Process Specification
PCS-2500
Issue: 5
Date: October 26, 2016
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POLYURETHANE PAINT - TWO-COAT PROCESS
PEINTURE POLYURETHANE - GAMME BICOUCHE
Distribution Restricted
YES
NO
X
Suppliers Portal Access Allowed
YES
X NO
To access to Restricted Documents:
- Safran Landing Systems/ Landing Gear and Integration Division Supplier, submit completed file SCFORM
18 to your local Supplier Quality Representative
- Safran Landing Systems/ Landing Gear and Integration Division Personnel, contact the Material &
Processes laboratory of your site
Issue N° Date
Changes
1
Original issue.
Création du document.
Cancels and supersedes IFC 30.117.05MD et IFC 30.117.05 MDE
Annule et remplace l'IFC 30.117.05 MD and IFC 30.117.05 MDE
Change of viscosity cups
Changement des coupes viscosimétriques
Clarification of approved Akzo Nobel site
Recommendation about top coat colour
New recommendations about degreasing
Modification of oven uniformity class
Elimination of data sheets which were in Issue 2 appendices
New para: qualification test and requirements
Para 5 – Health and Safety updated
Safran Landing Systems/Landing Gear and Integration Division instead of MessierBugatti-Dowty in the entire document
Para 11 – Introduction of alternative to C 21/100 UVR for over layer configuration
(amelioration type B, as per PV-8660 justification)
2
3
4
5
06/1999
05/2002
04/2008
02/18/2016
10/26/2016
Compiled by
J. ECHOUARD: Materials and Process Laboratory Engineer (F)
Approved on file
J EL-RABBANI: Special Processes Quality Assurance (C)
Approved on file
I. BENNETT: Design (UK)
-
Agreed by
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R. LEE: Stress (C)
V. COSSART: Functional Group leader Operations – Special
processes (F)
Approved on file
Approved on file
Approved on file
Approved on file
Specification prime owner
P. TAYLOR: Materials and Processes Laboratory Manager (F)
Page 1/18 E
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Toute copie après la date de publication est pour information seulement. Avant utilisation, vérifier sa validité.
Ce document est la propriété de Safran Landing Systems et ne peut être reproduit ou communiqué sans son autorisation
Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
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INDEX
1.
INTRODUCTION
3
2.
SUBJECT AND SCOPE
3
3.
ASSOCIATED SPECIFICATIONS
3
4.
DEFINITIONS
4
5.
HEALTH AND SAFETY
4
6.
PAINT SHOP
5
7.
QUALIFICATION OF THE OPERATORS
6
8.
ACCEPTANCE INSPECTION OF THE PAINTS
7
9.
STORAGE OF THE PRODUCTS
7
10.
PREPARATION OF THE SURFACES TO BE PAINTED
9
11.
PRODUCTS AND COMPOSITION OF THE PROCESS
10
12.
APPLICATION OF THE PAINT
13
13.
LOCAL RESTORATION OF THE PAINT
16
14.
INSPECTION BEFORE AND AFTER PAINTING
17
15.
QUALIFICATION TEST PROGRAMME AND REQUIREMENTS
18
APPENDIX:
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APPENDIX A - EXAMPLE OF A CRITICAL OPERATION SHEET
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20
Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
PCS-2500
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Polyurethane Paint - Two Coat Process
1. Introduction
A. This specification cancels and supersedes IFC30-117-05 MDE.
B. Paint protection shall not be considered simply as an improvement to the external appearance of
components; it constitutes a very important operation, the satisfactory execution of which contributes to
the correct behaviour of the parts in service and thus to the safety of the aircraft. It is essential that all
personnel involved in the application or the inspection of paint be thoroughly aware of the importance
of their work.
2. Subject and Scope
A. This document defines the application characteristics for the protective treatment by non-flexible twocoat polyurethane paint, resistant to phosphate esters, mineral oil, synthetic hydrocarbons and
plus
synthetic ester fluids (Skydrol, Hyjet IVA , MIL-H-5606 and MIL-H-83232).
B. When called up on a drawing, the application of this standard is mandatory for all manufacturing work
carried out at Safran Landing Systems/ Landing Gear and Integration Division, its Partners or its SubContractors.
3. Associated Specifications
Aerospace Series - Paints and Varnishes-Technical Specification
B. ISO 1513
Paints and Varnishes - Examination and Preparation of Samples for Testing
C. ISO 3251
Paints and Varnishes - Determination of Volatile Matter and Non Volatile Matter
D. ISO 2409
Paints and Varnishes - Cross-Cut Test
E. ISO 2431
Paints and Varnishes - Determination of Flow Time by use of Flow Cups
F. ISO 2811
Paints and Varnishes - Determination of Density
G. MIL-A-8625
Anodic Coatings for Aluminium and Aluminium Alloys
H. AMS 2750
Pyrometric
I.
