicago Pneumatic Tool Co.

EFFECTIVITY: ALL
Ardrox 6025 Phos-It (Inhibited Phosphoric Acid) No. P-89507 / 8
70-80-30
Supplier Chromalox
Trade Name Chromalox Cartridge Heater Cat. No. CIR 3031 (3.0 in. x 0.5 in. dia) Cimperial 1070 ALSEAL 519 Conapoxy AD-10 Conathane TU 901 B38/4000 Corrotherm CT33M CT-404 CRC Precision Cleaner Plus CRC Super Degreaser
Ref No. C10-091 Cartridge Heater
Cincinnati Milacron Coatings For Industry Inc. Conap, Inc. Consortium International Pharmaceutiques et Chimique Corro Therm Inc. CRC Industries, Inc
C02-047 Cutting Fluid C03-091 Paint C01-100 Epoxy C03-058 Casting Resin C10-197 Hollow Glass Beads C03-055 Aluminum Paint C03-040 Coating C04-254 Cleaner, Electrical Contact C04-253 Cleaner, Electrical Contact C03-019 Yellow Coloring C03-029 Black Lamp C03-020 Blue Coloring C03-080 Paint C03-036 Paint C03-086 Primer C03-007 Primer C01-166 Primer, High Temperature C01-098 Adhesive C01-127 Epoxy Material C10-130 Cloth, Glass Fiber C10-112 Fabric, High Strength Woven Graphit C01-182 Adhesive C01-165 Adhesive C01-103 Film C01-066 Epoxy Film C01-098 Adhesive
Creanova
Class B Unical 8661810 No. 866 Pigment Unical 7214
Creative Coatings Co. Inc. Cytec Engineered Materials Inc.
Series 646-58-6473 TT-E-527 Color 36231 BR 6747-1 BR-127 BR-154 BR-34B-32 Primer CYCOM 919 GFK 3070 PW T300 Fiber Weavestyle 3K E773FR/120 Fabric, High Strength Woven Graphite 12.5x12.5 tows/in. W322 FM 300M .08 psf FM 350 NA S .09 psf FM-1000 .03 psf 0.005 in. to 0.007 in. thick FM-123-5 .06 psf FM-34B-32 Adhesive (Supported or Unsupported)
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name FM-96 FM-96U FM350U NA .06 psf FM410-1 FM490A HT424 Supported Film (0.135 psf) HT424 Two Part Primer HT424 Two Part Thixotropic Paste M6725-1 MXB 7740/120
Ref No. C01-111 Adhesive Film C01-112 Adhesive Film C01-139 Adhesive Film C01-132 Adhesive, Foam C01-132 Adhesive, Foam C01-054 Adhesive C01-099 Primer C01-053 Adhesive C01-067 Primer C10-130 Cloth, Glass Fiber C01-053 Adhesive
Cytec Eur.
HT424 Two Part Thixotropic Paste
Supplier D & B Industrial Daniels Mfg. Corp.
Trade Name Tape, Silicone Self-Adhering (GE PN 3003M70) 736L680G01, 0.032 in. dia. A10-218 F10-02 MPT-200A-SC SCT-TB1 SCT323 SCT327
Ref No. C10-125 Tape, Silicone SelfAdhering C10-143 Safety Cable Assembly C10-145 Cable, Safety Cable C10-144 Ferrule, Safety Cable C10-147 Tester, Safety Cable C10-146 Test Block C10-148 Crimping Tool C10-148 Crimping Tool C03-077 Primer, WaterReducible Epoxy C03-079 Primer C02-021 Oil, 1010 C01-083 Adhesive C10-012 Tape, Masking High Temperature C10-012 Tape, Masking High Temperature C10-012 Tape, Masking High Temperature
Deft Inc.
44-GN-11 Deft 44-W-7
Delta Petroleum Inc. Dentsply/Caulk Division DeWal Industries
Hydrocol Jet Grip Cement Kit No. 675570 D/W 410 D/W 497 D/W 498
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name D/W 500 D/W 501
Ref No. C10-012 Tape, Masking High Temperature C10-012 Tape, Masking High Temperature C10-098 Dip Seal Type 2 C02-011 Graphite C05-111 Chalk C10-185 Light Source C10-184 Cable, Fiber Optic C10-186 Pipe Light C10-183 Adapter, Light Pipe C04-169 Cleaner, Compound C04-139 Cleaner, Compound C01-172 Sealant C01-006 RTV C01-007 RTV C01-154 RTV C01-158 RTV C01-014 Silicone Adhesive C01-153 RTV C02-062 Grease C02-045 Lubricant C02-062 Lubricant C02-057 Lubricant C02-069 Lubricant C02-009 Lubricant C10-129 RTV, Casting Material C01-179 Primer C01-151 Silicone Rubber C02-069 Lubricant C02-003 Lubricant C02-003 Lubricant
Dip Seal Plastic Inc. Dixon Ticonderoga Dixon Ticonderoga Co. Dolan-Jenner Ind. Inc.
Dip Seal Type 2, Code DS 58-7 Dixon No. 635 Dustless Chalk P/N 31144 170D B248 SK10040-0000 SX-5
Dow Chemical Co. Dow Corning Corp.
Diammonium EDTA Versene 220 3145 RTV 732 Black Multi-Purpose Sealant 736 Red Heat Resistant Sealant 90-006 93-006 Dow Corning 1200 Primer Red or Clear Dow Corning 730 Solvent Resistant Sealant Dow Corning1 33 Extreme Low Temperature Grease M8800 Molykote 33 Molykote 3400A Molykote M-77 Molykote Type Z RTV3110 S2260 Prime Coat Sylgard 170 Parts A and B
Dow Corning Corp. (France) Dow Corning Europe SA Dow Corning France SA
Molykote U-n (Available in Europe Only) Molykote D 321 R Molykote D 321 R
EFFECTIVITY: ALL
70-80-30
Supplier Drilube Co. DuBois Chemical Co.
Trade Name Spray Mix Type I Additive 73B (DuBois) C-1102 (Liquid) Jettacin
Ref No. C02-010 Lubricant C04-013 Chemical Additive C04-045 Cleaner, Compound C04-172 Solvent, General C10-039 Plastic Tape, High Shrink C05-087 Suspension Fluid C06-032 Alloy Powder
Dunstone Company Inc. Dynamation Research, Inc. Dynamet Powder Products
Hi-Shrink Tape, 0.002x1 in. AMS 3160 G183
Supplier E. V. Roberts and Associates E/M
Trade Name EPON 828 Everlube 810 (Concentrate) Everlube 811 or MIL-L-81329 equivalent Everlube ESNA 382 Formkote T-50
Ref No. C01-017 Epoxy C02-049 Lubricant C02-005 Lubricant C02-006 Lubricant C02-035 Anti-Seize Graphite C05-110 Wetting Agent C05-110 Wetting Agent C05-110 Wetting Agent C05-110 Wetting Agent C04-257 Cleaner, Electrical Contact C04-198 Solvent, General C04-140 Cleaner, Gas Path C04-140 Cleaner, Gas Path C05-099 Emulsifier C05-096 Developer C05-095 Developer C05-098 Emulsifier C05-093 Penetrant C05-097 Developer C05-094 Emulsifier
Eastman Kodak Co.
Photo-Flo 200, Catalog No. 146 4502-4 Fl oz. Photo-Flo 200, Catalog No. 146 4510-16 Fl oz. Photo-Flo 2100, Catalog No. 141 8904-1 gallon Photo-Flo 600, Catalog No. 146 4528-1 gallon
Ecolink, Inc.
Eco Spray Positron
ECT Inc.
R-MC Engine Cleaner, (4070 Type II) R-MC Engine Cleaner, (4072 Type IIRTU)
Eishin Kagaku Co., Inc.
F-4A-C/1 F-4S (NT) /1 F-5D/1 F-5E-SP/1 F-6A-SP/1 F-6A/1 F-6E-W/1
EFFECTIVITY: ALL
70-80-30
Supplier Eldorado Chemical Co., Inc.
Trade Name Eldorado AC-111 Eldorado AC-183 Eldorado ED-306LF Eldorado HTP-1150 and Additive ATP 1150A Eldorado HTP-1150L and Additive HTP-1150A Eldorado HTP-1190 Eldorado HTP-1190L ES-6
Ref No. C04-216 Cleaner, Acid Descaler C04-217 Acid C04-218 Cleaner, Heavy Duty Alkaline C04-212 Cleaner, Mild Alkaline C04-213 Cleaner, Mild Alkaline C04-214 Cleaner, Alkaline Permanganate C04-215 Cleaner, Alkaline Permanganate C05-087 Suspension Fluid C02-070 Grease C10-110 Almen Test Strips C10-205 Almen Strips for Shot Peening C04-228 Solvent C04-155 Remover, Plating C04-082 Remover, Plating C04-244 Remover, Plating C04-156 Remover, Plating C04-008 Remover, Coating C04-092 Remover, Plating C04-157 Chemical Additive C04-246 Remover, Plating C04-083 Remover, Plating C10-213 Teflon Sheet C10-212 Teflon Sheet C01-077 Sealing Compound C02-025 Oil, Preservation C02-014 Molybdenum Disulphite
Electrolube Electronics Inc.
SGB/2GX Almen Strips, Type A (0.0500.052 in.) Almen Strips, Type N (0.0300.032 in.)
EM Science Enthone, Inc.
Alcohol, Ethyl, Anhydrous, Denatured EN-79 Nickel Stripper Part A and Part B Enstrip A (Powder) Enstrip EN-86 Enstrip GT 317 Enstrip L-90 Enstrip Q516 Enstrip Regenerator Enstrip S Enstrip T-L (Concentrated Power)
EPM, Inc.
PTFE (Teflon) 25% GlassFilled Sheet PTFE (Teflon) Mechanical Grade Sheet
Epoxylite Corp. Equilon Enterprise
Epoxylite, 6203 Aeroshell Fluid 2T Aeroshell Grease 17
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Aeroshell Grease 7 Aeroshell Turbine Oil 2
Ref No. C02-016 Grease C02-021 Oil, 1010 C10-079 Cellulose, Acetate C10-031 Polyimide PaperDense Laminate C10-031 Polyimide PaperDense Laminate
Ernest F. Fullam, Inc. Essex Group Inc. IWI Operations
PN11340, (Replicating Tape 5 mil thick) Nomex 410 (Sizes 0.024, and, 0.030 in. available) Nomex 411, (Sizes 0.028/0.025 x 1.175/1.145 x 30.0 in.)
Supplier Fairchild Fasteners Direct Ferro Color Division Ferro Corp. Ferro Corp., Color Division Fiber-Resin Corp. Fibre Glass Evercoat Co. Field Abrasive Mfg. Co. Inc. Fine Organics Corp. Fire Research Lab. Fisher Scientific Co.
Trade Name Seal, Conical, VSF1015-N-3 Seal, Conical, VSF1015-N-4 V-9119 (Tan) 22-38010 61-860700 (Black) EY 4014 A and B Cream Hardener White Star PSA 2 in. dia., 120 S/C Envirosolv 655 Ocean No. 1522 Diethylenetriamine (High Purity Grade) Methylthymol Blue Fisher Reagent AC-414940010
Ref No. C10-028 Seal, Conical C10-029 Seal, Conical C03-078 Coloring Pigment C01-102 Coloring Pigment C03-023 Pigment C01-078 Adhesive C01-002 Catalyst C01-001 Body Filler C10-073 Abrasive Disk C04-252 Cleaner, Electrical Contact C03-003 Paint C01-024 Catalyst C04-138 Chemical C04-107 Remover, Paint/ Carbon C03-024 Panit C03-025 Paint C10-041 Impression Material C10-126 Impression Material C10-126 Impression Material C10-125 Tape, Silicone SelfAdhering
Flame Control Coating Inc.
Flame Control No. 11 Flame Control No. 170 Flame Control No. 190 Top Coat
Flexbar Machine Corp.
Facsimile No. 16130, Repro-rubber, Quicksetting Putty (1 3/4 lb.) No. 16131, Repro-rubber, Quicksetting Putty (7 lb.)
Flexfab
MOX-Tape 620-.5 (0.5 in. wide)
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name SB00520 (0.5 in. wide) SB01020 (1 in. wide)
Ref No. C10-151 Tape, Silicone SelfAdhering C10-151 Tape, Silicone C01-113 Teflon Sheet C02-031 Silicone C02-003 Lubricant C10-156 Wax, Laser Beam Stopping C10-002 Wax Strips
Fluoro Plastics Inc. Foam Seal/Novagard Fournier Freeman Mfg. and Supply Co.
Grade 50-55 Porous PTFE Versilube G-321 Molykote D 321 R Freeman Sheet Wax #165 Regular Plain Wax Strips-Preformed with adhesive back 1/2 x 1-1/4 thickness
Fuchs Lubricants Co. Furon Tape Division / Division of Saint Gobain
Windsor L-110 3807 Fiberglass Tape 23816 Fluorglas 2905-7 Tape #9710 Fluorglas 2975-8R Metal Tape 26020 Mystik 7000 Rubber, Silicone Sheet, molded, 0.125 inch (3.2 mm) thick
C02-021 Oil, 1010 C10-157 Class Cloth Tape C10-012 Tape, Masking High Temperature C10-012 Tape, Masking High Temperature C10-012 Tape, Masking High Temperature C10-012 Tape, Masking High Temperature C10-157 Class Cloth Tape C01-189 Rubber, Silicone Sheet
Supplier G and P Machinery Corp.
Trade Name 320 Grit, 2 X 16 in LDG, S/C, WP 1/4 in. Shred SH-1030-2 in 32 Brush Vonnegut Head with long trim brush SH-306 2 in. long trim brushes
Ref No. C10-062 Abrasive Cloth C10-060 Brush Unit
C10-061 Brush, Replaceable Type Sh-306 C10-119 Wire Mesh, 304L Stainless Steel
GDC / City Wire Cloth
Wire Mesh, 304L Stainless Steel, Twill Dutch Weave, (Wire Diameters: Warp: 0.0024 in. Shute: 0.0018 In.) 3-10 CS Viscosity
GE Company, Silicone Products Division

