Corocion Control Manual

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ATP Grid Index to Manufacturers Publications:

Sabreliner Corp.NA-265 SERIESCorrosion Control Manual

Section T_opic_

General Information

Title PageList of Chapters (Table of Contents)Manufacturers IntroductionRecord of RevisionsRecord of Temporary RevisionsLetter of Transmittal (Highlights of Changes)List of Effective Pages

Airframe Systems

20.00.00 Standard Practices Airframe20.00.00 List of Effective Pages20.00.00 General20.00.10 Corrosion on Airframe20.00.20 Corrosion on Electrical Equipment20.00.90 Sources of Commercial Proucts20.10.00 Cleaning20.10.05 Magnesium Alloys Cleaning and Protective Treatments20.10.10 Cleaning Iron and Steel20.10.15 Cleaning Aluminium and Aluminium Alloys20.10.20 Cleaning Corrosion and Heat Resistant Alloys20.10.25 Cleaning Copper and Copper Alloys20.10.30 Cleaning Titanium and Titanium Alloys20.10.35 Cleaning Plastic and Glass20.10.40 Polishing Sheet Acrylic Plastic20.10.45 Stripping Organic Finishes20.10.50 Stripping Organic Coatings from Metals20.10.55 Solvent Vapor Degreasing

03/03/2001 Copyright Aircraft Technical Publishers Page a of 5SE 0001 CV)

Section Topic

20.10.60 Abrasive Cleaning20.20.00 Sealing20.20.02 Sealing Methods20.20.02 Service Information Letter No. 5720.20.04 Sealing Integral Wing Fuel Tanks20.20.06 Fuel Tight Faying Surface Sealing for Areas/Normal20.20.06 Operating Temperatures from -65 to +200F20.20.08 Liquid Tight Sealing of Areas/Normal Operating20.20.08 Temperatures from -65 to 225F20.20.10 Pressure Tight Sealing for Areas/Normal Operating20.20.10 Temperatures from -65 to +225F20.20.12 Pressure Tight Sealing for Areas/Normal Operating20.20.12 Temperatures from -65 to +225F (Alternate Procedures)20.20.14 Fume Tight Sealing for Areas/Normal Operating20.20.14 Temperatures from -65 to +225F20.20.16 Application of Self-Contouring Sealing Pads for Areas20.20.16 Where Normal Operating Temperatures Do Not Exceed 225F20.20.18 Exterior Watertight Sealing for Areas/Normal Operating20.20.18 Temperatures from -65 to +225F20.20.20 Faying Surfaces Sealing for Areas/Normal Operating20.20.20 Temperatures from -60 to +225F20.20.22 Liquid Tight Sealing for Areas/Normal Operating20.20.22 Temperatures from 225 to 400F20.20.24 Pressure Tight Sealing for Areas/Normal Operating20.20.24 Temperatures from 225 to 350F20.20.26 Fume Tight Sealing for Areas/Normal Operating20.20.26 Temperatures from 250 to 400F20.20.28 Application of Self-Contouring Sealing Pads for Areasl20.20.28 Normal Operating Temperatures from 225 to 550F20.20.30 Flame Resistant and Liquid tight Sealing for Areas/20.20.30 Normal Operating Temperatures From 225 to 400F20.20.32 Faying Surface Sealing for Areas/Normal Operating20.20.32 Temperatures From -100 to +550F20.20.34 Installation of O-rings for Fuel System20.20.36 Installation of O-Rings for Fuel Sys Bolted Assy20.20.38 Instl Procedures for O-Rings Sealing of Bolted Assy20.20.40 Application of Tape or Sealant Corrosion Barriers20.20.40 between Magnesium and Other Metals20.20.44 Electrical Systems Room Temperature Curing Silicone20.20.44 Rubber Potting20.20,46 Potting Bendix Connector for Use to 300F

03/03/2001 Copyright Aircraft Technical Publishers Page 2 of 5SE 0001 CV)

Section Topic

20.20.48 Sealing Electric Terminations with Overcoating20.20.50 Sealing Neoprene Jacketed Multiconductor and Coaxial20.20.50 Cable and Kel-f Jacketed Coaxial Cable Terminations20.20.52 Moisture Proofing flee Components/Strippable Sealant20.20.54 Sealing Electrical Wire Bundles Passing thru Bulkheads20.20.56 Sealing Electric Terminations Subject to Temp Up to 300F20.20.58 Sealing Electrical Terminations Subject to a Maximum20.20.58 Temperature between 300 and 400F20.20.60 Application of Sealant Electrical Wire Bundles Passing20.20.60 through Bulkheads for Max Serv Temp from 350 to 500F20.30.00 Organic Base and Finish Coating20.30.05 Cati-Coat Primer Application20.30.10 Wash Prime Application20.30.15 Moisture and Fungus Resistant Coating Application20.30.20 Painting Metal Surfaces/Epoxy Poly a Mide Primer or20.30.20 Zinc Chromate Primer20.30.25 Conversion Type Coatings Application20.30,30 Polyurethane Finish Sys for Sabreliner A/C Ext Surface20.30.35 Mil-C-83286 Polyurethane Enamel Application20.30.40 High Impact Polyurethane Coating Application20.30.45 Urethane Finish Sys for Sabreliner A/C Ext Surfaces20.30.50 Wrinkle Finish Application20.30.55 Laminated and Molded Plastic Parts Finishing20.30.60 Abrasion Resistant Coating Application20.30.65 Rain Erosion Resistant Coating Application20.30.70 Spray Painting Methods Techniques20.30.75 Radome Coating Material Application20.30.80 Polyurethane Integral Fuel Tank Coating Application20.30.85 Organic Integral Fuel Tank Coating Application20.30.90 Protection of A/C In Out-Of-Doors Temporary Storage20.40.05 Anodizing and Coloring of Aluminium Alloys20.40.10 Chromic Acid and Sulfuric Acid Anodizing20.40.15 Dow No. 17 Anodize Process for Magnesium Alloys20.40.20 Application of TFE Infused Coating on Aluminum20.40.25 Application of Scale Inhibiting Compound20.40.30 Phosphate Treatment20.40.35 Application of Chemical Films to Aluminium Alloys20.40.40 Chemical Film Treatment for Titanium and Titanium Alloys20.40.45 Electrodeposited Hard Nickel Plating20.40.50 General Procedure for Brush Type Electroplating20.40.55 Tin Plating by Electrodeposition or Hot Dipping

03/03/2001 Copyright Aircraft Technical Publishers Page 3 of 5SE 0001 CV

Section Topic

20.40.60 Hard Chromium Plating20.40.65 Copper Plating20.40.70 Brush Cadmium Plating20.40.75 Nickel-Zinc Alloy Plating20.40.80 Electroless Nickel Plating20.40.85 Repair and Refinishing of Abraded, Scratched, Reworked,20.40.85 or Corroded Metal Surfaces

24.00.00 Electrical Power24.00.00 List of Effective Pages24.70.00 Accesory Compartment24.70.00 Battery Compartment

32.00.00 Landing Gear32.00.00 List of Effective Pages32.00.00 General32.80.00 Wheel Wells

Structures

52.00.00 Doors52.00.00 List of Effective Pages52.10.00 Passenger/Crew52.10.00 Main Entrance Door Corrosion Inspection52.20.00 Emergency Exit52.20.00 Inflight Escape Hatch Removal, Inspection Installation