PCS-2620
Hot Degreasing
J.
PCS-2622
Cold Degreasing (solvent)
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A. EN 3840
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K. PCS-2621
Alkaline Degreasing of Parts
L. PCS-2700
Paint Stripping
M. PCS-2220
Protective Chemical Treatment of Aluminium Alloys
N. PCS-2141
Low Embrittlement Cadmium Brush Plating
O. PCD-341
Manufacturing Sealed Process ("AFA" parts)
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
4. Definitions
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A. Batch
(1) A batch is to consist of parts which are subjected to the same painting operation without
interruption.
B. Oven-Load
(1) An oven-load is to be constituted of parts whose paint is cured at the same time and in the same
oven.
C. Two-Coat paint Process
(1) Paint Process consisting of primer and finish, with the primer fulfilling the functions of adhesion and
anti-corrosion coating.
D. Competent Authority: Person (or group of persons) within Safran Landing Systems/ Landing Gear and
Integration Division authorised to take decisions for granting exceptions to the present standard. This
(these) person(s) is (are) defined as follows:
“When there is a request for any deviation from the requirements of this specification, the request shall
be processed via the Quality Department responsible for the surveillance of the area/site of
manufacture. All queries relating to any technical aspect of the component must be addressed to the
technical design office responsible for the design of the part within Safran Landing Systems/ Landing
Gear and Integration Division.Technical design office means the combination of design analysis,
stress, performance and materials competencies within Engineering. Decisions on parts where the
component design, base material, its processing, or treatments are concerned will be provided via the
route. When the query addresses issues which will not affect the life or function of the part, e.g.
“cosmetic” variations, the decision will be given by the responsible Quality Department. (Please note
that surface finish, protective treatment variances and profile variations must not be interpreted as
“cosmetic”)”.
E. AFA: Articles of approved manufacture.
5. Health and Safety
A. The implementation of certain special processes involves the use of substances or chemical mixtures
which may represent a risk to health, safety or the environment. In addition to the applicable
regulations, Safran Landing Systems/ Landing Gear and Integration Division and its subsidiaries
(Messier-Dowty Inc., Messier-Dowty Ltd, Messier-Dowty Mexico SA DE CV, Messier-Bugatti-Dowty,
Messier-Dowty Suhzou Co) require that the use of certain substances by the operators of these
processes (sub-contractors or internal departments) be prohibited and/or restricted. Such prohibitions
and/or restrictions are described in the GRP-0087 Safran procedure.
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B. Additionally, in strict compliance with the Health and Safety regulations applicable to them, Safran
Landing Systems/ Landing Gear and Integration Division and its aforementioned subsidiaries:
•
encourage the operators of these processes (sub-contractors or internal departments), to opt for
the chemical substances presenting a minimal risk for a given family of processes, whenever
several choices are possible.
•
request from them to collect, to comply with and to implement the recommendations, the uses
identified and the preventive and protective measures provided in the material safety data sheets
for the chemical substances used in the processes and/or resulting from the evaluation of
chemical hazards at the place of work (workstation).
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
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6. Paint Shop
A. Instructions
(1) Installation
(a) The shop shall be an enclosed area, but one which is well ventilated and dust-free, employed
exclusively for the application of protective products. The air introduced by the ventilation
system shall not contain any solvent vapour from the degreasing tanks.
(b) In order not to contaminate the atmosphere inside the shop, an enclosed and ventilated area,
at the same temperature as the shop, shall be specially set up for the storage of the paint
drawn from stores and the preparation of the paint (mixing and dilution).
(c) The compressed air installation shall be equipped with filters for the retention of moisture, oil
and solid particles.
(2) Cleaning of the Shop
(a) Dust removal shall be by suction. The beams, consoles, supports and transfer equipment shall
be free of dust, liable to fall onto prepared or newly painted parts.
(3) Ambient Conditions
(a) The following ambient conditions shall be maintained while work is in progress:
1
Temperature
2
Relative humidity 35% to 75%
15 °C to 35 °C (59 °F to 95 °F)
(b) The recommended conditions are:
1
Temperature
15 °C to 25 °C (59 °F to 77 °F)
2
Relative humidity
40% to 70%
NOTE:
Exceptionally, relative humidity outside the range of 35% to 75% are acceptable,
providing special provision is made for the production of a test panel as in para
12.E.(1) or representative of the component. The panel shall be painted and cured at
the same time as the component and the adhesion of the paint film determined as
outlined in para 12.G.(2)(d).