EFFECTIVITY: ALL
C02-022 Silicone
70-80-30
Supplier
Trade Name FRV 1106 RTV 103 (Black) (GE Spec. A15F6A3) RTV 106 (Red) (GE Spec. A15F6B6) RTV 108 (Translucent) RTV 109 (Aluminum) RTV 118 (Translucent) RTV 133 (Black) RTV 157 (Gray) RTV 159 (Red) RTV 167 RTV 560 (Red) RTV 577 (White) RTV 5812 RTV 5813 RTV 60 (Red) RTV 615 (Clear) RTV 630 (Blue) RTV 664 (Blue) RTV 88 (Red) SS4004 (Pink) SS4155 (Blue) STO
Ref No. C01-153 RTV C01-006 RTV C01-007 RTV C01-056 Silicone Rubber C01-076 Silicone C01-094 RTV C01-176 RTV C01-122 Adhesive C01-178 RTV C01-172 Sealant C01-008 Silicone C01-049 Potting Compound C01-191 RTV, Silicone Elastomer C01-192 RTV, Silicone Elastomer C01-075 Silicone C01-164 Sealing Compound C01-042 Silicone Rubber C01-086 Silicone C01-150 Silicone Rubber C01-159 RTV Primer C01-092 Primer C01-005 Catalyst C03-093 Paint, Inorganic, Aluminum C01-092 Primer C10-119 Wire Mesh, 304L Stainless Steel
Gebruder M. und M. Morant GMBH General Electric France Gerard Daniel Company
Ceral 114 SS4155 (Blue) Wire Mesh, 304L Stainless Steel,Twill Dutch Weave, (Wire Diameters: Warp: 0.0024 in. Shute: 0.0018 In.) 86009 Glyptal 1201 S1193 S1194 S1195
GLYPTAL, INC.
C03-030 Aluminum Paint C01-038 Varnish C03-034 Paint C03-041 Paint C03-035 Reducer
EFFECTIVITY: ALL
70-80-30
Supplier Golden Empire Corp. Grainger Parts Greenfield Industries
Trade Name Solar Flux, Type I Gun, Heat Cat. No. 010 0083-20, (Burr, 1/8 in. Spherical Carbide) Cat. No. 048-1033-20 (Burr, 1/4 in. Spherical Carbide)
Ref No. C06-030 Flux, Welding C10-054 Gun, Heat C10-104 Burr, 1/8 in. C10-106 Burr
Supplier H.B. Fuller Co. H.C. Starck GmbH and Co KG
Trade Name Wax, Paraffin, HM4899 Amperit 281.287, (GE Spec. B50TF56, Class B) Amperit 282.296, (GE Spec. B50TF56, Class A) Amperit 286.295 Amperit 299.297 Amperit 413.284 Amperit 591.294 Amperit 742.298 Amperit 827.774
Ref No. C10-099 Wax C07-016 Nickel-Aluminum Composite Powder C07-016 Nickel-Aluminum Composite Powder C07-011 Nickel-Aluminum Composite Powder C07-022 Aluminum-Nickel Chromium Composite Powder C07-032 Nickel Chromium Aluminum Yttrium Powder C07-008 Chromium Carbide NiCr-C0- Matrix C07-003 Aluminum Oxide Powder C07-035 Zirconium OxideYttrium Oxide Composite Powder C07-016 Nickel-Aluminum Composite Powder C07-016 Nickel-Aluminum Composite Powder C07-011 Nickel-Aluminum Composite Powder C07-022 Aluminum-Nickel Chromium Composite Powder C07-032 Nickel Chromium Aluminum Yttrium Powder C07-008 Chromium Carbide NiCr-C0- Matrix C07-003 Aluminum Oxide Powder
H.C. Starck Inc.
Amperit 281.287, (GE Spec. B50TF56, Class B) Amperit 282.296, (GE Spec. B50TF56, Class A) Amperit 286.295 Amperit 299.297 Amperit 413.284 Amperit 591.294 Amperit 742.298
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Amperit 827.774
Ref No. C07-035 Zirconium OxideYttrium Oxide Composite Powder C04-169 Cleaner, Compound C02-056 Inhibitor C02-056 Inhibitor C02-048 Preservation Treatment C03-043 Compound, Molten Salt Chemical Surface Treatment C03-092 Coating C03-006 Coating C03-081 Coating C03-082 Coating C03-008 Conversion Coating C04-050 Cleaner, Heavy Duty Alkaline C03-046 Acid, Mixture/Solution C04-248 Inhibitor C04-010 Inhibitor C04-242 Inhibitor C04-010 Inhibitor C10-003 Fabric Glass C10-113 Honeycomb Core C10-008 Honeycomb Cor, Phenolic Reinforced Polyamid Fiber C10-050 Honeycomb C01-063 Epoxy C02-065 Lubricant C04-223 Tacks C06-041 Braze Foil C10-071 Safety Wire C10-071 Safety Wire
Hampshire Chemical Corp. Harry Miller Corp.
Hampene Diammonium EDTA Immunol 1228 Steelgard 1301DC Steelgard 1315
Heatbath Corp.
Nickel Penetrate Salts
Henkel Surface Technologies
Alodine 1132 Alodine 1200S Alodine 1200SRTU Alodine 1201 Alodine No. 1500 Ferlon Parcolene 41 Rhodine 51 Rodine 213 Rodine 31A Rodine XL1090
Hexcel Corporation
Fabric, Style No. 1581 HRH-10-1/8-3.0 HRH-10-3/8-3.0 (Specify 3/8 in. Thickness and Desired Length and Width) Nomex Honeycomb HRH-10 (0.1875 in cell, 3/16 in. thick) Reliabond 380
Hohman Plating and Mfg., Inc. Holland Manufacturing Co. Honeywell Amorphous Metals Honeywell Hardware Products Group
Surf-kote LOB-1800G Tacks, #3 Blued Cut METGLAS MBF 20 AMS 5685, (305 Stainless Steel), Safety Wire AMS 5687, (Inconel 600) Safety Wire
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name AMS 5689, (321 Stainless Steel) Safety Wire AMS 5690, (316 Stainless Steel) Safety Wire
Ref No. C10-071 Safety Wire C10-071 Safety Wire C10-046 Foil C02-054 Neutralizer C10-027 Binder, Aerobraze C10-020 Braze Stop-Off C06-019 Binder
Hoskins Mfg. Co Houghton International HTG Metal Methods
Chromel C Cosmoline 1104 Binder, Type 105 Braze Stop-Off, Type 110 (White) Type 215
Supplier ICI Paints Division Industrial Quartz Industrial Services, Inc. International Products Corporation (UK) International Products Corporation (USA) ISP Technologies, Inc. ITW Devcon
Trade Name Alocrom 1200 Brush Alocrom 1200 DIP Quartz Pins Allison VA1202 MRA P-80 P-80 M-PYPROL Devcon Plastic Steel, Liquid B (P/N 10210: resin plus catalyst kit) Devcon Release Agent #19600 EGA-503 (Devilbiss) JGA-510 (Devilbiss) 14 A Powder Daraclean 282 Daraclean 282GF Deodorized, High Flash Point Kerosene, Carrier II Rust Lick B WA-4 ZL-27A ZL-2C
Ref No. C03-084 Coating C03-083 Coating C10-023 Quartz Pins C10-200 Cut Off Wheel C02-076 Lubricant, Rubber C02-076 Lubricant, Rubber C04-090 Solvent, General C10-034 Plastic Steel
C10-035 Release Agent C10-087 Gun, Paint Spray C10-087 Gun, Paint Spray C05-088 Magnaglo Powder C04-168 Cleaner, Mild Alkaline Water Based C04-168 Cleaner, Mild Alkaline Water Based C04-181 Suspension Fluid C04-025 Rust Preventative C05-090 Water Conditioner C05-023 Penetrant C05-022 Penetrant
ITW Industrial Finishing ITW Magnaflux
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name ZL-37 ZL-60D ZP-14A ZP-4B ZP-9F ZR-10B
Ref No. C05-024 Penetrant C05-025 Penetrant C05-061 Developer C05-061 Developer C05-066 Developer C05-053 Emulsifier and Solvent C05-003 Marking Pens C05-003 Marking Pens C05-003 Marking Pens
ITW Mark-Tex
P/N 44404, Black D50TF8, Action Marker Nuclear Grade P/N 44729, White D50TF8, Action Marker Nuclear Grade P/N 55608, # 55 Valve Action Marker, # Y-608 Black Washout, High Purity P/N 80404, Q-404 High Purity Ink, Nuclear Grade
C05-004 Ink, Stamp Pad C05-002 Ink, Marking
ITW-Dykem Co.
Dykem (Steel Blue Layout Fluid, Transparent Blue Staining Color) Dykem Hi Spot Blue (No. 107) Dykem Remover and Thinner (No. 138)
C05-020 Dykem Hi Spot Blue C05-021 Dykem Remover and Thinner
Supplier J.S. McCormick Co. JAD Chemical Co. Josef Frohn
Trade Name Powdered Coke MA 109C (Type II) MA 110RTU (Type II) CCW14, Conditioned Cut Wire Steel Shot (GE Spec. D50TF11 Class B) CCW20 CCW31, Conditioned Cut Wire Steel Shot (GE Spec. D50F11CLB)
Ref No. C04-026 Abrasive C04-140Cleaner, Gas Path C04-140 Cleaner, Gas Path C04-166 Abrasive, Peening
JT Baker Inc.
Dimethyl Sulfoxide (DMSO)
C04-095 Chemical
EFFECTIVITY: ALL
70-80-30
Supplier Kamen Wiping Materials Co., Inc. Kano Laboratories Kenneth Industrial Products, Inc. Kerr Corp. Kindt-Collins Co.
Trade Name Kamen 900-1217 Kamen 900-99 Aerokroil (Aerosol) Kroil (Liquid) Plastiseal F Type 1 Red Compound (M.P. 132 deg. F.) SW 12 Wax Billet, Flat, In Broken Chunks Part No. 499A04 RL-6000-SA Series Degreasol 99-R CCW14 CCW20 CCW31, Conditioned Cut Wire Steel Shot (GE Spec. D50F11CLB)
Ref No. C10-182 Cloth, Cleaning C10-182 Cloth, Cleaning C02-053 Penetrating Oil C02-053 Penetrating Oil C01-004 Compound, Sealing C10-181 Compound, Surface Impression C10-156 Wax, Laser Beam Stopping C10-151 Tape, Silicone C04-171 Solvent, General C04-166 Abrasive, Peening C04-167 Abrasive, Peening C04-178 Abrasive, Peening