53.00.00 Fuselage53.00.00 List of Effective Pages53.00.00 General53.10.00 Forward Fuselage53.20.00 Center Fuselage53.30.00 AFT Fuselage

54.00.00 Nacelles/Pylons54.00.00 List of Effective Pages54.00.00 General

55.00.00 Stabilizers55.00.00 List of Effective Pages55.00.00 General


Section Topic

57.00.00 Wings57.00.00 List of Effective Pages57.00.00 General57.10.00 Center Wing57.10.00 Wing Structure

End of Index


IVI FGI

INTRO

Report No. 8B-76-023

Sabreliner

Corrosion

Control

Manual

ALL MODELS NA 265 AIRCRAFT

ORIGINAL ISSUE: 31 OCT 1976REVISED: 6 SEP 1991 REVISION NO. 9

Sabrelin~r,

COPYRIGHT, 1991 BV SABRELINER CORPORATION

RECORD OF REVISIONS

MFG REVNO DESCRIPTION ISSUEDATE ATPREVDATE INSERTEDBY

8B-76-023CORROSION CONTROL MANUAL

REVISION LOG

Mlnud Control Ile AoolBood To:Blonool Loootod At:

Brlc/ Inr~la Inur~l BYBov. Doto Boto (lnltlol) Rlmrlo

0 Oct 31/76 Basic Issue

1 Nov 01/76

2 Jan 06/78

3 Oct 06/78

4 Feb 01/80

5 May 15/816 Aug 17/84 Complete Reissue

7 Aug 31/&18 Jan 16/87

9 Sep 6/91 10-23-91 GM Ch. 20 and 52

REVISION LOGPage 1/2 Blank

o3 COPYRIGHT, 1991 BY SABRELINER CORPORATION Sep 6/91

RECORD OF TEMPORARY REVISIONS

TEMP ATP REV INSERT DATE REV REMOVEREV NO DESCRIPTION ISSUE DATE DATE BY REMOVED INCOR BY

9/29/00 20-20-02:3 (SIL57) 9/29100 3115101 ATPIIB

SR-76-23CORROSION CONTROL MANUAL

TR 89-1

TEMPORARY REVISION LOG

MlnuJ Control Wo: Atti(lned To:Mlnual Loccted At:

Temporsry Interllon Inrerted ByRev. No. Oets (Inltitl) Remtrke

TR 89-1

AUG.15 89

sn, 29/00 03/15/01

IQ

TEMPORARY REVISION LOGPage 1/2 Blank

0 COPYRIGHT, 1989 BY SABRELINER CORPORATION Aug T5/89


IMPORTANTREAD THIS NOTICE i i i

REVISION N~TICE

6 SEPTEMBER 1991

SABRELINER

CONTROLMANUAL

ALL MODELS NE 265 AIRCRAFT

REVISION INSTRUCTIONSThis is the latest revision dated 6 September 1991, Revision No. 9 to your Sabreliner Corrosion Control Manual, Report No.SR-76-023.

This is a general revision to the manual, affecting chapters 20 and 52, in chapter 20 a change was made to the AircraftSealing Methods Chart and in chapter 62 Inflight Escape Hatch Removal, Inspections and Installation was added, also allyellow TR 89-1 pages were deleted and replaced with white pages.

Insert the latest new or revised pages in accordance with the List of Effective Pages, remove and destroy supersededpages. This ensures that only the latest material remains in the manual.

Sabre~iner,COI1POIIATION

5B-76-023CORROBION CONTROL MANUAL

FRONTAL

LIST OF EFFECTIVE PAGES

Chapter/Section Page DateTITLE Sep 6/91REVISION LOG 1/2 Sep 6/91TEMPORARY

REVISION LOG 1/2 Aug 15/89FRONTAGL.E.P. 1/2" Sep 6/91CH.-LIST. 1/2+ Sep 6/91

The asterisk indicates pages revised, added, or deleted by the current revision.

FRONTAL-L.E.P.Page 1/2 Blank

COPYRIGHT, 1991 BY SABRELINER CORPORATION Sep 6/91

CORROSION CONTROL ~HANUAL

CHAPTER LISTING

LatestChapter RevisionNo. Title Date

Introduction Jan 16/87 1B0220 Standard Practices Airframe Sep 6/91 1C0224 Electrical Power Aug 17/84 3B0232 Landing Gear Jan 16/87 3C0252 Doors Sep 6/91 3D0253 .Fuselage 1 Aug 17/&1 3E0264 Nacelles and Psrlonn Aus:17/&l 3G0265 Stabilizers Aug 17/&1 3H0257 Wings Aug 17/84 3502

The asterisk indicates chapters revised by the current revision.

CH. LISTPage 1/2 Blank

a COPVRIOHT, 1991 BY SABRELINER CORPORATION Sep 6/91


INTRODUCTION

TABLE OF CONTENTS

Subject Chapter/Section/Subject PageGeneral Intro.

1Subject Matter Identification 1Page Numbering 1Figure IdentificationList of Effective Pages 1Chapter Table of ContentsPart NumberingRevisions Z

INTRO.-CONTEMTSPage 1/2 Blank

0 COPYRIGHT, 1984 BY SABRELINER CORPORATION Aug 17/84


INTRODUCTION


Chapter/Section Page Date

INTRO.-LEP 1/2 Aug 15/89INTRO.-CONTENTS 1/2 Aug 17/84INTRO. 1 Aug17/84

2" Aug 15/89Added 3/4 Aug 15/89

INTRO.-L.E.P.Page 1/2 Blank

a COPYRIGHT, 1989 BY SABRELINER CORPORATION Aug 15/89


INTRODUCTION

GENERAL PAGE NUMBERING

This manual contains maintenance oriented information Pages are numbered within each subject as follows:to guide owners/operators of Sabreliner airplanes in General Coverage and Description: Pages 1-100setting up a good preventive maintenance program for Trouble Shooting.: Pages 101-200corrosion control. Maintenance Practices,This manual is applicable to all Sabreliner series If all subtopics are brief,airplanes. The Structural Repair Manual, Illustrated they are combined into one topic: Pages 201-300Parts Catalog, and Maintenance Manual for a particular If individual subtopics are so lengthy that a combinationSabreliner airplane are to be used in conjunction with this would require many pages, each subtopic is coveredmanual, individually as follows:

FORMAT Servicing: Pages 301-400Removal/Installation: Pages 401-500

This manual has been prepared to agree with the Adjustment/Test: Pages 501-600functional breakdown utilized in Maintenance Manuals Inspection/Check: Pages 601-700prepared in accordance with Air Transport Association Cleaning/Painting: Pages 701-800(ATA) specification No. 100. Approved Repairs: Pages 801-900SUBJECT MATTER IDENTIFICATION FIGURE IDENTIFICATIONSubject matter is identified by a three element number as Figures (illustrations) are numbered consecutivelyfollows: within each topic as follows:

-XX-XX Figures in Description: Figure 1, 2, 3, 4, 5, etc.

Chapter Number----I~f Figures in Trouble Shooting: Figure 101, 102, 103, etc.Figures in Maintenance Prac-Section Number tices, When not subdivided: Figure 201, 202, 203, etc.