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(c) The shop shall be equipped with a recording hygrometer and a recording temperature indicator.
The records shall be kept to ensure traceability of the painting conditions applied on the parts.
(d) Sudden changes of temperature and relative humidity occurring at the start of drying can be
prejudicial to the subsequent drying of the product. Furthermore, condensation may take place,
preventing the adhesion of subsequent Coats. The shop shall be maintained to relatively
constant conditions during the curing time of all Coats.
(4) Display of the Process Sheets
(a) The mixtures, viscosities, drying times and the curing durations and temperatures defined in
Technical Data sheets of product, together with the degreasing methods shall be displayed in
the shop, on a large-size poster.
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
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(b) Latest issue of Technical Data Sheets are available at the AKZO Nobel Aerospace Coatings
website: www.anac.com or by the supplier contact.
(5) Equipment for Preparing the Mixtures
(a) For preparing the paint, the operators shall use graduated containers for mixtures by volume
and a balance for mixtures by weight.
(b) If at all possible, the shop shall be equipped with an automatic mixer.
B. Checks
(1) Installation
(a) Check during audits that the provisions defined in para 6.A.(1) are being observed.
(2) Ambient Conditions
(a) The ambient temperature and relative humidity shall conform to the conditions defined in para
6.A.(3)(a).
(b) If the conditions are outside these limits, produce a painted test panel according to 6.A.(3)(b)2.
(c) Restore unsatisfactory installations to conformance.
(3) Compressed Air
(a) Check the cleanliness of the compressed air at least once per week, at the start of work and
before the first Application.
(b) Method of Checking:
1
Degrease a glass or polished metal plate and wipe it with a clean rag; (Use of clean white
card is an acceptable substitute to the glass/metal plate)
2
Hold the air outlet perpendicularly to the plate, at a distance of 20 to 25 cm (8 to 10 in), and
blow at the full rate for at least 15 seconds
3
During and after the blowing, look for the appearance of droplets of oil or water
4
After the test, the plate should appear as clean as at the beginning
(c) Adjust the conditions for the filtration of the compressed air until the desired result is obtained
(4) Ovens and infra red furnaces.
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(a) Ovens must be in accordance with AMS-2750 class 5 requirements.
(b) Calibration of infra red furnaces parameters shall be followed up to maintain paint properties as
described in para. 15.
(c) Force drying of primer and finishing coat is not permissible at a temperature over 71 °C (160
°F) on assemblies incorporating elastomer and is not permissible at a temperature over 112 °C
(234 °F) on detail parts.
7. Qualification of the Operators
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
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A. The operators responsible for the Application of the paint shall have received prior training in the
standard practice for this Process succeeding to their qualification according to Quality procedure in
force in the site.
8. Acceptance Inspection of the Paints
A. The checks listed below are to be carried out on all the products given in para 11.B.
B. Documents
(1) Check the presence of the Certificate of Conformance in accordance with EN 3840 on which
shall be indicated the expiry date of the product. The expiry date shall be added to the container
label if it is not already shown.
C. Identification
(1) Check that the following information is shown on the containers:
(a) Manufacturer’s Name
(b) Description of the product (thinner, finish, etc)
(c) Colour of the product in the case of finish
(d) Contents in litres or net weight
(e) Batch number
(f) Date of manufacture
(g) Date of life expiry
D. Testing
(1) Given the risk of the deterioration of the products once the containers have been opened, no
acceptance tests for paints are proposed. Nevertheless, if checks carried out during use reveal a
deficiency of any kind, either all or part of the batch in the stores is to be subjected to examination,
according to ISO 1513 or it shall be quarantined and the supplier consulted.
(2) In this case, the following tests shall be performed:
(a) Density according to ISO 2811
(b) Viscosity according to ISO 2431
(c) Dry extract according to ISO 3251
E. General Inspection Requirement
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(1) Consignments which are unsatisfactory or which have less than 9 months to life expiry shall be
rejected.
9. Storage of the Products
A. Instructions
(1) Keep the products in stores which are frost-free, under cover and ventilated, and as far as possible
at a temperature between 15 °C to 25 °C (59 °F to 77 °F), remote from any source of ignition and
oxidising products. In particular, make sure that the containers are sheltered from the sun.
(2) A few moments before they are placed in storage, turn the containers upside down so as to seal the
lids on the inside (optional in the case of containers provided with sealing rings).