Kirkhill-TA Co. Kleer-Flo Co. KME
Kolene Corp.
Alko N Salt Kolene 1 Kolene DGS Virgo Molten Salts
C04-154Cleaner, Molten Salt C04-103Cleaner, Molten Salt C04-091Cleaner, Molten Salt C04-070Cleaner, Molten Salt C04-029Paint Thinner C04-024 Solvent, General C02-080 Lubricant
Kop-Coat, Inc. Kop-Coat, Inc. (Vernon, CA) Krylon Products Group, the Specialty Div. of SherwinWilliams Co.
Kop-Coat Reducer, T-1329-66 (Type II Epoxy) Brolite AA-59107 All Purpose Silicone Spray P/N S00206 Krylon 1358 Krylon 1601 Krylon No. 1303 Krylon No. K1302 Krylon No. S-500
C03-074 Primer, Gray C03-075 Paint, Gloss Black C03-068 Coating, Clear C01-034 Acrylic Cement C01-034 Acrylic Cement
EFFECTIVITY: ALL
70-80-30
Supplier LabCem Inc. Labinal Division, Systeme Aeronautique Laminated Shim Co.
Trade Name Acetic Acid, Liguid (50% Concentration) Brisol-ox Shims Metal, RFI 1795-1 (0.004 in. Thick) Shims Metal, RFI 1795-2 (0.005 in. Thick) Shims Metal, RFI 1795-3 (0.006 in. Thick) Shims Metal, RFI 1795-4 (0.007 in. Thick) Shims Metal, RFI 1795-5 (0.008 in. Thick) Shims Metal, RFI 1795-6 (0.009 in. Thick)
Ref No. C04-227 Acid C02-070 Grease C10-155 Shims, Metal C10-155 Shims, Metal C10-155 Shims, Metal C10-155 Shims, Metal C10-155 Shims, Metal C10-155 Shims, Metal C10-202 Polishing Paste, Diamond C10-074 Diamond Compound C10-080 Polishing Paste C10-080 Polishing Paste C10-080 Polishing Paste C10-081 Thinner (Strong Grade) C05-013 Solutions C05-014 Solutions C05-016 Electrolytc Cleaners C05-017 Electrolytc Cleaners C05-019 Stencils C10-019 Release Agent C03-051 Brush Plating C10-203 Belt, Aluminum Oxide
Lapmaster International
1 Micron Diamond Compound Grade No. 45 Heavy Duty Polishing Paste, Diamond, 15 micron Polishing Paste, Diamond, 3 micron Polishing Paste, Diamond, 6 Micron Thinner (Strong Grade)
Lectroetch Co.
250A 250A Nuclear Grade Formula 3 Cleaner Formula 3 Cleaner, Nuclear Grade LSG
Lily Industries Inc. Liquid Development Company (LDC) Local Purchase
Release Agent, RAM225 LDC Plating Solutions 100 Mesh, Belt, Aluminum Oxide
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name 120 Grit, Aluminum Oxide, Sandpaper Roll 120 Grit, SiC, wet/dry, abrasive Paper 180 Grit, SiC, wet/dry, Abrasive Paper 180-240 Mesh, Belt, Aluminum Oxide 320 Grit, Abrasive Paper, Aluminum Oxide 320 Grit, Abrasive Paper, Silicon Carbide Wet/Dry 36-Grit 400 Grit Silicon Carbide Wet/ Dry 60-Grit 600 Grit Silicon Carbide Wet/ Dry Acid, Acetic, (Commercial Grade or Better, A-A-55829 Acid, Anhydrous Citric Acid, Hydrofluoric (70%) Alcohol, Denatured Alcohol, Methyl Ammonium Chloride, Crystal Certified or Reagent Grade Ammonium Hydroxide, Reagent Grade AMS 3411 Beeswax Brush, Wire Stainless Steel (0.003 - 0.005 in. dia wires) Calcium Carbonate, Powder Certified or Reagent Grade Cellosolve Acetate Chromic Acid Citrikleen HD Class 3 AMS 3079 Compound Carbon Removal (Fed. Spec. P-C-111b)
Ref No. C10-105 Sandpaper C10-141 Abrasive Paper C10-141 Abrasive Paper C10-204 Belt, Aluminum Oxide C10-120 Abrasive Paper C10-121 Abrasive Paper C04-174 Grit, Aluminum Oxide C10-190 Abrasive Paper C04-173 Grit, Aluminum Oxide C10-191 Abrasive Paper C04-097 Acid C04-238 Citric Acid C04-011 Acid C04-014 Alcohol C04-180 Alcohol, Methyl C04-133 Chemical C04-134 Chemical C06-010 Flux C10-154 Beeswax C10-173 Brush, Wire Stainless Steel C04-135 Chemical C04-230 Chemical C04-094 Acid C04-045 Cleaner, Compound C02-024 Preserva-tive Film C04-006 Remover, Paint/ Carbon
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Desiccant (MIL-D-3464, Type I) Fastener, Self-Locking 0.301 Nylon tie wraps 1/4 in. wide x 13.38 in long Ferric Chloride (Commercial Grade or Better) Film, Polyester, (Mylar), 0.0020.004 in thick Fluid, Calibrating, MIL-PRF7024 Foam, Urethane, 2 in. (51 mm) thick Fruit Stones (Pits) Gloves, Film Latex or Nylon/ Polyethylene Disposable Gloves, White Cotton Disposable Hydrochloric Acid, 22 degrees Be O-H-765 Hydrochloric Acid, Reagent Grade Hydrofluoric Acid (48%) O-H795 Isobutyl Alcohol Isopropyl Alcohol Kerosene, Deodorized (VV-K220) Magnesium Hydroxide plus Water Meta Nitrobenzenesulfonic Acid - Sodium Salt MIBK (Methyl Isobutyl Ketone) MIL-C-22750 MIL-PRF-6085 MIL-R-9300, Type I Milk-of-Magnesia (unflavored) Mineral Spirits (ASTM D-235 Type II, Class C) Napth, Fed. Spec. (TT-N-95 Type II)
Ref No. C10-001 Desiccant C10-152 Fastener, Self-Locking
C04-098 Chemical C10-142Film, Polyester C05-006 Fluid, Calibrating C01-025 Urethane C04-117 Abrasive, Other C10-140 Gloves C10-139 Gloves C04-071 Acid C04-136 Hydrochloeic Acid C04-126 Acid C04-151 Solvent, General C04-035 Solvent, General C04-125 Solvent, General C02-061 Anti-Seize Compound C04-096 Chemical C04-170 Solvent, General C03-056 Epoxy Paint C02-050 Preservation Oil C01-026 Epoxy Resin C02-061 Anti-Seize Compound C04-002 Solvent C04-018 Naphtha,
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Nitric Acid (Commercial Grade), 42 degrees Be O-N-350 O-G-491 Oil, AMS 3160 Suspension Fluid Oil, Engine Lubricating Oil, Engine Lubricating (MIL-L23699) Oxalic Acid (Commercial Grade or Better) Petrolatum VV-P-236 Phosphoric Acid Plastic Sheet, Polyethylene (1.5 mil thickness or greater) Potassium Dichromate O-P-559 Potassium Hydroxide O-P-566 Potassium Nitrate, Crystal Certified or Reagent Grade Potassium Permanganate (MIL-P-19970) Powder, Aluminum (Fed. Spec. A-A-341) Rice Hulls Rubber, Silicone, Shore A40 (1/4 in. thick) SAE 20-20 Sodium Carbonate (O-S-571) Sodium Cyanide Sodium Dichromate Sodium Hydroxide Sodium Nitrite (1%) Commercial Quality Solvent, Acetone (Fed. Spec. 0-A-51) Solvent, Hexane Solvent, Methyl-Ethyl-Ketone (ASTM D 740) Solvent, Methyl-Propyl-Ketone Solvent, Stoddard (MIL-PRF 680 Type I, Type II, or Type III)
Ref No. C04-072 Acid C05-091 Glycerine C05-087 Suspension Fluid C02-019 Oil C02-023 Oil C04-099 Chemical C02-008 Petroleum Jelly C04-093 Acid C10-128 Plastic Sheet, Polyethylene C04-108 Chemical C04-127 Chemical C04-137 Chemical C04-118 Chemical C10-007 Powder, Aluminum C04-116 Abrasive, Other C01-064 Silicone C02-038 Oil C04-123 Chemical C04-086 Remover, Plating C04-229 Chemical C04-084 Chemical C02-056 Inhibitor C04-003 Solvent C04-021 Solvents, General C04-001 Solvent C04-196 Solvent, General C04-002 Solvent
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Solvent, Trichloroethylene, Technical (Fed. Spec. O-T-634) Sulfuric Acid (Commercial Grade 65 deg. Be O-S-809) Tartaric Acid (Commercial Grade or Better) Toluene Industrial Toluene Solvent (Reagent Grade) Tool, Safetywire TT-P-1757 Type 1 or 2 Class C (AMS3110) Color Y Tubing, Non-Toxic Vinyl Plastic Type 1 Red Compound (M.P. 132 deg. F.) Walnut Shells Wire Cutter, Flush Side Cushioned
Ref No. C04-004 Solvent C04-101 Acid C04-100 Acid C04-036 Solvent, General C04-102 Solvent, General C10-150 Tool, Safetywire C03-001 Primer C10-006 Tubing C10-181 Compound, Surface Impression C04-115 Abrasive, Other C10-149 Wire Cutter C01-083 Adhesive C01-015 Ablative Silicone
Local Purchase from Dental Supplier Lockheed Martin Space Systems Company - Michoud Operations Loctite Aerospace
Dental Cement Kit (Liquid/ Catalyst and Powder) MA-25 Ablative Coating Parts A, B, & C EA 9628NW .085 psf EA 9628UNS EA 9689.08 (Class E) EA 9689.10 PSF GK (Class D) Hysol EA 901NA/B-1 Hysol EA 9205 Hysol EA 934NA Hysol EA 9394 Hysol EA 9394/C2 Hysol EA 9395 Hysol EA 9396 Hysol EA 9396/C2 Hysol EA 956 Hysol EA 960F Hysol EA 9689.06 psf