Subject Number When subdivided:Servicing: Figure301, 302,303,etc.

EXAMPLE: RemovallInstal lation: Figure 401, 402, 403, etc.Adjustment/Test: Figure ~01, 502, 503, etc.

20-10-30 Inspection/Check: Figure 601, 602, 603, etc.t Cleaning/Painting: Figure 701, 702, 703, etc.Approved Repairs: Figure 801, 802, 803, etc.Subject 30 Cleaning Titanium and Titanium LIST OF EFFECTIVE PAGES

AlloysA list of effective pages is the first sheet in each chapter

A "00" section identifies material of a general nature and will be revised whenever the affected chapter isapplicable to the entire chapter. A "00" subject number revised. The list should be used as a cross reference whenidentifies material applicable to an entire section. inserting revised pages. This ensures that all obsolete

material is removed and the manual is kept current.EXAMPLE:

CHAPTER TABLE OF CONTENTS20-00

Chapter 20 Standard PracticesSection00 Information pertinentEach chapter is prefaced with a table of contents

to all sections of with the following headings:Chapter 20. DESCRIPTION

TROUBLE SHOOTING20-10-00 MAINTENANCE PRACTICES

Chapter 20 Standard PracticesSection10 Cleaning ProceduresfSubject 00 Information pertinent to

all subjects in Section 10

INTRO.Page 1



INTRODUCTION (Continued)

PART NUMBER 2. Caution Operating procedures or practices that ifnot strictly observed will result in damage to the

Part numbers are used in this manual only as means of equipment.identification when nomenclature alone is inadequate.Consult the applicable Sabreliner Illustrated Parts EXAMPLE:Catalog for exact identification of spare parts by number. III!UIIII1ZI

REVISONS Do not operate engines with eowling or eowlpccllele removed.

The LIST OF EFFECTIVE PAGES with each chapterserves as a tool for maintaining the manual. The LIST OF 3. Warning-- Operatingprocedures orconditionsthatEFFECTIVE PAGES will be revised whenever the if not strictly observed will result in personal injurymaterial in the affected chapter is revised. When revision

or loss of life.pages are received, the list should be used as a crossreference for inserting the new/revised material and EXAMPLE:deleting obsolete material. This ensures that all obsolete UlkB1BnBBmaterial is destroyed and the manual is kept current.

I~cgition ewitchmustbe in the OFFposition whenRevisions to text are indicated by change bars (vertical rototiny the propellers by ~a?uE.lines) in the margin adjacent to the revised material.Revisions to illustrations may be indicated by change NON-SABRELINER APPROVED PARTSbars, zip-a-tone shading on electrical sche-matics, and pointing fingers (CSP on mechanical,hydraulic, and pneumatic diagrams.

Only Sabreliner parts or Sabreliner approved partsWhen more than 50 percent of a page is changed, a major obtained from approved sources are to be used in con-change symbol( Ia is placed in the ne,tion with the maintenance and repair of Sabrelinerlower outside corner of the page 1/4" above the top line of airplanes.pagination.

Genuine Sabreliner parts are manufactured and in-When a new page is being added to an existing manual or spected under rigorous procedures in accordance with asection that has all new information included, a new Production Certificate (PC) to insure airworthiness andchange symbol I Ism-- is used. suitability for use in Sabreliner aircraft application.A REVISION LOG page is provided for recording revi- Parts purchased from sources other than Sabreliner, orsions by revision date and the dates they were inserted in its approved vendors, may not have the required tests andthe manual., inspections performed and may be different in fabrica-

tion techniques and materials. A non-approved part mayA TEMPORARY REVISION LOG page is provided for seriously compromise the safety of the aircraft.recording Temporary Revisions (yellow sheets) by revi-sion number, issue date, and the dates they were inserted Government surplus parts, salvaged airplane parts,in the manual. reworked parts obtained from non-Sabreliner approved

sources, or parts, components or structural assembliesWARNINGS, CAUTIONS, AND NOTES which do not have proper documentation may have a

service history which is unknown or cannot be authen-Warnings, cautions and notes are used to set off in- ticated. These parts may have been subjected to unac-structions that require other than ordinary precautions, ceptable stresses or temperatures or have hidden damageDefinition and examples of each of the three types of which is not discernible through routine visual or usualprecautionary notices follow: non-destructive teeting techniques. This may render the

1. Note An essential clarification of a following part, component or structural assembly unsuitable andoperating procedure or condition. unsafe for aircraft use, even if such part, component or

structural assembly were originally manufactured byEXAMPLE: Sabreliner or an approved source.

NOTE Sabreliner Corporation expressly disclaims any respon-One complete turm ofthe acljuetment eerew sibility for malfunctions, failures, damage or injurywill r&iee or lower the preeslcre a2ywozi- caused by the use of non-Sabreliner approved parts.mutely 1 poi.

INTRO.PageZAug 15/89 COPYRIGHT, 1989 BY SABRELINER CORPORATION


INTRODUCTION (Continued)

NON-SABRELINER APPROVED PARTS (Contd)

NOTE

Sabreliner Corporationespressly reserveethe right to suloereede, cancel and/or de-clare obsolete, prior notice, anypart, part number, hit or publication rc5f-erenced in Uuis manual.

IlrrmRI

INTRO.Page 3/4 Blank

COPYRIGHT, 1989 BY SABRELINER CORPORATION Aug 15/89

CHAPTER

STANDARDPRACTICES(AIRFRAME)


CHAPTER 20

STANDARD PRACTICES AIRFRAME

TABLE OF CONTENTS

Subject Chapter/Section/Subject Page(;eneral 20-00-00

Causes and Nature of CorrosionTypesofCorrosion 2Cathodic Metals

CorrosiononAirframe 20-00-10

Corrosion Prone AreasLocation of Magnesium PartsCleaning AirframeCleaning Materials, Methods, and Applications 701

Corrosion On Electrical Equipment 20-00-20

Cleaning Electrical/Electronic Equipment Components 1

SourcesotCommercial Products 20-00-90

Cleaning Compounds(;orrosion Preventing Compounds 2Aircraft SealingCompoundsEpoxy-Polyamide Primers 5Polyurethane Top Coat 6Paint/Primer Remover 5Chemical ConversionCoatings 5

Cleaning 20-10-00

Scope 1Preliminary Cleaning 1Detail Requirements 1

Magnesium Alloys Cleaning and ProtectiveTreatments 20-10-05

General 1Pre-treatment CleaningProtective Treatment TouchupProtective Treatment Application

CleaningIronand Steel 20-10-10General 1Cleaning Methods

Cleaning Aluminum andAluminum Alloys 20-10-15

General 1Notes and PrecautionsCleaning Procedures 1

PO-CONTENTSPage 1

0 COPYRIGHT, f 984 BY SABRELINER CORPORATION Aug 17/84

SR-76-023(oHR()SI()N CONTROL MANIIAI,

TABLE OF CONTENTS (Continued)

Suhject C hapter/Section/Subject PageCleaning Corrosion and Heat Resistant Alloys 20-10-20

(;eneial 1Cleaning 1

C:ltaningCopperand CopperAlloys 20-10-25

GeneralCleaning Methods 1

Cleaning Titanium and Titanium Alloys 20-10-30

General 1Process I,imitation 1

Processing Requirements 1Processing Solutions 1

Cleaning Plastic and Glass 20-10-35

(;encral 1I Materials I

Cleaning Procedures 1

Polishing Sheet Acrylic Plastic 20-10-40

C;eneral 1~laterials 1

EquipmentjTools 1Removing Scratches 1.