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
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(3) Arrange the containers so that the ‘first-in, first-out’ procedure is followed.
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
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10. Preparation of the Surfaces to be Painted
A. Instructions
(1) Ensure that the last surface treatment before the painting is not contaminated by, for example:
(a) Stains caused by the intermediate operations (re-machining, assembly, etc)
(b) The storage duration and conditions.
(2) Check that:
(a) There is no sign of oxidation
(b) The surface finish of the part to be painted is compatible with the achievement of the natural
appearance of the paint (not grainy)
(c) The surface finish of the parts is that called up on the drawing (particularly hollow bodies)
(3) If not, rectify any unsatisfactory parts before painting.
B. Degreasing
(1) Degrease using vaporised chlorinated solvents in accordance with PCS-2620. It is recommended
that, for parts with particular geometries (internal diameters), this vaporised degreasing be
preceded by a cold degreasing process in accordance with PCS-2622. Alternatively degrease
using alkaline degreasing process in accordance with PCS-2621.
(2) If vaporised degreasing is incompatible with the materials existing on the part or if it cannot be
performed, a cold degreasing in accordance with PCS-2622, using an approved solvent acceptable
to the parent metal, is permissible. Any other degreasing method shall, prior to using, be submitted
to Competent Authority for approval.
(3) The rags supplied shall satisfy the following requirements:
(a) They shall be white and non-fluffy
(b) They shall be made of 100% cotton
(c) They shall not have been treated with either starch or silicones
(d) They shall not contain any stains (such as grease, ink, etc)
(e) They shall be completely dry
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(4) Any fluid which meets the requirements PCS-2622 may be used for cold degreasing, however,
experience has shown that the best results are usually obtained with Methyl Ethyl Ketone (MEK).
NOTE 1:
A double degreasing, using MEK, may have to be carried out.
NOTE 2:
In very specific cases, where the surface treatment and the painting are carried
out without interruption and where every precaution is taken to protect the parts
from any contamination (such as handling, contact with dirty packaging,
remachining), the degreasing may be made optional. Each specific case must be
considered by the Production Manager, with the prior agreement of the Competent
Authority.
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
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C. Masking
(1) The masking shall be applied very carefully, avoiding any deposit of adhesive on surfaces to be
painted.
(2) It is to consist either of metal covers or any suitable masking tape such as aluminium or PTFE.
(3) The use of anti-adherent products on the parts, such as PTFE sprays and silicone-based products,
is totally prohibited.
(4) After masking, a cold degreasing, in accordance with PCS-2622, shall be carried out if necessary.
D. Checks
(1) Check that:
(a) The degreasing has been carried out in accordance with para 10.B.
(b) The masking has been applied in accordance with para 10.C.
(2) Carry out a daily check of the effectiveness of the degreasing with the different products used, in
the following manner:
(a) Spray the part or the test panel with a mist of pure demineralised or distilled water
(b) Check that the film of water is unbroken. Any separation into droplets or any break in the film
will be a sign of inadequate degreasing
(c) Amend the degreasing conditions until an unbroken film is obtained.
NOTE:
A reduction in the frequency of the check of the effectiveness of the degreasing, for
example “weekly”, is possible, with the agreement of the Competent Authority, following
the introduction of a statistical monitoring of the results (of SPC type).
11. Products and Composition of the Process
A.
Commercial Designation of the Paint Scheme Products:
(1) Primer: 463-12-8 AKZO NOBEL AEROSPACE COATINGS
-
Manufactured Approved site: Rijksstraatweg - 2170 BA Sassenheim The Netherlands.
(2) Top-coat: Aerodur Finish C21/100 or Aerodur Finish SGL Aluminium
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Manufactured Approved site: Rijksstraatweg - 2170 BA Sassenheim The Netherlands.
(3) Top-coat as overlayer (alternative to C21/100): Aviox® Finish 77702 or Eclipse® manufactured
by AKZO NOBEL AEROSPACE COATINGS
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
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B. Products
PRIMER (two component
epoxy-amine)
1 Coat
Thicknesses :
Base
Primer 463-12-8
Hardener
CA 116
Thinner
C25/90S or TL/159 or TL/139
Base
Aérodur SGL Alum. Finish
20 – 25 µm
(0.0008 – 0.0010 in)
TOP COAT
1 Coat
Other colours: C21/100 UVR
Thicknesses :
Hardener
S66/22R
40 – 50 µm
Thinner
C25/90S or TL/139 or TL/159
(0.0016 – 0.0020 in)
TOP COAT alternative
for over layer only (see
NOTE 3)
Base
Aviox ® Finish
77702
Eclipse ®
Hardener
90150
PC-233
Activator
99322 or 99330
TR-111 or TR-112
(1) For details of the Processes, refer to Data sheets of AKZO Nobel Aerospace coatings supplier.