C01-130 Adhesive Film C01-131 Adhesive Film C01-136 Adhesive Film C01-136 Adhesive Film C01-010Adhesive C01-166 Primer, High Temperature C01-011 Adhesive C01-155 Adhesive C01-156 Adhesive C01-174 Adhesive C01-147 Adhesive C01-157 Adhesive C01-106 Epoxy C01-129 Adhesive C01-139 Adhesive Film
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Hysol EA 9689.09 psf Hysol EA 9890 Hysol EA 9891RP
Ref No. C01-165 Adhesive C01-162 Abradable Seal Material C01-161 Abradable Seal Material C10-192 Mold Release C01-187 Sealant C01-040 Primer C01-040 Primer C01-143 Locking Agent C01-048 Locking Agent C01-055 Sealant C01-012 Locking Agent C01-118 Adhesive C01-084 Adhesive C01-084 Adhesive C01-110 Retaining Compound C01-114 Compound C01-041 Locking Agent C01-149 Retaining Compound C01-041 Locking Agent C01-160 Primer C02-046 Lubricant C02-032 Anti-Seize Compound C01-090 Primer C01-057 Adhesive C03-026 Primer C03-004 Paint C02-053 Penetrating Oil C02-053 Penetrating Oil C02-014 Molybdenum Disulphite C02-035 Anti-Seize Graphite C07-004 Silver Alloy Wire C06-005 Braze Alloy C06-016 Lithobrage BT
Loctite Corp.
Frekote 44-NC Loctite 088 Loctite 19269 Loctite 21348 Loctite 242 Loctite 271 Loctite 277 Loctite 290 Loctite 430 Loctite 567 Loctite 592 Loctite 609 Loctite 620 Loctite 638 Loctite 640 Loctite 680 Loctite 7090 P/N 12695 Loctite C 200 Solid Loctite C5A Copper Loctite Primer T 7471 Loctite Superbonder 496
Lord Corp. Chemical Products Group LPS Laboratories, Inc.
Aeroglaze 9929 Chemglaz 11, White A276 LPS-1 LPS-LST M-Everlube 211-G
Lubri-Film Div. Lucas-Milhaupt Inc.
Tioform LF 22 BR 300 (NT) Braze 541 Lithobraze BT
EFFECTIVITY: ALL
70-80-30
Supplier Ludlow Corp., Packaging Div.
Trade Name PK 22C
Ref No. C10-009 Paper, Greaseproof
Supplier MacDermid, Inc.
Trade Name ARP 2 Agent Iridite 14-2 Metex Strip Aid
Ref No. C04-222 Surfactant C03-064 Conversion Coating C04-085 Remover, Coating C04-191 Cleaner, Compound C04-189 Cleaner, Acid Descaler C04-190 Cleaner, Acid Descaler C04-183 Cleaner, Acid Descaler C02-072 Corrosion Inhibitor C04-184 Cleaner, Mild Alkaline C04-205 Cleaner, Compound C04-182 Cleaner, Heavy Duty Alkaline C04-188 Cleaner, Alkaline Permanganate C04-187 Cleaner, Heavy Duty Alkaline C04-185 Remover, Paint/ Carbon C04-260 Solvent, General C04-186 Cleaner, Mild Alkaline C04-197 Solvent, General C04-241 Chemical C01-024 Catalyst
MagChem
MagChem Aerodet MagChem AP-9186 MagChem AP-954 MagChem AP-988 MagChem Corrotek MagChem DG-Kleen MagChem Evasol MagChem HDL-202 and Additive Deox MagChem HDP-2524 MagChem HDP-2888 MagChem Kemstrip-596 and additives: OLS-96, A-96, and S96 MagChem Skysol MagChem Soluwax MagChem Teksol
Ammonium Bifluoride Flakes Diethylenetriamine (High Purity Grade), Product Code: H768 or 3356
Mallinckrodt, Inc. Marian Inc. Markel Corp.
Dimethyl Sulfoxide (DMSO) MIL Style A-A-59163 Type I (0.5 in. or 1.0 in wide) Flexite Spiral Cut Cable Wrap (Teflon 1/4 in OD x 0.03 thick x 0.375 pitch)
C04-095 Chemical C10-125 Tape, Silicone SelfAdhering C10-084 Cable Wrap
EFFECTIVITY: ALL
70-80-30
Supplier Markem Corp.
Trade Name No. 6893 Liquid Epoxy Ink (White) No. 6896, Stamp Pad Ink, (White)
Ref No. C05-010 Ink Marking Epoxy C05-010 Ink Marking Epoxy C05-084 Developer C05-085 Developer C05-047 Penetrant C05-060 Emulsifier C05-050 Penetrant C05-048 Penetrant C01-145 Jointing Compound C10-075 Coolant C02-074 Tapping Fluid C02-074 Tapping Fluid C10-075 Coolant C04-153 Abrasive, Plastic
Marktec Corp.
DN-600P DN-900D OD-1700A Penetrant OD-1700B OD-2800-I Penetrant OD-2800-II Penetrant
Marston Lubricants, LTD Master Chemical Co.
SQ32L Trim Sol Trim Tap NC Trim Tap NC Heavy VHP E210
MaxiBlast, Inc.
MB-2 (20/30), Plastic Blast Media (MIL-P-85891, Type II, Grade A, 3.5 Mohs Hardness) MB-3 (30/40), Plastic Blast Media (MIL-P-85891, Type II, Grade A, 3.5 Mohs Hardness)
McGean-Rohco, Inc., Cee-Bee Division
Cee-Bee A-202 Cee-Bee A-477 and Additives: Additive A, Additive O Cee-Bee A-7X7 Cee-Bee Alko Cee-Bee C-105 HF Cee-Bee C-46 Cee-Bee C-623 Cee-Bee J-19 Cee-Bee J-19L Cee-Bee J-3 Cee-Bee J-84A
C04-022 Remover, Epoxy C04-194 Remover, Paint/ Carbon C04-165 Cleaner, Mild Alkaline C04-250 Cleaner, Carbon Removal Gel C04-148 Remover, Silicone Rubber C04-039 Cleaner, Heavy Duty C04-143 Acid C04-142 Cleaner, Acid Descaler C04-142 Cleaner, Acid Descaler C04-239 Cleaner C04-049 Cleaner, Heavy Duty Alkaline
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Cee-Bee J-84AL Cee-Bee J-88 Cee-Bee J-88A Cee-Bee J-88L Cee-Bee No. B-55 Cee-Bee P-109B Cee-Bee R-43C Cee-Bee WDO Intex 8201 (Liquid) Super Bee 262 Super Bee 300LF
Ref No. C04-049 Cleaner, Heavy Duty Alkaline C04-055 Cleaner, Alkaline Permanganate C04-055 Cleaner, Alkaline Permanganate C04-055 Cleaner, Alkaline Permanganate C04-023 Cleaner, Acid Descaler C04-255 Cleaner, Acid Descaler C04-060 Remover, Paint/ Carbon C02-064 Oil C04-044 Cleaner, Compound C04-211 Cleaner, Compound C04-221 Cleaner, Mild Alkaline C10-108 Brush
McMaster Carr
Cat. No. 7237T4 (or equivalent) Disposable Brush Natural Bristle Cat. No. 7798T2 (or equivalent) Disposable Brush Natural Bristle Cat. No. 9566K23 (or equivalent) Cork Stoppers, 15/ 16 in. dia. large end Cloth, Wire Mesh, Cat. No. 9226T29 Perforated Steel, Cat. No. 9255T631 Perforated Steel, Cat. No. 9358T14 Syringe, Polyethylene, Adhesive
C10-108 Brush
C10-107 Cork Stoppers
C10-094 Cloth, Wire Mesh C10-095 Perforated Steel C10-095 Perforated Steel C10-208 Syringe C01-024 Catalyst
Merck KGaA
Diethylenetriamine (High Purity Grade), Product Code: 803274 Almen Strips, Type A (0.0500.052 in.) Almen Strips, Type N (0.0300.032 in.)
Metal Improvement Co.
C10-110 Almen Test Strips C10-205 Almen Strips for Shot Peening
EFFECTIVITY: ALL
70-80-30
Supplier Metcut Research Miller Stephenson Chemical Co.
Trade Name Type FM-1000 0.005 in. to 0.007 in. thick 143DF 143V EPON 828 MS-111 Stripper MS-122B MS-122DF MS-122V MS-143V-10.0
Ref No. C01-103 Film C10-011 Compound Mold Release C10-011 Compound Mold Release C01-017 Epoxy C04-088 Remover, Paint/ Carbon C10-013 Compound, Release Agent C10-013 Compound, Release Agent C10-013 Compound, Release Agent C10-215 Release Agent C10-048 Cloth, BleederOsnaburg C04-164 Cleaner, Mild Alkaline C01-126 Netting C05-019 Stencils C05-107 Electrolyte C05-109 Neutralizer C05-106 Electrolyte C05-015 Monode MSC-1 C05-018 Monode MSC-3 C05-108 Electrolyte C04-153 Abrasive, Plastic
Miltix-Morgan Fabrics Modern Chemical, Inc. Mohawk Fabric Co. Inc. Monode Marking Products Inc.
Cloth, Bleeder-Osnaberg Blue Gold Industrial Cleaner D117 Blue (Long Life) Monode A-10, Electrolyte Monode APC, Neutralizer Monode C-10, Electrolyte Monode MSC-1 Monode MSC-3 Monode T-10 (NC), Electrolyte
MPC Industries, Patent Plastics, Inc.
X-OFF P/N SFC 1735 (20/40), Plastic Blast Media (MIL-P85891, Type II, Grade A, 3.5 Mohs Hardness) 31-400-1352 31-400-1353 31-400-1354 31-400-1355 31-400-1356
MTU Maintenance GmbH
C10-158 Silicone Rubber Masking Ring Set C10-158 Silicone Rubber Masking Ring Set C10-158 Silicone Rubber Masking Ring Set C10-158 Silicone Rubber Masking Ring Set C10-158 Silicone Rubber Masking Ring Set
EFFECTIVITY: ALL
70-80-30
Supplier Netherland Rubber Co. Noble Tool Corp. Norton Company / Division of Saint Gobain
Trade Name N6E12156SIL-XXXX P/N 4013518-290 P/N 4013518-319 150R100B99-1/8 (Grinding Wheel, 6 in x 1/8 in x 1 1/4 in.) 32A60K8VBE 39C80H12V 57A80L8V, 8.0 in. OD x .500 in. x 1.25 in. ID Cup Wheel Grinding, 32A60J5VBE Grinding Wheel 23A80-L8V Grinding Wheel, 32A460K5VBE No. W215, Grit A90R V. Grade O