StrippingOrganic Finishes 20-10-45General 1Materials 1

Stripping Methods 1

Stripping Organic Coatings From,Metals 20-10-50

(;eneral 1Materials 1

Stripping Methods 1

Solvent Vapor Degreasing 20-10-55General 1Materials 1

Degreasing Techniyues 1

AbrasiveCleaning 20-10-60

General 1Sulface Preparation 1Ab~nsive Blasting 1Miscellaneous Methods~Ieparation of Aluminum and Magnesium for Bonding or Encapsulation 2P1ocessina after Abrasive Cleaning

PO-CONTENTSPage 2Aug ~1/84 o COPYRIGHT, 1984 BY SABRELINER CORPORATION

SR-76-023CORROSI

SR-76-023(()HROSION CONTROL MANUAL


Subject Chapter/Section/Subject PagePressure Tight Sealing For Areas with Normal Operating

Temperatures From -65 to +2250F 20-20-10

General 1Materials 1Equipment 1Installation NotesSealing Sequence

Pressure Tight Sealing For Areas with NormalOperating Temperatures From -65 to +2250F(Alternate Procedures) 20-20-12

General 1Materials 1Equipment 1Installation NotesSealing ProceduresSealing Rubber Parts

Iume Tight Sealing For Areas with Normal OperatingTemperaturesFrom -65to+2500F 20-20-14

General 1Materials 1Equipment 1Installation NotesSealing Procedures

Application of Self-Contouring Sealing Pads for AreasWhere Normal Temperatures Do NotExceed 2259F 20-20-16


Exterior Watertight Sealing for Areas With NormalOperating Temperatures From -65to +2250F 20-20-18

General 1Materials 1Equipment 1Application NotesSealing Procedures 1

Faying Surface Sealing for Areas with Normal OperatingTemperaturesFrom -60to+225"F 20-20-20

General 1Materials 1E:quipment 1Installation NotesSealing Procedures

PO-CONTENTSPaRelAug 17/84 a COPYRIGHT, 1984 BY SABRELINER CORPORATION

SR-76-023CORROSION CONTROL MANUAI,

TABLE OF (I1:ONTENTS (Continued)

Subject C h a r~t.t! r, Sec tion/Subject PageLiquid Tight Sealing for Areas With Norn\at c)l,clrnting

TemperaturesFrom 225to400"F ~C)-XO-22General 1MaterialsEquipment 1Sealing Procedures 1

Pressure Tight Sealing for Areas With Normal OperatingTemperatures From 225 to 3500F 20-20-24

General 1Materials 1Equipment 1Installation NotesSealing Sequence

Fume Tight Sealing for Areas With Normal OperatingTemperatures From 250 to 4000F ...........2()-20-26

General 1MaterialsEquipment 1Installation Notes

Application of Self-Contouring Sealing Pads for Areas WithNormal Operating Temperatures From225to5500F 20-20-28

General 1MaterialsEquipment 1Installation NotesSealingProcedure 2

Flame Resistant and Liquid Tight Sealing for Areas WithNormal Operating Temperatures From225 to 4000F

General 1Materials 1Equipment 1Installation NotesSealing Procedures 1

Faying Surface Sealing for Areas With Normal OperatingTemperatures From -100 to +550oF .........20-20-32


Installation of O-Ring for Fuel System 20-20-34General 1Materials 1Installation Notes

PO-CONTENTSPage 5


SK-7Ci-023


Subject Chapter/Section/Subject PageInstallation of O-Rings for Fuel Systems and

Bolted Assemblies ......20-20-36

(;eneral 1Materials 1Installation Notes 1

Installation Procedures for O-Ring Sealing of BoltedAssemblies 20-20-38

General 1hlaterialsInstallation Notes 1Se;llina Procedure 1

A Pplication of Tape or Sealant Corrosion Barriers BetweenMagnesium andOtherMetals 20-20-40

General 1Materials 1Installation Notes 1Sealing Procedures 1

F:lectrical Systems Room Temperature CuringSilicone Rubber Potting .20-20-44

General 1Materials 1Installation NotesSealing Procedures

Potting Bendix Connector for UseTo 3000F 20-20-46

General 1Materials 1Equipment NotesInstallation Notes

Sealing Electric TerminationsWith Overcoating ......20-20-48

C;eneral 1Materials 1Installation Notes

Sealing Neoprene Jacketed Multiconductor and CoaxialCable and Kel-F Jacketed CoaxialCable Terminations .....20-20-50

(;eneral 1Materials 1Installation Notes 1

IIL~

20-CONTENTSIaRr 6Aua ~1/X4 COPYRIGHT, 1984 BY SABRELINER CORPORATION

SR-76-023C()KHOSION (:ONIKOI,


Suhject Cha~ter/Section/Subject IaRtMoisture Proofing Electrical Components With

Strippable Sealant 20-20-52General IMaterials 1Installation Notes 1Sealing Sequence

Sealing Electrical Wire Bundles PassingThrough Bulkheads ..~.20-20-54

General 1Materials 1

Equipment 1Installation NotesMold PreparationMoldInstallation 4

Sealing Electric Terminations Subject to TemperaturesUp to 3000F 20-20-56

(;eneral 1MaterialsEquipment 1installation Notes 1

Sealing Procedure 1

Sealing Electrical Terminations Subject to a MaximumBetween 300 and 4000F 20-20-58

(;eneral 1Materials 1

Equipment 1Installation Notes 1

Sealing Procedures

Application of Sealant to Electrical Wire Bundles PassingThrough Bulkheads for Maximum ServiceTemperatures From 350 to 500"F 20-20-60

General 1Material 1Installation NotesSealing Procedures 1

()rganic Base and Finish Coating 20-30-00Application of Polyurethane Integral Fuel Tank Coating 201Application of Epoxy-Polyamide Primer 203Application of Polyurethane Top Coat 205Application of Impact Resistant Polyurethane Top-Coat 206HemavinR FaintjPrimer FinishesCorrosion Removal/Paint Touch-Up Kit

PO-CONTENTSPage 7

0 COPYRIGHT, 1984 BY SABRELINER CORPORATION Aug.31/84

SK-76-023(()R K()SI()N C()NI~ROI, MANUA I,


Subject Chapter/Section/Subject PageCati-Coat Primer Application 20-30-05

C;c!neral 1~vIaterialsInstallation Notes 1

Wash P~imer Application 20-30-10

(;ener~l 1;L1HterialsF:cluipment 1Iiistallation Notes I

Moisture and Fungus Resistant CoatingApplication 20-30-15

(;eneralMaterials 1Installation Notes t

Painting Metal Surfaces With Epoxy PolyamidePrimer or Zinc Chromate Primer ...........20-30-20


Equipment 1Installation Notes

Conversion Type Coatings Application ..........20-30-25General 1Materials 1

Application NotesIn8tallation Notes 1

Polyurethane Finish System ForSabreliner Aircraft Exterior Surfaces ......20-30-30