NOTE 1:
If the drawing does not specify the colour of the finish, the aluminium colour shall always
be applied.
NOTE 2:
On cadmium plating and on areas with concave radii of curvature or very undulating
shapes, where the paint application is difficult to control, following thicknesses are
allowed:
•
Primer thickness: 20 – 40 µm
•
Top coat thickness: 40 – 90 µm
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This authorization is applicable only for external areas with no functional role.
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NOTE 3:
When the drawing requires to paint a marking on top of the top coat (i.e. over layer),
C21/100 UVR can be substituted by Aviox ® Finish 77702 or Eclipse ®, with the colour
as specified by drawing
C. Preparation of the paints before their Application
(1) Instructions
(a) The mixing of products obtained from different manufacturers is not authorised.
(b) The Application of the paint shall not take place for at least the induction time given in Data
Sheets after mixing the base and hardener.
(c) Utilisation of an automatic mixer which reduces induction time requires prior agreement from
Competent Authority.
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
For indication: Induction time for primer is 30 min and induction time for top-coats is
15 to 30 min.
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NOTE:
(2) Checks on each paint before its application:
(a) Expiry Dates
1
Check that the life expiry dates marked on the containers have not been exceeded. Reject
any container whose life expiry date has been exceeded.
2
Extension of the shelf life duration.
At the discretion of the Competent Authority only, in the exceptional event of supplies
being exhausted and the absolute necessity of using a sealed or opened container which
has passed its shelf life expiry date, the life of a batch of paint may be extended, provided
test specified by the supplier are carried out and the results adequate.
(b) Homogeneity of the Mixtures (during the preparation and prior to filling the spray gun).
1
Dip a clean rod into the mixture deemed to be ready for use.
2
Withdraw the rod, allowing the paint to run on to the surface of the mixture.
3
Check that there is no difference in the colour of the paint running off the rod and the
surface of the mixture.
4
Continue to homogenise the mixture until the desired result is obtained.
(c) Viscosity:
1
Check the viscosity of each mix after induction time waiting period and within the pot life in
accordance with ISO 2431 (ISO cup).
a Use a flow cup and a stop-watch.
b Choose the cup called for by the instructions for the Process used.
c Check that the exit hole is completely clean.
d Close the hole off with a finger.
e Fill the cup completely.
f Remove the meniscus of the paint by passing the straight edge of a blade across the
edge of the cup.
g Remove the finger and start the stop watch at the same time.
-
h Stop the stop-watch when the stream of paint is interrupted.
i
Note the duration of the flow.
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NOTE:
For each type of paint applied, a reduction in the frequency of the viscosity
checks is possible, with the agreement of the competent authority, following the
introduction of statistical monitoring of the results (of SPC type).
2
If the result is not satisfactory, thinner may be added within the limits authorised in Data
Sheet of product given in para 11.B.
3
If the result is not satisfactory after the addition of the thinner, the product shall be rejected.
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
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12. Application of the Paint
A. Painting of AAM/ AFA Parts
(1) Articles of Approved Manufacture (AAM) as defined by PCD-341 specification, whose internal
surfaces are painted in accordance with the instructions of this Standard, are to be subject to a
validation. This validation shall include a check of the suitability of the choice of the operating
parameters by thorough tests, if necessary destructive, in order to confirm conformance with the
criteria of the present Standard. This check is to be the subject of a validation report, compiled in
accordance with paras 14.D and 14.E of this Standard. The parameters are to be recorded on a
critical operation sheet (COS), in accordance with Appendix A of this standard.
B. Painting of Non-AFA Parts of Traceability Class 1
(1) Non-AFA parts in ultra high strength (UHTS) steel or aluminium alloy, of traceability Class 1,
whose internal surfaces are painted, are to be the subject of a technical data sheet. This technical
data sheet is identical to a COS, except that there is no validation.
C. Painting of Non-AFA Parts of Traceability Classes 2 and 3
(1) For parts of traceability Classes 2 and 3, the compilation of a technical sheet is left to the
discretion of the workshop.
D. Application Instructions
(1) Normal Operating Conditions
(a) The paint is normally to be applied by spray gun. During spraying, parts and paints shall be at
the same stabilised temperature as that of the workshop and the atmosphere in the latter as
defined in para 6.A.(3).