Ref No. C10-198 Plugs C05-113 Inspection System C05-114 Optical Refractor C10-065 Grinding Wheel C10-076 Grinding Wheel C10-077 Grinding Wheel C10-069 Grinding Wheel C10-024 Cup Wheel Grinding C10-004 Grinding Wheel C10-026 Grinding Wheel C10-058 Abrasive Wheel C01-113 Teflon Sheet C04-206 Cleaner, Compound C02-001 Anti-Seize Compound
Norton Performance Plastics Corporation Nuvite Chemical Compounds, Corp. Nyco SA
Zitex Nu-Gear-SC Nyco GA47
Supplier O.M.G Americas Oakite Products Inc., Div. of Chemetall
Trade Name Class B AN325 985P12 985P13 985P14 9D1B 9D4A 9D76 9PR12 9PR3 Androx 2302 and Additives 2302S, 2302-AA, 2302-SA Ardrox 1064-K Ardrox 1218 (Inhibited Phosphoric Acid)
Ref No. C06-024 Braze Alloy Nickel Powder C05-042 Penetrant C05-046 Penetrant C05-043 Penetrant C05-082 Developer C05-081 Developer C05-083 Developer C05-059 Emulsifier C05-058 Emulsifier C04-245 Remover, Paint/ Carbon C04-160 Solvent, General C04-121 Acid
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Ardrox 1618 Ardrox 163 Ardrox 1630 Ardrox 1635 Ardrox 185 Ardrox 185L Ardrox 1871 Ardrox 1873 Ardrox 1873A Ardrox 188 and Additives 188LC/188LP Ardrox 188RFU and additives 188LC/188LP Ardrox 1900B Ardrox 2204 Ardrox 311 Ardrox 321-N Ardrox 3962 Ardrox 552 Ardrox 6077 Ardrox 6085 Ardrox 631 Ardrox 6333 Ardrox 6333A Ardrox 6366 Ardrox 6367 Ardrox 6368 Ardrox 690 Ardrox 690-I Ardrox 8800 Ardrox Base Oil HF
Ref No. C04-247 Remover, Carbon C04-169 Cleaner, Compound C04-081 Cleaner, Compound C04-074 Cleaner, Acid Descaler C04-052 Cleaner, Heavy Duty Alkaline C04-052 Cleaner, Heavy Duty Alkaline C04-067 Cleaner, Acid Descaler C04-066 Cleaner, Acid Descaler C04-240 Cleaner, Acid C04-058 Cleaner, Alkaline Permanganate C04-058 Cleaner, Alkaline Permanganate C04-210 Cleaner, Compound C04-147 Remover, Silicone Rubber C02-063 Oil C03-071 Coating C02-064 Oil C04-224 Solvent C04-204 Cleaner, Compound C04-209 Cleaner, Mild Alkaline C04-064 Cleaner, Mild Alkaline C04-163 Cleaner, Mild Alkaline C04-163 Cleaner, Mild Alkaline C04-140 Cleaner, Gas Path C04-140Cleaner, Gas Path C04-140 Cleaner, Gas Path C04-062 Remover, Paint/ Carbon C04-124 Chemical Additive Inhibitor C05-088 Magnaglo Powder C04-181 Suspension Fluid
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Ardrox P133D Ardrox P134D
Ref No. C05-045 Penetrant C05-044 Penetrant C04-226 Cleaner C03-028 Curing Agent C10-092 Abrasive Brush C10-097 Brushes, Wire C10-114 Nylon Brushes Abrasive Coated C01-108 Fiber Glass
Olin Corporation Omni Specialty Corp. Osborn International
Caustic Soda, Liquid (50% Concentration) Caytur 21 Brush No. 22299 (320 grit) with adapter No. 1A Brushes, Wire, 0.003 in. (0.08 mm) Cat. No. 22259, 320 Grit
Owens-Corning Fiberglass Corporation
Milled Cat. No. 731ED 1/16 in. or 1/8 in. long
Supplier P. Viennot S. A. Parker-Hannifin Corp., Stratoflex Division Parkway Products, Inc. PAS Patco Corp. Patterson Dental Supply
Trade Name Porous PTFE (NATO Supply Code F0585) 2681-11 (Chafe Guard) GE P/N 3003M28P05 GE PN 9193M42 (Red) AA5629-1D1A Patco #110-50 Red 091-1578 (Wax, Utility) Size No. 25, Reamers, Root Canal Stainless Steel Size No. 50, Reamers, Root Canal Stainless Steel Size No. 70, Reamers, Root Canal Stainless Steel Size No. 75, Reamers, Root Canal Stainless Steel
Ref No. C01-113 Teflon Sheet C10-127 Chafe Guard C03-015 Paint C01-046 Epoxy repair kit C10-021 Tape, Duct C10-109 Wax C10-159 Reamers, Root Canal Stainless Steel C10-159 Reamers, Root Canal Stainless Steel C10-159 Reamers, Root Canal Stainless Steel C10-159 Reamers, Root Canal Stainless Steel C05-112 Comparator C05-112 Comparator
Paul N. Gardner Company, Inc.
MA-81-34-37, Inch Scale, 3/4 inch, in 0.005 intervals MA-81-34-42, LENSCOPE Magnifier, 10X, lens and storage case
Pechiney World Trade Inc. Penn-Fibre and Specialty Co.
Dimethyl Sulfoxide (DMSO) Wear Strip Nylatron GS, 0.938 in. wide, 0.074 in. thick
C04-095 Chemical C10-066 Wear Strip Nylatron GS
EFFECTIVITY: ALL
70-80-30
Supplier Permabond International Corp. Permacel Petroferm Inc. Phillips Supply Co. Poly-Pacific International Inc. Polycraft Products, Inc. Polymet Corp.
Trade Name Permabond 910 Permacel P-212 Permacel P21 Bioact 105 Precision Cleaner Coconut Oil, Coco 20 Coconut Oil, Misty Coco-15 Multicut Plastic Media Type 2UREA 20/40 mesh GE01-2 KIT PMET 818 PMET 822 PMET 842 PMET 880 PMET 885 PMET 886 PMET 980 PMET 994
Ref No. C01-057 Adhesive C10-157 Class Cloth Tape C10-070 Tape, Glass Fiber C04-251 Solvent Cleaner C04-028 Cleaner C04-028 Cleaner C04-153 Abrasive, Plastic C01-180 Seal Kit C07-049 Alloy 718 Wire C06-037 Weld Wire C06-031 Weld Wire C06-033 Weld Wire C07-042 Nickel-Aluminum Wire C07-043 Nickel-ChromiumAluminum Wire C06-023 Weld Electrode C06-009 Coating, Alloy-Cobalt Base C01-120 Adhesive C07-014 75:25 Nickel-Graphite Powder C07-015 85:15 Nickel-Graphite Powder C07-013 Copper-Nickel Powder C07-007 Tungsten Carbide 12% Cobalt Aggregate C07-027 75% Chromium Carbide; 25% Nickel Chromium Powder C07-027 75% Chromium Carbide; 25% Nickel Chromium Powder C07-008 Chromium Carbide NiCr-C0- Matrix C06-012 Braze Alloy, Powder C07-023 Aluminum Bronze Alloy Thermal Spray Powder C07-017 Aluminum Powder
Portland Plastics Powder Alloy Corp.
Plastisol PP-0274 PAC 1058B PAC 1059B PAC 12 PAC 127 (Class A and B) PAC 130 (GE Spec. B50TF137, Class B) PAC 131 (GE Spec. B50TF137, Class A) PAC 133 PAC 1424 PAC 16FC PAC 19SP
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name PAC 2008P
Ref No. C07-035 Zirconium OxideYttrium Oxide Composite Powder C07-005 Molybdenum Wire C07-021 Nickel-Silicon-Boron Powder C07-020 Copper-Nickel-Indium Powder C07-003 Aluminum Oxide Powder C07-038 Inco 718 Powder C07-041 Inconel 718 Powder HVOF Application C07-037 Aluminum Silicon Polyester Powder C07-016 Nickel-Aluminum Composite Powder C07-022 Aluminum-Nickel Chromium Composite Powder C07-032 Nickel Chromium Aluminum Yttrium Powder C07-012 Nickel-Chromium Powder C07-012 Nickel-Chromium Powder C07-004 Silver Alloy Wire C04-122 Acid C07-051 Copper-Zinc-Silver Pre-alloyed Wire C07-054 Copper-Nickel-Indium Wire C07-043 Nickel-ChromiumAluminum Wire C07-042 Nickel-Aluminum Wire C07-049 Alloy 718 Wire C07-044 Aluminum Wire 99% Pure Minimum C07-056 Bronze Alloy Wire C07-055 Wire
PAC 4 PAC 65 PAC 658C PAC 701B PAC 718B PAC 718F PAC 905-3 PAC 906, (GE Spec. B50TF56, Class A) PAC 908C PAC 9620AM PAC 98C-1 (GE Spec. B50TF40 Class A Coarse) PAC 98F (GE Spec. B50TF40 Class B Fine) PAC A13 PPG Industries, Inc. Praxair / TAFA Concord Corrosol 853 (Inhibited Phosphoric Acid) 30S 58T 73 MXC 75 B 78T O1T TAFA 10T TAFA 13T
EFFECTIVITY: ALL
70-80-30
Supplier Praxair / TAFA Indianapolis
Trade Name 1243M 1342VM (Class A) 1485I
Ref No. C07-022 Aluminum-Nickel Chromium Composite Powder C07-007 Tungsten Carbide 12% Cobalt Aggregate C07-035 Zirconium OxideYttrium Oxide Composite Powder C07-016 Nickel-Aluminum Composite Powder C07-035 Zirconium OxideYttrium Oxide Composite Powder C07-017 Aluminum Powder C07-037 Aluminum Silicon Polyester Powder C07-039 Aluminum Oxide Powder C07-003 Aluminum Oxide Powder C07-025 Cobalt-MolybdenumChromium-Silicon Powder C07-031 Cobalt-MolybdenumChromium-Silicon Powder C07-047 Cobalt-MolybdenumChrome-Silicon Powder C07-048 Metal Powder C06-034 Braze Filler Powder C07-027 75% Chromium Carbide; 25% Nickel Chromium Powder C07-027 75% Chromium Carbide; 25% Nickel Chromium Powder C07-008 Chromium Carbide NiCr-C0- Matrix C07-036 Copper-Nickel-Indium C07-020 Copper-Nickel-Indium Powder C07-013 Copper-Nickel Powder C07-023 Aluminum Bronze Alloy Thermal Spray Powder C07-001 Molybdenum Powder