(;eneral 1Materials 1F,quipnient 1Installation Notes

MIL-C-83286 Polyurethane EnamelApplication 20-30-35

General 1Materials 1Equipment 1Installation Notes 1rol:urethane System Application f,

IPIQ

PO-CONTENTSPage 8AuR:31/84 o COPYRIGHT, 1984 BY SABRELINER CORPORATION

SR-76-023COHROSION CONTROL MAIVL:AI,


Subject Chapter/Section/Subject PageHigh Impact Polyurethane

Coating Application ....20-30-40General 1Materials t

Equipment 1Application NotesApplication of Coating

Urethane Finish System For SabrelinerAircraft Exterior Surfaces 20-30-45

General 1Materialsinstallation Notes 1Surface Preparation 1Mixingand HandlingPrimer ApplicationApplication of Urethane Top CoatClean-UpAdhesionandFinish 2

Wrinkle Finish Application .20-30-50General 1Materials 1

Laminated and Molded PlasticParts Finishing ........20-30-55

GeneralMaterials 1Installation 1

Mixing and HandlingSurface Finish 1FillerApplication 2

Ahrasion Resistant Coating Application 20-30-60General IMaterials 1Installation Notes

Rain Erosion Resistant Coatings Application .....20-30-65GeneralMaterials 1Installation Notes 1

Coating Application

Spray Painting Methods and Techniques(Instruction and Information Guide) ........20-30-70

C;eneral 1Equipment 1Cleaning YSprayCunTechnjqua-- AirType 6Spray Painting ProblemsFacilities 18

IQ

20-CONTENTSPage 9

0 COPYRIGHT, 1984 BY SABRELINER CORPORATION Aug ~1/84

SR-76-023c()KH()SION CONTROI, MANIIAI,


Su~,.iect Chapter/Section/Subject PageKadome Coating Material Application ..........20-30-75

(;ent1al 1Materials 1Installation Notes 1

Polyurethane Integral Fuel TankCoating Application

General 1Matelials 1Equipment 1Installation Notes 1

()rganic Integral Fuel TankCoatings Application

General 1Materials 1Installation Notes 1

Irotrction of Aircraft in Out-of-DoorsTemporary Storage

(;eneral 1Materials 1EquipmentInstallation Notes

Anodizing and Coloring of AluminumAlloys ..........,20-40-05

GeneralMaterialsPreparationAppiication NotesFinish

Ch,amic Acid and Sulfuric AcidAnodizing

General 1I,imitations....................................................................................... 1Application NotesFinish

I)ow No. 17 Anodize Process ForMagnesium Alloys

(;eneral...1................................................................................

1Materials 1Ecluipment 1I,imitationsSafetS 1c\pplication Notes.L\nodizinR P,ocedure~tl.il-,VinR of Dow No. 17(oatinRsKe\\~ollr ;tndior Re~ail of I)ow No. 17 C:oatings 2Coating

(ILTllr~ll20-CONTENTSIa8e 10AuR ~1/84 o COPYRIGHT, 1984 BY SABRELINER CORPORATION

SR-76-023C~OKH()SLON CONTKOL MAKUAI,


Subject Chapter/Section/Subject PageApplication of TFE Infused Coating on

Aluminum 20-40-20

General 1

Equipment 11Coating Quality

Tests 1

Application of Scale InhibitingCompound 20-40-25

GeneralMaterials 1

Application Notes

Phosphate Treatment ......20-40-30


Safety 1Surface Preparation 1Finish 1

Application of Chemical Films toAluminum Alloys .......20-40-35


Properties of Class 1A CoatingApplication Notes 1

Chemical Film Treatment for Titaniumand Titanium Alloys ....20-40-40


Application Notes 1Finish 1

Electrodeposited Hard NicklePlating 20-40-45

General 1

Application Notes 1Finish

(;eneral Procedure For Brush Type!Electroplating 20-40-50

GeneralMaterials 1

F,quipmentApplication NotesApplication of Tin to C;lass-Fiber

Reinforced Plastic Surface 9Posl Plating Treatment 9Plate Ii~equirements tt

PO-CONTENTSPage ii

0 COPYRIGHT, 1984 BY SABRELINER CORPORATION Aug 31:81

SR-7fi-023(c,K K()SI()N CONTHOI. M AN t:Al.


Su I,ject Chapter/Section/Subject PageIin ~latinR By Elettrodeposition or

Hot Dipping .20-40-55

(;eneral 14laterials 1

A pplication Notes 1(I:o:ltinB

liard Chlamium Plating ....20-40-60

(;eneral 1~I-,plication Notes 1Finisll 1

Tests 1

(ol,l,er Plating ..20-40-65(;eneial 1

1

Xpplication Notes 1Surface Preparation 1(oppet Plating Procedures I

~31ush Cadmium Plating ....20-40-70

i;eneral 1

Desciiption IMaterials 1

Equipment 2Installation Notes 2

Plating Finish 7

Nickel-Zinc Alloy Plating ...20-40-75

General IMateiials 1

Requirements 1Sulface Preparation 2Nickel-%ine Plating ProttetlulesStril,l,i na of Defective Com posit Coatings 6

~lectroless Nickel Plating ...20-40-80(;eneral 1AI,plication Notes IFinish 1

Kepail and Refinishing of Abraded, Scratched,Reworked, or Corroded MetalSurfaces

......................20-40-85

General 1Rewo,k PIocedures for Aluminum 1K~\\olk Procedures for IJnplRtedCopper and Ferrous Alloys 2

I,occdules fol M~anesium F,xtrusions, Castings, or Forgings 2of Ilaled Surfaces.

lam~ICT

20-CONTENTSPage 12Aug 31/84 o COPYRIGMT, 1984 BY SABRELINER CORPORATION

SR-76-0~3CORHOSION CO~THOI, MAh~UAI,

CHAPTER 20


LIST OF TABLES

Chapter/~ection/Subject Table No. Title Page!60-00-00 1 Metals in C;alvanic Series X

20-00-10 1 Periodic Corrosion Inspection ......................................7701 Cleaning Procedures and Agents 707

20-10-00 1 Solvents and Applications 1

20-10-20 1 Acid Descaling and Passivating Solutions :32 Cleaning Inconel, Inconel X, and Inconel 718

20-10-45 1 Finishes, Strippers, and Thinners 3

20-10-50 1 Chemical Strippers 4

20-10-60 -1 Processing After Abrasive Cleaning 4

20-20-02 1 Aircraft Sealing Methods, Compounds, and Areas 32 Spacing of Clamp-Up Devices 1

20-20-38 1 0-Ring Installation Dimensions 3

20-5 201 Coating Cure Schedule 203

20-30-20 1 Spray Guns and Accessories 22 Pressure Settings 2

20-30-30 1 Spray Guns and Accessories2 Pressure Settings 2

20-30-35 1 Spray Guns and Accessories2 Pressure Settings 2

20-30-70 1 2Air Pressure Drop In Hoses2 Faulty Patterns and Suggested Corrections 93 Spray Painting Problems. Possible Causes, and Possible Remedies 14

20-.30-80 1 Coating Cure Schedule 4

20-40-05 1 Chromic Acid Anodize and Dye Process 22 Sulfuric Acid Anodize and Dye Process 33 Sulfuric Acid Anodize and Pigment Precipitation Process4 Sulfuric Acid Process Variables 65 Stripping Procedure fi