(2) Painting of Hollow Parts
(a) If, in the case of hollow parts, application by spray gun is not suitable (due to the part's
complex geometry or an internal diameter of less than 35 mm), filling and draining or roller
application is permissible. The proportion of thinner is in this case determined by the
experience of the operator, and shall be less than that indicated in the data sheet for the
process where the consistency recommended is that appropriate for application by spray gun.
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(3) Painting of Parts in UHTS Steel
(a) The application of this two-Coat Process on unprotected UHTS steel (without lowembrittlement cadmium-plating or without galvanising) is permissible, its epoxy-amine type
primer not being a cause of embrittlement.
(4) Painting in Areas with Close Tolerances
(a) In areas controlled by tolerances, if the notes on the drawing are as follows:
“Primer only” Two coats of primer shall be applied. However, for interference fits, if the note
carries this indication and the tolerances are incompatible with the thickness of the two coats,
the application of one coat of primer only is acceptable.
Page 13/18 E
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
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(5) Curing Conditions of the Different Coats
(a) The recommended curing times of the different coats in each process are given in data sheets
of products given in para 11.B. Curing conditions or alternative heating methods like infra red
require prior agreement from Competent Authority and supplier recommendations.
E. Check of the Process on Test Specimens
(1) Every week add a panel made from 7075 alloy to a batch of parts to be painted. This panel shall
be about 110 mm x 90 mm size (4.33 in x 3.54 in), 2 mm thickness (0.08 in) and protected by
sealed chromic anodising according to MIL-A-8625, type I or IB, class 1.
(2) Mark the test specimen with the date of the test and the paint Process tested.
(3) Carry out an adhesion test in accordance with ISO 2409 (grid + adhesive tape).
(4) Amend the conditions for the Application of the paint if the result of this test exceeds 2, from the
classification given in ISO 2409.
(5) The test specimens shall be kept for at least a year, protected against contamination and physical
damage.
(6) All results shall be recorded.
F. Checks During the Application
(1) Temperature of the parts:
(a) make sure that the parts are at the temperature of the workshop.
(2) Number of Coats, Appearance:
(a) Check on all parts the presence of the appropriate primer, together with its appearance
(absence of runs, gaps, lumps, foreign bodies, etc), before applying the next coat, particularly
in hollow bodies. Re-treat any unsatisfactory parts.
G. Check of the Parts After Final Painting
(1) Sub-contracting
(a) Check that the sub-contractor is included in the current Quality Standard.
(b) Check that the Certificate of Conformance is present.
(2) Check of the Paint
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NOTE: This para describes the inspection methods to be used and the list of the inspection checks to
be carried out for each paint (primer and top-coat).
(a) Appearance
1
Check that there are no gaps particularly on edges, blisters, runs, scratches or embedded
foreign bodies.
2
Rework unsatisfactory parts in accordance with para 13.
(b) Conformance with the Drawing
1
Check the conformance with the drawing. Rework unsatisfactory parts in accordance with
para 13.
Page 14/18 E
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
(c) Thickness of the Coats
Check the total thickness at three points, by one of the following methods:
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1
2
a
A magnetic method (steels), for example Microtest
b
An electro-magnetic method, for example Permascope or Elektro Test
c
Metrology (for parts made from non-metallic materials).
Acceptance Standard
a
If the results are satisfactory, acceptance of the batch.
b
If the results are not satisfactory, inspection of the entire batch and acceptance or
rejection in accordance with the following requirements.
Coat too thin: Have another coat added if possible, if not have the part stripped
and the painting repeated.
Coat too thick: Normally acceptable, provided that there are no geometrical
constraints. A duplicate check of the adhesion is then obligatory.
(d) Adhesive Tape Test
1
Check that the expiry life of the tape, which shall have an adhesive strength of 6.5 ± 0.5
N/cm (55 to 64 oz/in. width), is not out of date. Tapes meeting this requirement
include:3M’s 2525, 250, 2526, 2517 and Adhetec’s 1750 tape.
2
Press a piece of adhesive tape on the surface to be tested.
3
Rub the area of contact vigorously, then tear the tape off sharply at an angle of 45 to 90
degrees to the part.
4
No detachment shall be observed. If the result is unsatisfactory, repeat the test on all the
parts in the batch and have the unsatisfactory parts repainted.