AI-1037, (GE Spec. B50TF56, Class A) AI-1075
AL-104 AL-228 ALO-105-1 ALO-159 CO-109 CO-111 CO-111 CO-273-5 CO-273-5 CRC-106 (GE Spec. B50TF137, Class A) CRC-108 (GE Spec. B50TF137, Class B) CRC-109 CU-101-1 CU-102 CU-103 CU-104-5 MO-102
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name NI-107 (GE Spec. B50TF40 Class A Coarse) NI-108 NI-109, (GE Spec. B50TF56, Class A) NI-115 NI-120 NI-122 NI-164/NI-211 NI-183 NI-183 NI-183-4 NI-185, (GE Spec. B50TF56, Class B) NI-202-1 NI-202-3 NI-298 NI-334 NI-362-3 NI-365-3 (GE Spec. B50TF271 Class B) NI-453 (GE Spec. B50TF166, Class A) WC-114 (Class A and B) WC-559 ZRO-113/114
Ref No. C07-012 Nickel-Chromium Powder C07-011 Nickel-Aluminum Composite Powder C07-016 Nickel-Aluminum Composite Powder C07-015 85:15 Nickel-Graphite Powder C07-014 75:25 Nickel-Graphite Powder C07-022 Aluminum-Nickel Chromium Composite Powder C07-032 Nickel Chromium Aluminum Yttrium Powder C06-032 Alloy Powder C07-052 Alloy Powder Rene 80 C07-053 Alloy Powder Rene 80 C07-016 Nickel-Aluminum Composite Powder C07-038 Inco 718 Powder C07-041 Inconel 718 Powder HVOF Application C06-013 Braze Alloy Powder C06-027 Nickel Braze Alloy C06-014 Braze Alloy Powder C06-036 Weld Powder C07-034 Nickel AluminumMolybdenum Composite Powder C07-007 Tungsten Carbide 12% Cobalt Aggregate C07-040 Powder, 17% Tungsten Carbide Cobalt C07-035 Zirconium OxideYttrium Oxide Composite Powder C07-029 Powder, Magnesium Zirconate C03-063 Primer, Epoxy
ZRO-218 PRC-Desoto International Inc. 515X349-Base, 910X533 Activator
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name 528X310 and Activator 910X464 (Type III) 538C306 and Activator 910X464 (Type II) A15D3 Pasa-Jell 107 Gun, Sealant, Semco Model 250-A6, P/N 250065 Pasa-Jell 105 PR 1422 PR 1750 B-2 PR-1440 AMS-S-8802 PR-1826 Class B-1/4 PR1440-B-2 Pro-Seal 501 PS 870-B-2 Super Koropon 515-700
Ref No. C03-060 Epoxy Paint C03-060 Epoxy Paint C04-027 Chemical Surface Treatment C10-068 Gun, Sealant C04-150 Compound, Surface Treatment C01-062 Sealing Compound C01-073 Sealing Compound C01-062 Sealing Compound C01-190 Sealant C01-115 Adhesive C01-140 Adhesive C01-115 Adhesive C03-087 Primer C10-036 Abrasive Wheel C10-072 BrightBoy Stick C10-072 BrightBoy Stick C10-059 Abrasive Wheel C10-043 Rubberized Abrasive C10-089 Cutoff Wheel C10-131 Peel Ply C04-166 Abrasive, Peening C04-167 Abrasive, Peening
Precision Abrasives and Tools
Abrasive Wheel, Spec. No. 808M BrightBoy Stick Holder, 801-X BrightBoy Stick, ST-90-ALO801-R Cratex 79F Cratex 8-C No. 3, Cutoff Wheel, 1.0 in. x 0.040 in., (25.4 mm x 1.92 mm)
Precision Fabrics Group Inc. Premier Shot Company
Peel Ply, Style 52006/51789, SRB CCW14 CCW20, Conditioned Cut Wire Steel Shot (GE Spec. D50TF11 Class B) CCW31, Conditioned Cut Wire Steel Shot (GE Spec. D50F11CLB)
Prescott and Co., Ltd. Protech Lab Corporation
Compound, Gear Marking, No. 10 Yellow Type FM-1000 0.005 in. to 0.007 in. thick
C05-001 Compound, Gear Marking C01-103 Film
EFFECTIVITY: ALL
70-80-30
Supplier Quaker Chemical Corp.
Trade Name Ferrocoat 364AC Ferrocoat 366
Ref No. C02-055 Preservative C02-055 Preservative
Supplier Radiac Abrasives
Trade Name Grinding Wheel, A70-0-10BB Rubber Wheel 1 x 0.030 x 1/16 A240, U2RR860
Ref No. C10-038 Grinding Wheel C10-044 Rubber Wheel C02-026 Penetrating Oil C05-003 Marking Pens C05-009 Polyvinyl Alcohol C01-169 Silicone C01-170 Silicone C01-168 Silicone C01-167 Silicone C10-179 Cloth, Class PTFE Coated (Non-porous) C10-178 Cloth, Glass PTFE Coated (Porous) C10-133 Film, Polymer FEP, Un-perforated, C10-132 Film, Polymer C10-051 Film, Release, Perforated C10-051 Film, Release, Perforated C10-134 Cloth, Breather/ Bleeder C10-138 Tape, Sealant, Vacuum Bag C10-135 Tape, Shrink #2 C10-056 Tape, Flash-breaker, Pressure Sensitive C10-137 Film, Vacuum Bag C04-175 Cleaner, Compound C04-176 Cleaner, Compound C04-177 Abrasive, Tumbling
Radiator Specialty Co. Ratioplast GmbH Rexco Chemical Co. Rhone-Poulenc
L1 Liquid Wrench, Industrial Grade LN9051 Red Partial Film No. 10 Catalyst 147B Primer - MB RTV 147A RTV 148
200TFNP 200TFP A5000 A5000P3 E3760-P1-(0.002) E3760-P2-(0.001) RC-3000-10 SM 5144 Tape, Shrink #2 Vac Pack, E3760-PS4 Vac-Pak, HS-8171
Richwood Industries Inc.
# 42 Compound # 43 Compound RC Tumbling Nuggets, Size # 10
EFFECTIVITY: ALL
70-80-30
Supplier RM Engineered Products, Inc.
Trade Name Tape, Brown Ceramic Filled TFE, Etched one side (GE PN 3046M82) Supertect ST-A Turbinade TA-A Royco 22CF Royco 27 Royco 44 Royco 481 Royco 483 Royco 64 Royco 81MS Royco HF825
Ref No. C01-097 Tape, Brown Ceramic Filled C02-053 Penetrating Oil C02-053 Penetrating Oil C02-017 Grease C02-016 Grease C02-001 Anti-Seize Compound C02-021 Oil, 1010 C02-025 Oil, Preservation C02-014 Molybdenum Disulphite C02-020 Oil C02-013 Lubricant C02-033 Petrolatum
Roly International Royal Lubricants Co., Inc.
Ruger Chemical Co.
White Fonoline
Supplier S.S. White Technologies Saint-Gobain Performance Plastics Sandstrom Products Co.
Trade Name No. 3 P/N AP123 Tape, Brown Ceramic Filled TFE, Etched one side (GE PN 3046M82) Sandstrom 27A MoS2 Base and Corrosion Inhibitor (GE Spec. A50TF192 Class B) Prismacolor Verithin Silver Pencil T.E.C. Marker (Black) AA5629-1D1A Wire Mesh, 304L Stainless Steel,Twill Dutch Weave, (Wire Diameters: Warp: 0.0024 in. Shute: 0.0018 In.) Wire Mesh, Aluminum, 0.0024 in. dia. x 0.0018 in. dia. Wire, 48.0 in. wide x 12.0 ft. long
Ref No. C10-018 Grit Blast C01-097 Tape, Brown Ceramic Filled C02-004 Lubricant
Sanford Corp.
C05-003 Marking Pens C05-003 Marking Pens C01-046 Epoxy repair kit C10-119 Wire Mesh, 304L Stainless Steel
Satair A/S SEFAR America
C10-118 Wire Mesh, Aluminum
Select-Tech, Inc.
AMMO-301 (20/40), Plastic Blast Media (MIL-P-85891, Type II, Grade A, 3.5 Mohs Hardness)
EFFECTIVITY: ALL
70-80-30
Supplier Selig Chemical Industries, Inc. Div. of National Services Industries, Inc. SEPR Ceramic Beads and Powders
Trade Name Isoparaffinic Solvents CE-SX94, GB-SX-94, and L-SX-94 Z150, Ceramic Peening Media, 0.006 - 0.008 in. (0.15 - 0.29 mm) Z210, Ceramic Peening Media 0.008 -0.016 in. (0.20 -0.41 mm) Z300, Ceramic Peening Media, 0.011 -0.017 in. (0.30 -0.425 mm)
Ref No. C04-199 Solvent, General
Sermatech International Inc.
Applicator, Coating (Part No. 97301) Small PBX Ceramic Cement Sermalloy J Sermaseal 565 Sermetel 1076HS Sermetel 1636 Sermetel 196 Sermetel 409 Sermetel W
C10-101 Applicator C03-022 Cement C03-047 Coating, High Temperature C03-090 Coating, Solid Film Inorganic Sealant C03-089 Coating, Chromium Oxide Pigmented C03-088 Coating, Aluminum Oxide Pigmented C03-039 Coating C03-012 Color Coating C03-038 Paint C03-085 Primer C01-017 Epoxy C02-016 Grease
Seymour of Sycamore Shell Chemical Co. Shell International Trading Co., International Aviation Division
Seymour Hi Tech 16-897 EPON 828 Aeroshell Grease 7
Aeroshell Turbine Oil 2 Royco Grease 22 MS Sherwin, Inc. D-100 D-104 D-106 D-90G ER-83A FP-22B RC-65 RC-77
C02-021 Oil, 1010 C02-044 Grease C05-078 Developer C05-079 Developer C05-079 Developer C05-076 Developer C05-057 Emulsifier C05-038 Penetrant C05-039 Penetrant C05-115 Penetrant
EFFECTIVITY: ALL
70-80-30
Supplier Sherwin-Williams, Inc. Shurtape SIA Adhesives, Inc.
Trade Name Tri-Flow Superior Lubricant Shurtape PC623 Elastolock 2710 Part A & Part B MA-529 WCG (P/N 1153M28P01) MA-529 WCG (P/N 1153M28P02) MA557