20-40-15 1 DC Dow No. 17 Anodize Process Sequence for Magnesium Alloys 32 Anodizing Time in Minutes

20-40-20 1 Near Life Test Specimens 12 Abrasion Test Specimens 2

PO-TABLESPage I

o COPYRIGHT, 1984 BY SABRELINER CORPORATION Aug 31/84

SR-i6-023COKROSION CONTROL MANUAL

LIST OF TABLES (Continued)

Chapter/Section/Subject Table No. Title Page20-40-30 1 Cross Reference Chart 3

2 Type I Phosphating Procedure 43A Type II Phosphating Procedures Procedure for

PhosphatinR with Parco 1A 53B Type II Phosphating Procedures Procedure for

Phosphating with Cryscote HC 63C Type Il Phosphating Procedures Procedure for

PhosphatinR with Turco 4432 74 Type III Phosphating Procedures 8

20-40-35 1 Chemical Film Immersion Procedure 32 Chemical Film Spray Procedure3 Chemical Film Brush-On Procedure 6

20-40-40 1 Immersion Chem Film Process for Titanium 22 Brush Chem Film Process for Titanium 3

20-40-50 1 Processing with Non-Proprietary Solutions 32 Processing with Proprietary Solutions 63 Plating Processes with Proprietary Solutions 84 Cold Plating of Contacts of Modules with Assembled Contacts 95 Post-Plating Treatment 106 Plating Quaiity Requirements 10

20-40-55 1 Type I Tin Plating By Stannate Process 42 Type I Tin Plating By Fluoborate Process 53 Type I TinPlating By Sulfate (Kenvert) Process 64 Type I Tin Plating By Sulfate (Lea-Ronal) Process 75 Type II Tin Plating 8

20-40-65 1 Procedure for Copper Plating Carbon and Low Alloy Steels 22 Copper Plating of CRES and Heat-Resistant Alloys,

Series 400 Stainless Steels 33 Procedure for Stripping Copper Plating 4

20-40-70 1 Characteristics of Dalic Plating Solutions 3Characteristics of Selectron Plating Solutions 4Characteristics of Brooktronics Plating Solutions 4

20-40-75 1 Carbon and Low Alloy Steels 32 CRES and 400 Series Stainless Steels 43 Copper and Copper Base Alloys 54 Stripping Defective Composite Coatings 6

Ia

PO-TABLESPage 2Aug 31/84 o COPYRIGHT, 1984 BY SABRELINER CORPORATION

8&-76-023CORROSION CONTROL NIANUAL

CHAPTER 20


LIST OF ILLUSTRATIONS

Cbapter/Section/Subject Figure No. Title Page20-00-00 1 Simplified Corrosion Cell for Electro Corrosion 2

2 Corrosion Prevention Using an Organic Film 23 Effects of Corrosion Removal Solutions on Fitted Aluminum 34 Extreme Fitting Corrosion of Steel Parts 45 Extreme Fitting Corrosion of Aluminum Parts 46 Intergranular Corrosion 57 Extreme Exfoliation Corrosion at Nutplates 58 Extreme Exfoliation Corrosion 69 Extreme Case of Surface Corrosion and Dissimilar Metal Corrosion 7

10 Galvanic Corrosion of Magnesium Adjacent to Steel Fastener 711 Area Relationship in Dissimilar Metal Contact 812 Concentration Cell Corrosion 913 Filiform Corrosion at Lap Joint 1114 Filiform Corrosion at Fastener Head 11

20-00-10 1 Exterior Surface Materials NA 265-40 22 Exterior Surface Materials NA 265-60 33 Exterior Surface Materials NA 265-65 44 Exterior Surface Materials NA 265-70 55 Exterior Surface Materials NA 265-80 66 Corrosion Prone Areas NA 265-40 97 Corrosion Prone Areas NA 265-60 108 Corrosion Prone Areas NA 266-70 119 Corrosion Prone Areas NA 265-80 12

10 I~Jocation of Magnesium Parts 13701 Protective Covers Installed During Cleaning and Paint Stripping 706702 Cleaning Sequence 706

20-20-00 1 Sealant Dimensions 2

20-20-02 1 Applying Sealant to Faying Surface 22 Prepacking a Void 53 Prepack Groove Sealing 64 Sealing of Separable Surfaces 76 SealingFixedWindows 96 Sealing Pilots Sliding Window 107 Sealing Windshields 118 Injection Groove Sealing 139 Basic Dimensions of a Sealing Groove 13

10 Counterbore Dimensions for installing Rivets in a Sealing Groove 1411 Counterbore Dimensions for Sealing Groove at a Bolt I~ocstion 1412 Groove Configuration for a Double Row of Fasteners 1513 Nozzle Tip Position 1614 Application of Fillets 1615 Lapping Structure .250 In. Max Thickness 1616 Lapping Structure Over 0.250 In. Thickness 1717 Unacceptable Fillets 17

20-1 LLUSPage 1

(D COPYRIGHT, 1991 BY SABRELINER CORPORATION Sep 6/91


LIST OF ILLUSTRATIONS (Continued)

Chapter/Section/Subject Figure No, Title Page20-20-02 18 Butt Gaps 18Contd 19 Seam Edge Facing High Leg of Flange or Angle 18

20 Sealing Holes and Slots up To 0.125 In. 1921 Fastener Leak Path Seals 2022 Rivet and Bolt Leak Path Seals 2123 Dome Nut Leak Path Seals 2224 Sealant Bridge 2325 Wing Anti-Icing Duct Sealing 24

20-20-08 1 Sealing Holes and Slots 22 Sealing Holes 1/8 To 1/4 In, Diameter 2

20-20-10 1 Sealing Holes and Slots 22 Sealing Seams and Joints Z

20-20-12 1 Sealing Joggles 22 Sealing Holes and Slots Up to 1/8 In, Wide 23 Sealing 1/8 to 1/4 In, Holes and Slots 34 Sealing Seams and Joints 3

20-20-14 1 Sealing 1/8 In. Max Holes 22 Sealing 1/8 to 1/4 In. Holes 23 Gap Sealing 34 Hole and Slot Sealing 3

20-20-16 1 Typical Sealant and Mold Release Application 22 Typical Excess Sealant Trimming 23 Typical Tooling Hole and Gap Sealing 3

20-20-22 1 Sealing Holes 12 Sealing Seams and Joints Z3 Sealing Stiffened Seam 2

20-20-24 1 SealingJoggles 22 Sealing Holes 23 Sealing Beads and Fillets 34 Sealing But Joints 3

20-20-28 1 Typical Primer Application 22 Typical Sealant Application 23 Typical Assembly During Cure 34 Typical Tooling Hole Back-Up 3

20-20-30 1 Typical Hole Sealing 22 Typical Seam, Joint, and Rivet Seals

I 33 Typical Joffgle and Stiffener Sealing 3

20-20-32 1 Sealing Compound Pot Life Z

Itlrli~

20-lllUSPage 2Aug 31/84 o COPYRIGHT, 1984 BY SABRELINER CORPORATION


LIST OF ILLUSTRATIONS (Continued)

Chapter/Section/Subject Figure No. Title Page20-20-38 1 Typical Counterbore 0-Ring SealinR 2