(e) Curing
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1
In order to ensure complete curing perform one of the two following tests:
a
MEK method. Rub the paint with a rag soaked in methyl ethyl ketone (MEK) over a
length of approximately 2 to 3 cm (1 in), making 50 passes. At the end of the test, the
primer shall not be visible (it is acceptable for the rag to have been slightly coloured by
the top-coat finish).
b
Phosphate Ester method. Press a pad soaked in phosphate ester fluid against the
painted part for 10 minutes. Wipe dry with tissue and inspect. No marks shall appear
on the paint.
c
If the result of either test is unsatisfactory:
-
- Check the oven
- Repeat a curing cycle
- Repeat the test. If the result is again unsatisfactory, have the unsatisfactory parts
stripped and repainted.
(f) Inspection Checks to be Carried Out:
Page 15/18 E
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
Appearance on all parts
b
Conformance with the drawing on all parts
c
Thickness on 10% of the parts in the batch, with a minimum of 2 parts
d
Adhesion on 10% of the parts in the batch, with a minimum of 2 parts
e
Cure on one part per oven-load
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a
13. Local Restoration of the Paint
A. Product for Local Restoration of the Paint
(1) For local restoration of the paint, use product presented in para 11.B of this PCS or product
presented in para 11.C of the PCS-2530.
B. Instructions
(1) If the restoration cannot be performed in a paint shop but only in an area not equipped with
hygrometric measuring equipment, it is acceptable to consider hygrometer readings taken
elsewhere on the same site. Each operation is to be performed by exceeding the damaged area to
be repainted by at least 2 mm (0.08 in) all round. The new paint shall cover the whole of the
roughened area.
(2) Restoration of recent paint, not cured. For parts on which the paint has not been oven-cured, or
whose drying time at ambient temperature is less than 7 days:
(a) Remove any non-adherent paint with adhesive tape to delimit the area to be repainted
(b) Degrease in accordance with para 10.B
(c) Repeat the paint process: primer, primer + top coat or top coat only depending on the degree
of the deterioration
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(d) If an Infra-Red lamp is used to accelerate the curing of the top-coat, the process (lamp,
curing, conditions, maximum surface cured) shall be validated by the Competent Authority as
follows:
1
The lamp shall be validated by the paint manufacturer
2
The paint manufacturer shall define the curing conditions with the lamp (time,
temperature, distance from the part, wave length,etc) and the maximum paint surface
cured with such a lamp
3
Qualification test shall be performed (curing test by MEK and adhesion test before and
after immersion in the relevant fluids)
4
The level of curing shall be tested by MEK for each painted surface
-
(3) Restoration of hardened or old paint. For parts on which the paint has been oven-cured or whose
drying time at ambient temperature is more than 7 days:
(a) Remove any non-adherent paint with adhesive tape to delimit the area to be repainted.
(b) Roughen with Scotch-Brite or fine abrasive paper, taking care not to alter the basic protective
treatment (cadmium-plating, anodising, etc), otherwise carry out a local repair on a clean
surface:
1
By brush cadmium-plating steel, in accordance with PCS-2141
2
By MCAC restoration, in accordance with PCS-2550
Page 16/18 E
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
or
Chemical oxidising of aluminium, in accordance with PCS-2220
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3
(c) Degrease in accordance with para 10.B.
(d) Repeat the paint Process: primer, primer + top-coat finish or top-coat finish only depending
on the degree of the deterioration.
C. Check that the instructions in para 13 have been complied with, in particular:
(1) The replacement of all the missing or defective coats
(2) The damaged area has been exceeded by at least 2 mm (0.08 in)
(3) The coverage of the whole of the roughened area
D. Complete Renewal of the Paint
(1) Stripping
(a)
As indicated in PCS-2700, except on parts in IXEF or in Epoxy-Glass Composites. In these
cases, mechanical stripping only (sanding) is authorised, care being taken not to alter the
surface of the parts (risk of laying bare the glass fibres).
(b)
After stripping, follow the full normal painting procedure from para 10, as if for a first
application.
14. Inspection Before and After Painting
A. All the checks described below shall be carried out:
(1) On parts with accessible internal and external surfaces: carry out the checks on one production
part.
(2) On AFA parts with inaccessible surfaces: carry out the checks on a rejected part or on a model
which has the same geometry as the inaccessible surfaces. The part or the model shall be reusable
for revalidations. The part or the model is to be open to allow the checks to be carried out and to
make the whole of the painted surface accessible.
B. Checks
(1) Prior to Painting
(a) Degreasing: carry out a water film test. The water shall wet the surface completely, without any
break in the film or separation into droplets.
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(b) Confirm the presence of the surface treatment on the surfaces to be painted as indicated on
the drawing as defined in para 12.F.(2)(b).