Ref No. C02-077 Oil, Lubricating C10-021 Tape, Duct C01-181 Epoxy Adhesive C01-188 Adhesive, Aluminum Filled Epoxy Film C01-188 Adhesive, Aluminum Filled Epoxy Film C01-132 Adhesive, Foam C03-050 Brush Plating C01-021 Adhesive C10-148 Crimping Tool C02-075 Hydraulic Fluid C04-200 Solvent, General C10-197 Hollow Glass Beads C10-197 Hollow Glass Beads C10-197 Hollow Glass Beads C07-020 Copper-Nickel-Indium Powder C01-050 Rubber Cement C07-040 Powder, 17% Tungsten Carbide Cobalt C07-047 Cobalt-MolybdenumChrome-Silicon Powder C06-023 Weld Electrode C07-025 Cobalt-MolybdenumChromium-Silicon Powder C07-031 Cobalt-MolybdenumChromium-Silicon Powder C06-015 Braze Alloy C06-012 Braze Alloy, Powder C07-041 Inconel 718 Powder HVOF Application C07-037 Aluminum Silicon Polyester Powder C07-001 Molybdenum Powder C07-029 Powder, Magnesium Zirconate
SIFCO Selective Plating-Div., SIFCO Industries Smooth-On Inc. Snap-On Special Products Solutia Inc. Sovitec France S.A.
Selective Plating Supplies Metal-Set A4 Part A and B JRC8V32C Skydrol 500B-4 SkyKleen Glass Bead Size 11 Glass Bead Size 12 Sovitec T 212
Special Metals Corporation, Powder Division Starkey Chemical Stellite Coatings Deloro Stellite, Inc.
Vertex VPC-72C Rubber Cement and Thinner Deloro Stellite JK117SP JK 558 Tribaloy 800 Tribaloy T-400 Tribaloy T-800
Sulzer Metco, Inc.
Amdry 100 C (GE Spec. B50TF81, Class A) Amdry 103 Amdry 1718 Amdry 2010 Amdry 313X Amdry 333
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Amdry 500 Amdry 500C Amdry 718 Cl B Amdry 956, (GE Spec. B50TF56, Class A) Amdry 960 Amdry 962 AMI 775 AMS 4778 / Acrylic Binder 0.037 in. thick x 0.75 in. Wide Diamalloy-3001 Metco 101B-NS Metco 101B-NS and Metco 404NS Blend Metco 101SF Metco 202NS
Ref No. C07-036 Copper-Nickel-Indium C07-020 Copper-Nickel-Indium Powder C07-038 Inco 718 Powder C07-016 Nickel-Aluminum Composite Powder C07-022 Aluminum-Nickel Chromium Composite Powder C07-032 Nickel Chromium Aluminum Yttrium Powder C06-029 Braze Alloy C06-026 Braze Alloy Tape C07-047 Cobalt-MolybdenumChrome-Silicon Powder C07-003 Aluminum Oxide Powder C07-018 Alumina/NickelAluminum Powder C07-039 Aluminum Oxide Powder C07-033 Zirconium OxideYttrium Oxide Composite Powder C07-035 Zirconium OxideYttrium Oxide Composite Powder C07-035 Zirconium OxideYttrium Oxide Composite Powder C07-029 Powder, Magnesium Zirconate C07-014 75:25 Nickel-Graphite Powder C07-015 85:15 Nickel-Graphite Powder C07-011 Nickel-Aluminum Composite Powder C07-019 Nickel-Aluminum Composite Wire C07-008 Chromium Carbide NiCr-C0- Matrix
Metco 204NS
Metco 204NS-G
Metco 210NS-1G Metco 307NS-3 Metco 308NS-3 Metco 404NS Metco 405NS Metco 430NS
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Metco 439NS Metco 43C-NS (GE Spec. B50TF40 Class A Coarse) Metco 43F-NS (GE Spec. B50TF40 Class B Fine) Metco 443NS Metco 447NS
Ref No. C07-010 50% Tungsten Carbide Self-Bonding Blend C07-012 Nickel-Chromium Powder C07-012 Nickel-Chromium Powder C07-022 Aluminum-Nickel Chromium Composite Powder C07-034 Nickel AluminumMolybdenum Composite Powder C07-016 Nickel-Aluminum Composite Powder C07-016 Nickel-Aluminum Composite Powder C07-023 Aluminum Bronze Alloy Thermal Spray Powder C07-023 Aluminum Bronze Alloy Thermal Spray Powder C07-017 Aluminum Powder C07-013 Copper-Nickel Powder C07-020 Copper-Nickel-Indium Powder C07-037 Aluminum Silicon Polyester Powder C07-001 Molybdenum Powder C07-025 Cobalt-MolybdenumChromium-Silicon Powder C07-031 Cobalt-MolybdenumChromium-Silicon Powder C07-026 Chromium CarbideNickel-Aluminide Composite Powder C07-007 Tungsten Carbide 12% Cobalt Aggregate C07-040 Powder, 17% Tungsten Carbide Cobalt C07-027 75% Chromium Carbide; 25% Nickel Chromium Powder
Metco 450NS, (GE Spec. B50TF56, Class A) Metco 480NS, (GE Spec. B50TF56, Class B) Metco 51F-NS Metco 51NS Metco 54NS-1 Metco 57NS Metco 58NS Metco 601NS Metco 63 NS Metco 66F-NS Metco 68F-NS-1 Metco 70-CNS and Metco 404NS Blend Metco 72F-NS (Class A) Metco 73F-NS-1 Metco 81NS (GE Spec. B50TF137, Class B)
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Metco 81VF-NS (GE Spec. B50TF137, Class A) Metco Aluminum Wire Metco Sprabronze AA Metcoloy 33 Metcoseal AP Metcoseal APT Ni-Pd-Cr-B Nickel Braze Alloy (GE Spec. B50TF90) Rene 80 Spraybond Sulzer Metco 4538 Sulzer Metco 8400 Sulzer Metco 8443 Sulzer Metco 8718
Ref No. C07-027 75% Chromium Carbide; 25% Nickel Chromium Powder C07-028 Aluminum Wire C07-024 Aluminum Bronze Alloy Wire C07-006 Nickel-Iron-Chromium Wire C01-030 Sealer C01-031 Thinner C06-025 Braze Alloy C06-027 Nickel Braze Alloy C06-032 Alloy Powder C07-005 Molybdenum Wire C07-050 Nickel-ChromiumSilicon-Iron Powder C07-042 Nickel-Aluminum Wire C07-043 Nickel-ChromiumAluminum Wire C07-049 Alloy 718 Wire C02-073 Oil C10-214 Fluid, Leak Detection C10-214 Fluid, Leak Detection C04-159 Abrasive, Tumbling C04-130 Abrasive, Tumbling
Sunnen Products Co. Swagelok Sweco Inc.
MV-30 Real Cool Snoop Snoop F7-16C 0.44 in (11.2 mm) cylinder fine cut Sweco 30 deg. Angle Cut Cylinders B1-4 (1/4 dia. x 11/ 32) Sweco 30 deg. Angle Cut Cylinders B3-16 ( 3/16 dia. x 11/32)
Syon Corporation
Resin Pack # 039-080055-685
C01-060 Epoxy
EFFECTIVITY: ALL
70-80-30
Supplier Supplier T. C. Specialties, Inc. Trade Name Trade Name 10-P2-3 and Catalyst EC-110 (Type III) 4221-T27875 4222T36231 and Catalyst 0200T126 4224-T12197 and Catalyst 0200T129 4229-T17038 and Catalyst 0200T129 (Gloss) 4229-T27038 and Catalyst 0200T126-Semigloss 4229-T37038 and Catalyst 0200T126 - Lusterless 463-12-8 and Catalyst CA-116 643-3-9 and Catalyst X-310A 646-58-3695 and Catalyst X-501 646-58-7038 and Catalyst X-501 Akzo Nobel 10-P20-13 and Catalyst EC-213 Akzo Nobel 646-58-7925 and Catalyst X-501 Akzo Nobel 666-58-7038 and Catalyst X-503 TL-29 TL-52 TR-48 (Type I Polyurethane) TR-49 (Type II Epoxy) Tape Works Tempil Inc. / Division of ITW Machbloc Blue Tempilstik 1100 deg. F. Tempilstik 1150 deg. F. Tempilstik 1200 deg. F. Tempilstik 1250 deg. F. Tempilstik 400 deg. F. Tempilstik 600 deg. F. Tesa Tape Inc. (TTI) TESA 53793 Ref No. Ref No. C03-060 Epoxy Paint C03-073 Paint, Epoxy C03-056 Epoxy Paint C03-009 Paint C03-010 Paint C03-010 Paint C03 -010Paint C03-005 Primer C03-059 Polyurethane Paint C03-070 Paint, Polyurethane C03-069 Paint, Polyurethane C03-017 Primer C03-018 Paint C03-076 Paint, Flat Black C03-057 Paint Thinner C03-062 Paint Thinner C04-029 Paint Thinner C04-029 Paint Thinner C10-193 Masking Putty C05-012 Temperature Marking C05-012 Temperature Marking C05-012 Temperature Marking C05-012 Temperature Marking C05-012 Temperature Marking C05-012 Temperature Marking C10-063 Masking Tape
EFFECTIVITY: ALL
70-80-30
Supplier The Brulin Corporation The M.F. Cachat Co. The Milburn Co. The Westaim Corporation Thomas and Betts Corp. Timminco Corp. Tiodize Co., Inc.
Trade Name Brulin 815 GD Type BJ0-0930 Ply-2 2101 TY-RAP P/N TY27M Magnesium Alloy Wire (AMS 4395) Tiolube 70 organic solvent base dry film lubricant (GE Spec. A50TF192 Class B) Tiolube 75/75 Water base, dry film lubricant (GE Spec. A50TF192 Class B)
Ref No. C04-237 Cleaner C10-093 Filler, Phenolic Microballoons C10-064 Protective Hand Cream C06-003 Powder NickelAluminum C10-152 Fastener, Self-Locking C07-002 Weld Wire C02-004 Lubricant
C02-004 Lubricant
Titeflex, Inc. TORAY Plastics of America Treibacher-Schleifmittel
95340 (Chafe Guard) GE P/N 3003M28P02 Lumirror Film (Release Agent) 120 Mesh 220 Mesh 320 Mesh (USA), 325 Mesh (International), Aluminum Oxide 325 Mesh (International) 500 Mesh