2 Typical Sleeved Joint O-Ring Sealing a3 Typical Non-Sleeved O-Ring Sealing

20-20-40 1 Typical Applications of Tape As ACorrosion Barrier 22 Typical Application of Tape And Sealing Compound Combined :33 Typical Application of Sealant As A Corrosion Barrier 44 Typical Application of Aerodynamic Smoother to Mold Line Joints 5

20-20-46 1 Connector Preparation 12 Injection of Potting Compound Into Connector 2

20-20-50 1 Potting Using Temporary Molds 22 Potting Using Stacked Permanent Molds 33 Potting 900 Entry Multiconductor Cable 34 Potting Coaxial Cables 4

20-20-52 1 Typical Sealing Areas of a Quick-DisconnectConnector and Lead-in Wires 1

20-20-54 1 Passing Wire Bundles Thru Connector Shells 22 Passing Wire Bundles Thru Bulkhead Holes 23 Passing Wire Bundles Thru Doubler 34 Molds For Connector Shells 5

5 Seal Dimensional Requirements 56 Standard Cup Molds 67 Cup Mold Preparation 68 Sealing Between Wires 79 Typical Mold Installations 8

20-20-58 1 Assembling Connector 12 Connector Potting 23 Sealant Injection 3

20-20-60 1 Booted Sealing Feedthroughs 12 Sealing Split-Fitting Bulkhead Feedthroughs 2

20-30-65 1 Coating Laminate Edges 2

20-30-70 1 Principal Parts of Spray Gun 12 Pressure Tank3 Cleaning Cup Type Gun 44 t~ieaning Tank Type Gun 11..1 55 Cleaning Gun Nozzle and Fluid Connections6 Gun To Part Distance

66

7 Some Problems Caused By Tilted Gun8 Spray Gun Motions 79 Spraying Corners 9

10 Correct Spray Patterns11 Relationship of Aircap Position to Spray Pattern 1112 Spray Gun Adjustment 12L313 Causes of Jerky or Fluttenng Spray

20-30-75 1 Edffe Treatment

111~

20-ILLUSPage 3/4 Blank



CHAPTER 20

STANDARD PRACTICES AIRFRA1ME


Chapter/ Chapter/Section Page Date Section Page Date

20-L.E.P. 1* Sep 6/91 12 Aug 17/842 Sep 6/91 13/14 Aug 17/843+ Sep 6/91 701 Aug 17/844* Sep 6/91 702 Aug 17/84

703 Aug 17/8480-CONTENTS 1 Aug 17/&1 704 Aug 17/84

2 Aug 31/84 705 Aug 17/843 Aug17/84 706 Aug17/844 Aug 17/84 707 Aug 17/845 Aug 31/84 708 Aug 17/846 Aug 31/&1 709 Aug 17/847 Aug 31/84 710 Aug 17/848 Aug 31/84 711/712 Aug 17/849 Aug 31/84

10 Aug 31/84 20-00-20 1/2 Aug 17/8411 Aug 31/84 20-00-90 1* Sep 6/9112 Aug 31/84 2 Aug 17/84

20-ILLUS 1* Sep 6/91 3 Aug 17/842 Aug 31/84 4 Aug 17/84

3/4 Aug 31/84 6 Aug 17/846 Aug 17/84

20-TABLES 1 Aug 31/842 Aug 31/84 20-10-00 1/2 Aug 17/84

20-00-00 1 Aug 17/84 20-10-05 1 Aug 17/842 Aug17/84 2 Aug17/843 Aug 17/84 20-10-10 1/2 Aug 17/844 Aug 17/846 Aug 17/84 20-10-15 1 Aug 17/846 Aug 17/84 2+ Sep 6/917 Aug17/84 3 Aug17/848 Aug17/84 4 Aug17/849 Aug 17/84 5/6 Aug 17/84

10 Aug 17/84 20-10-20 1 Aug 17/8411/12 Aug 17/84 2 Aug 17/84

20-00-10 1 Aug 17/84 3 Aug 17/842 Aug17/84 4 Aug17/843 Aug17/84 5/6 Aug17/844 Aug 17/84 20-10-26 1 Aug 17/846 Aug17/84 2 Aug17/846 Aug 17/847 Aug 17/84 20-10-30 1 Aug 17/848 Aug17/84 2 Aug17/849 Aug 17/84 20-10-35 1/2 Aug 17/84

10 Aug 17/8411 Aug 17/84


20-L.E.P.Page 1

e COPYRIGHT, 1991 BV SABRELINER CORPORATION Sep 6/91


LIST OF EFFECTIVE PAGES (Continued)

Chapter/ Chapter/Section Page Date Section Page Date20-10-40 1/2 Aug 17/&1 20-20-08 1 Aug 17/84

2 Aug 17/8420-10-45 1 Aug 17/842 Aug 17/&1 20-20-10 1 Aug 17/84

3/4 Aug 17/&1 2 Aug 17/8420-10-60 1 Aug 17/84 20-20-12 1 Aug 17/84

2$ Sep 6/91 2 Aug 17/&13+ Sep 6/91 3/4 Aug 17/&14 Aug 17/&1 20-20-14 1 Aug 17/84

20-10-65 1 Aug 17/&1 2 Aug 17/842 Aug 17/&1 3/4 Aug 17/&1

20-10-60 1 Aug 17/84 20-20-16 1 Aug 17/&12 Aug 17/84 2 Aug 17/843 Aug 17/84 3/4 Aug 17/&14 Aug 17/&1 20-20-18 1 Aug 17/&1

20-20-00 1 Aug 17/84 2 Aug 17/842 Aug 17/84 20-20-20 1 Aug 17/843 Aug 17/84 2 Aug 17/844 Aug 17/845 Aug 17/84 20-20-22 1 Aug 17/846 Aug 17/84 2 Aug 17/&17 Aug 17/84 20-20-24 1 Aug 17/&48 Aug 17/&4

z Aug 17/8420-20-02 1 Aug 17/84 3/4 Aug 17/84

2 Aug 17/&1 20-20-26 1/2 Aug 51/&13+ Sep 6/914 Aug 17/84 20-20-28 1 Aug 17/845 Aug17/84 2 Aug 17/846 Aug 17/84 3/4 Aug 17/847 Aug 17/84 20-20-50 1 Aug 17/&18 Aug 17/84 2 Aug 17/849 Aug 17/84

10 Aug 17/84 3/4 Aug 17/&111 Aug 17/84 20-20-32 1 Aug 17/8412 Aug 17/84 2 Aug 17/8413 Aug 17/&1 20-20-54 1/2 Aug 17/8414 Aug 17/&115 Aug 17/&1 20-20-36 1/2 Aug 17/8416 Aug 17/&1 20-20-38 1 Aug 17/8417 Aug 17/84 2 Aug 17/8418 Aug 17/8419 Aug 17/84 3/4 Aug 17/8420 Aug 17/84 20-20-40 1 Aug 17/8421 Aug 17/84 2 Aug 17/8422 Aug 17/84 3 Aug 17/8423 Aug 17/84 4 Aug 17/8424 Aug 17/84 5 Aug 17/84