(2) After Painting
(a) Appearance as defined in para 12.F.(2)(a).
(b) Thickness of the Coats as defined in para 12.F.(2)(c).
(c) Adhesion as defined in para 12.F.(2)(d).
(d) Curing as defined in para 12.F.(2)(e).
NOTE: A reduction in the frequency of these checks is possible, with the agreement of the
Competent Authority, following the introduction of statistical monitoring of the results (of
SPC type).
Page 17/18 E
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
C. Instruments
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(1) Calibrated thickness gauge according to Quality procedure in force.
D. Validation Parameters
(1) The validation parameters are indicated in the Critical Operation Sheet in Appendix A. Any
parameter followed by the letter "S" is a significant parameter. Any change to a significant
parameter implies a revalidation.
E. Validation Report
(1) Compile a report consisting of:
(a) The inspection equipment and methods used
(b) The Critical Operation Sheet, completed with the details of the operating conditions
15. Qualification Test Programme and Requirements
A
Scope of the Qualification Test Programme
This qualification test programme define what tests to perform to be qualified as a competent shop
for paint application per PCS-2500.
This tests do not exempt from carrying out all the production check required along this PCS.
B
Qualification Test Programme and Requirements
These qualification tests have to be carried out on all substrates painted per this PCS-2500 by the
shop:
(a) Each Metallic substrates with its anti-corrosive first protection
(b) Each Non Metallic substrate with its initial protection coating.
NOTE The Competent Authority shall requires further tests to qualify a competent shop for paint
application per PCS-2500
Property
Test method
Unscribed neutral salt
corrosion resistance
ASTM B 117
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Paint adhesion on all
substrate-surface treatement
Requirement
-
1500h without corrosion
ISO 2409
Test shall be performed on a
minimum of two coupons
Scratch Test
ISO 1518 and CQ 734-34
Water immersion
ISO 2812 (1000h at 23 °C +/- 2 °C)
Coupons scribbed on one face
Fluid susceptibility
Immersion in Hyjet 5 (Skydrol)
during 336h at 70 °C +/- 2 °C
per MIL H 83282
Ranking: inferior or equal to 1
No penetration to the substrate up to a load of
1500 g weight before immersion and 1200 g
after immersion
Requirement after immersion:
Adhesion: ranking inferior or equal to 1
Scratch test: 1200 g with no penetration to the
substrate
Page 18/18 E
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Process specification
PCS-2500
Issue: 5
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Date: October 26, 2016
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Process specification
PCS-2500
Issue: 5
Date: October 26, 2016
APPENDIX A - EXAMPLE OF A CRITICAL OPERATION SHEET
CRITICAL OPERATION SHEET
PROCESS
N° 2
PAINTING OF INTERNAL SURFACES ON PARTS
STDS:
PAINTING: NOZZLE GUIDANCE
TYPICAL DIAGRAM
PCD 341
PCS 2500
STEEL WHOSE UTS > 1450 MPa AND ALUMINIUM ALLOYS
S Indicate the chronology and the type *): _________________________________
1 DEGREASING
________________________________________________________________________________________________
S
POSITION OF THE PART: (SEE SKETCH)
_______________________________________________________________________________________________
2
S
NOZZLE GUIDANCE (+ SKETCH)
3
S
TYPE OF NOZZLE
SEQUENCE OF OPERATIONS
4
S
PRESSURE (POT)
5
S NUMBER OF
PASSES
6
S
TOOL REF.
(MASKS)
SKETCH
PRIMER
FINISH
From --------- bar
To --------- bar
From --------- bar
To --------- bar
From --------- bar
To --------- bar
From--------- bar
To --------- bar
--------------------
DEGREASING:
--------------------
--------------------
TYPICAL DIAGRAMS (chronology)
Issued by
-
Issue
Date
Checked by
Signatures
MATERIAL
_________________
PLANT
STRENGTH
WORK POSITION
REFERENCE OF THE
VALIDATION REPORT
PART NUMBER
_________________ ______________________________________________
ON: _______
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SHEET
1
DRAWN
BY: _________
NOTE: In case of S parameter modification (one or several), a revalidation is requested.
Quality Signature
VALIDATION
DESCRIPTION
OF THE PART
______________________________________________
____________________
*) Degreasing: indicate all the degreasing conditions: solvent, vaporised or liquid, method (degreasing machine or by rag),
position of the parts (with a sketch) during the degreasing, state whether the operation takes place in several stages.
Date
SIGNATURE________
SCHEDULE N°
Page 18/18 E
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1