C10-127 Chafe Guard C10-199 Polyester Film Sheet C04-114 Abrasive, Grit C04-113 Abrasive, Grit C04-220 Abrasive, Grit
C04-220 Abrasive, Grit C04-112 Abrasive, Grit C02-064 Oil
Turco Products, Inc. Subsidiary of Henkel Surface Technologies
Aquasorb
DD2A Deodorized, High Flash Point Kerosene, Turco 6809 E41 Jet Clean B Maskant, Turco No. 537 NAD NAD-SB P41H1 P60H Plaudit
C05-067 Developer C04-181 Suspension Fluid C05-055 Emulsifier and Solvent C04-078 Cleaner, Compound C10-014 Maskant C05-070 Developer C05-069 Developer C05-029 Penetrant C05-101 Penetrant C04-078 Cleaner, Compound
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Turco 2538 Turco 3976 Turco 4008 Turco 4104 Turco 4181 Turco 4181-L Turco 4316 Turco 4316-L Turco 4338-C Turco 4338-L Turco 4409 (Inhibited Phosphoric Acid) Turco 4460-BK Turco 4781-7 Turco 4781-7L Turco 4848-92 Turco 5279-A Turco 5668 and Additives #1, #2, and #3 Turco 5805 Turco 5884, (Type I) Turco 5948 DPM Turco 5948 DPM Thick Turco 5948-R Turco 6045 Turco 6780 Turco 6783-50 (Type II) Turco 6869
Ref No. C04-059 Remover, Paint/ Carbon C04-128 Cleaner, Heavy Duty Alkaline C04-048 Cleaner, Heavy Duty Alkaline C04-073 Acid C04-009 Cleaner C04-009 Cleaner C04-080 Cleaner, Alkaline Permanganate C04-080 Cleaner, Alkaline Permanganate C04-054 Cleaner, Alkaline Permanganate C04-054 Cleaner, Alkaline Permanganate C04-119 Acid C04-201 Solvent, General C04-053 Cleaner, Heavy Duty Alkaline C04-053 Cleaner, Heavy Duty Alkaline C04-132 Cleaner, Compound C04-043 Cleaner, Compound C04-105 Remover, Paint/ Carbon C04-250 Cleaner, Carbon Removal Gel C04-140 Cleaner, Gas Path C04-208 Cleaner, Compound C04-232 Cleaner, Compound C04-152 Cleaner, Mild Alkaline C04-149 Remover, Silicone Rubber C04-203 Solvent, General C04-140 Cleaner, Gas Path C04-202 Solvent, General
EFFECTIVITY: ALL
70-80-30
Supplier
Trade Name Turco Demask 625 Turco IND 79 Turco Liquid Sprayeze NP-LT Turco Maskolene Turco Scale Gon #5 Turco Stripper No. 5351 Thick Turco Super Carb Turco Vitro-Klene Turcoform Mask 540-R WP-100 LSBD WP-100H WP-170LSBD
Ref No. C03-053 Demasking Compound C04-225 Solvent C04-193 Cleaner, Mild Alkaline C03-067 Paint Booth Coating C04-195 Cleaner, Acid Descaler C04-034 Remover, Paint/ Carbon C04-076 Remover, Paint/ Carbon C04-033 Cleaner, Mild Alkaline C10-014 Maskant C05-030 Penetrant C05-030 Penetrant C05-033 Penetrant C10-124 Tape C10-047 Grinding Wheel
Tyco Electronics / Raychem Interconnect Tyrolit North America Inc.
S-1255 Thermoset Adhesive Tape Grinding Wheel, Electrolytic, A80-150-DM347 DIMI Brass Bond
Supplier U. S. Gypsum Co. U.S. Technology Corp.
Trade Name Ultracal 30 Ultracal All PolyPlus 20/40 Mesh, Plastic Blast Media (MIL-P-85891, Type II, Grade A, 3.5 Mohs Hardness) Ultrachem Assembly Fluid No. 1 Silica-Alumina Fiberfrax Diethylenetriamine (High Purity Grade) Triton X-100 Adiprene, L-167 Caytur 21
Ref No. C01-124 Plaster, Stable C01-123 Plaster Stable C04-153 Abrasive, Plastic
Ultrachem, Inc. Unifrax Corporation Union Carbide Corp.
C02-007 Assembly Fluid C06-022 Ceramic Fiber Insulation C01-024 Catalyst C04-015 Wetting Agent C03-027 Elastomer C03-028 Curing Agent
Uniroyal Chemical Co.
EFFECTIVITY: ALL
70-80-30
Supplier Unisorb Installation Technologies United States Welding USF / Surface Preparation
Trade Name Vibration Dampening Material, Unisorb HB-1/2 (Sheet 1/2 in. x 3 ft. x 5 ft.) 4643 AL Turbaloy 220 Aluminum Oxide Grit, 180 Mesh
Ref No. C10-030 Vibration Dampening Material C06-008 Weld Electrode C06-039 C10-049 Aluminum Oxide Grit
Supplier Van Waters and Roger, Inc. Vantico
Trade Name Triton X-100 Epibond 1210A / 9610 Epibond 8543 (Parts C/B) Epocast 1636 A/B RP6402-1 Resin and Hardener
Ref No. C04-015 Wetting Agent C01-074 Adhesive C01-117 Adhesive C01-070 Potting Compound C01-144 Urethane C10-042 Grit Blast Media C04-111 Chemical Additive, Antirust C04-109 Chemical Additive, Anti-Solidifying C10-115 Grit Blast Media C04-110 Chemical Additive, Wetting Agent C06-019 Binder C10-195 Braze Stop-Off C06-003 Powder NickelAluminum C06-027 Nickel Braze Alloy C06-012 Braze Alloy, Powder C06-014 Braze Alloy Powder C06-026 Braze Alloy Tape C06-013 Braze Alloy Powder C06-002 Braze Alloy C06-015 Braze Alloy C06-017 Tape, Braze
Vapor Blast Mfg. Co.
1250 Novaculite Metrolux No-Pack Novaculite 200 Surfacto
Vitta Corporation
Braz-Binder Gel Grade ST Braz-Stop 1YT Vitta-Braz 1013 Vitta-Braz 1090 Vitta-Braz 1142 Vitta-Braz 1777 Vitta-Braz 1778 Vitta-Braz 1778 Vitta-Braz 1779 Vitta-Braz 1782 Vitta-Braz 1782, Braze Tape
EFFECTIVITY: ALL
70-80-30
Supplier W. W. Grainger W.L. Gore and Associates, Inc. Wall-Colmonoy Corp.
Trade Name Permatex, Form-A-Gasket No. 2 Tetra-Etch Braze Stop-Off, Nicrobraz Green Braze Stop-Off, Nicrobraz Red, Type II Braze Stop-off, Nicrobraz White, Type II LM Nicrobraz Nicroblast Grit Nicrobraz 130 Nicrobraz 135 Nicrobraz Flux Nicrobraz No. 320
Ref No. C01-003 Compound, Sealing C04-007 Surface Treatment C10-015 Braze Stop-Off C10-016 Braze Stop-Off C10-194 Braze Stop-Off C06-014 Braze Alloy Powder C06-028 Blasting Grit C06-013 Braze Alloy Powder C06-002 Braze Alloy C06-038 Flux, High Temperature C01-036 Cement C01-136 Adhesive Film C01-136 Adhesive Film C01-165 Adhesive C02-018 Penetrating Oil C06-020 Braze Alloy Foil
Watkins & Associates
EA 9689.08 (Class E) EA 9689.10 PSF GK (Class D) Hysol EA 9689.09 psf
WD-40 Company Wesgo Metals, A Division Morgan Technical Ceramics, Inc.
WD-40 AMS 4778 (0.001 - 0.003 in. Thick) AMS 4779 (0.001 - 0.003 in. Thick) AMS 4787 / BAu-4 AU-6 Braze Alloy Foil (AMS 4777) Ni-Pd-Cr-B Palniro 7
C06-020 Braze Alloy Foil C06-004 Braze Alloy Gold Nickel C06-021 Braze Alloy Foil C06-041 Braze Foil C06-025 Braze Alloy C06-006 Braze Alloy GoldNickel-Palladium C07-014 75:25 Nickel-Graphite Powder C07-015 85:15 Nickel-Graphite Powder C07-037 Aluminum Silicon Polyester Powder C02-033 Petrolatum
Westaim Corp.
75:25 Nickel Graphite Powder 85:15 Nickel Graphite Powder Westaim 1601
Witco Corp.
White Fonoline
EFFECTIVITY: ALL
70-80-30
Supplier Wm. Buchanan Supply Co.
Trade Name 240 grit aluminum oxide. Greaseless #240
Ref No. C10-096 Compound, Polishing
Supplier Zip-Chem Products
Trade Name ZIP-D-5460NS MoS2 Colloidal Suspension (GE Spec. A50TF192 Class C) Zirspra 8 w/o YS (-200, +325)
Ref No. C02-004 Lubricant
Zircoa Products
C07-035 Zirconium OxideYttrium Oxide Composite Powder C07-035 Zirconium OxideYttrium Oxide Composite Powder C04-140 Cleaner, Gas Path C04-140 Cleaner, Gas Path C10-086 Tape, Graphit Cloth
ZrO-8%Y203 (-200, +325)
Zokman Products, Inc Zoltek
ZOK27, (Type II) ZOK27-RTU, (Type IIRTU) Panex 30, SW08 1.5 in. wide
EFFECTIVITY: ALL
70-80-30
EFFECTIVITY: ALL
70-80-30

Honeywell AS907 Standart Practices Manual

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Engines, Systems & Services Phoenix THE ATTACHED STANDARD PRACTICES MANUAL, 72-05-14 IS ISSUED FOR USE IN SUPPORT

Engines, Systems & Services Phoenix

VOLUME I STANDARD PRACTICES MANUAL

PART NUMBER 3030001-4

MODEL NUMBER AS907-1-1A

STANDARD PRACTICES MANUAL

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List of Effective Pages

Table of Contents LEP-1 LEP-2 Dec 01/03 Dec 01/03 Introduction

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Chapters 70 STANDARD PRACTICES

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INTRODUCTION TABLE OF CONTENTS

SUBJECT INTRODUCTION Scope. Task Coding.

CHAPTER/ SECTION/ SUBJECT

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STANDARD PRACTICES MANUAL AS907-1-1A

ATA NUMBERING SYSTEM

ELEMENT ONE SYSTEM CHAPTER