6 Aug 17/8420-20-04 1 Aug 17/842 Aug 17/&1 20-20-44 1 Aug 31/84

2 Aug 31/8420-20-06 1/2 Aug 17/84


PO-L.E.P.Page 2Sep 6/91 a COPYRIGHT, 1991 BY SABRELINER CORPORATION

SR-76-023CORROSION CONTROL ~HANUAL


Chapter/ Chapter/Section Page Date Section Page Date

20-20-46 1 Aug 31/&1 20-30-30 Contd 4 Aug 31/842 Aug 31/&1 5 Aug 31/84

3/4 Aug 31/&1 6 Aug 31/847/8 Aug 31/84

20-20-48 1 Aug 31/&12 Aug 31/84 20-30-35 1 Aug 31/84

2 Aug 31/8420-20-50 1 Aug 31/84 3 Aug 31/84

2 Aug 31/&1 4 Aug 31/&13 Aug 31/&1 5 Aug 31/&14 Aug 31/&1 6 Aug 31/&1

20-20-52 1/2 Aug 17/84 20-30-40 1 Aug 31/8420-20-54 1 Aug 31/84 2 Aug 31/84

2 Aug 31/&1 20-30-45 1 Aug 31/&13 Aug 31/84 2 Aug 31/844 Aug 31/&1 3/4 Aug 31/845 Aug 31/&16 Aug 31/84 20-30-50 1/2 Aug 31/847 Aug 31/84 20-30-56 1 Aug 31/848 Aug 31/84 2 Aug 31/84

9/10 Aug 31/8420-30-60 1/2 Aug 31/84

20-20-56 1 Aug 31/842 Aug 31/84 20-30-65 1 Aug 31/84

2 Aug 31/&120-20-68 1 Aug 17/&1 3/4 Aug 31/84

2 Aug 17/843 Aug 17/&1 20-30-70 1 Aug 31/844 Aug 17/84 2 Aug 31/84

3 Aug 31/8420-20-60 1 Aug 17/84 4 Aug 31/84

2 Aug 17/84 5 Aug 31/8420-30-00 201 Aug 17/84 6 Aug 31/84

202 Aug 17/84 7 Aug 31/84203 Aug 17/84 8 Aug 31/84204 Aug 17/84 9 Aug 31/84206 Aug 17/84 10 Aug 31/84206 Aug 17/84 11 Aug 31/84207 Aug 17/84 12 Aug 31/84208 Aug 17/84 13 Aug 31/84

14 Aug 31/8420-30-05 1/2 Aug 31/84 16 Aug 31/8420-30-10 1 Aug 31/84 16 Aug 31/84

2 Aug 31/84 17 Aug 31/8418 Aug 31/84

20-30-15 1 Aug 31/842 Aug 31/84 20-30-75 1 Aug 31/84

2 Aug 31/8420-30-20 1 Aug 31/84 3/4 Aug 31/84

2 Aug 31/843 Aug 31/84 20-30-80 1 Aug 31/844 Aug 31/84 2 Aug 31/84

3 Aug 31/8420-30-25 1/2 Aug 31/84 4 Aug 81/8420-30-30 1 Aug 31/&1 20-30-85 1/2 Aug 31/84

2 Aug 31/843 Aug 31/84


PO-L.E.P.Page 3

a COPYRIGHT, 1991 BY SABRELINER CORPORATION Sep B/gl

8~3-76-023CORROBION CONTROL biANUAL


ChapteF/ Chapter/Section Page Date Section Page Date

20-30-90 1 Aug 31/&1 20-40-55 1 Aug 31/&12 Aug 31/&1 2 Aug 31/843 Aug 31/84 3 Aug 31/844 Aug 31/84 4 Aug 31/&1

5 Aug31/8420-40-05 1 Aug 31/84 6 Aug 31/84

2 Aug 31/&1 7 Aug 31/848 Aug 31/&1 8 Aug 31/&44 Aug 31/&15 Aug 31/84 20-40-60 1/2 Aug 31/&16 Aug 31/84 20-40-65 1 Aug 31/&1

20-40-10 1/2 Aug 31/84 2 Aug 31/&13 Aug 31/&1

20-40-15 1 Aug 31/&1 4 Aug 31/&12 Aug 31/843 Aug 31/&1 20-40-70 1 Aug 31/844 Aug 31/&1 2 Aug 31/84

6/6 Aug 31/&1 3 Aug 31/844 Aug 31/&1

20-40-20 1 Aug 31/84 5 Aug 31/&12 Aug 31/&1 6 Aug 31/&1

20-40-25 1/2 Aug 31/84 7/8 Aug 31/&120-40-30 1 Aug 31/84 20-40-75 1 Aug 31/84

2 Aug 31/&1 2 Aug 31/&23 Aug 31/84 3 Aug 31/844 Aug 31/84 4 Aug 31/&16 Aug 31/&1 5 Aug 31/&16 Aug 31/84 6 Aug 31/847 Aug 31/&1 20-40-80 1/2 Aug 31/848 Aug 31/84

20-40-86 1 Aug 31/&120-40-35 1 Aug 31/84 2 Aug 31/&1

2 Aug 31/&1 3 Aug 31/&13 Aug 31/84 4 Aug 31/&14 Aug 31/845 Aug 51/846 Aug 31/84

20-40-40 1 Aug 31/842 Aug 31!84

3/4 Aug 31/8420-40-45 1/2 Aug 31/8420-40-50 1 Aug 31/84

2 Aug 31/&13 Aug 31/844 Aug 31/845 Aug 31/846 Aug 31/847 Aug 31/&48 Aug 31/849 Aug 31/84

10 Aug 31/84

~C The asterisk indicates pages revised, added, or deleted by the current revision.

PO-L.E.P.PageaSep 8/91 o COPYRIGHT, 1991 BY SABRELINER CORPORATION


CHAPTER 20


GENERAL CAUSES AND NATURE OF CORROSION

Corrosion is the destruction of metals by chemical or Corrosion is caused by direct chemical attack, as in theelectrochemical action. This destroys the integrity of case of contact with acids, or by electrochemical attack,affected areas by converting the metal into a powdery or which is similar to action on the plates in a storageflaky metallic oxide, hydroxide, or sulphate compound, battery. All corrosion is electrical in nature; involving the

flow of electrons and ions between two points through aCorrosion of metal surfaces begins the instant the conductive medium. The conductive medium may befabrication process is completed and, left unchecked, moisture or gas containing corrosive agents such as salt,continues until the material is exhausted. The rate of

chlorides, or sulphuric acid; or may be a direct metal-to-deterioration, or lack of it, depends on corrosion metal contact or connection.preventative measures taken and on the environment towhich the part is subjected. The two points of difference of electrical potential will

involve one of the following conditions:E ffective corrosion control is accomplished in two phases:(1) preventive maintenance, and (2) corrective Dissimilar metalsmaintenance. Preventive maintenance includes frequent Differential between grain boundary and graininspections and cleaning. Corrective maintenance

centerincludes the complete removal of corrosion products andrenewal of protective coatings. Both phases are of equal Different metallic crystaline compositions withinimportance in any successful program of corrosion the same metalcontrol. Where corrosion has progressed unchecked, Between corrosive elements on surface of metal andthe resulting damage may require replacement of parts or metal Itselfma;or components assemblies. Inspections,conscielltiousiy performed, reveal scratches in protective In each case, an electrolyte of some kind is present,coatings or plated surfaces which could result in creating an electrical cell similar to a storage battery.corrosion, result in the detection of areas requiring touch- One point or area becomes the anode (negative pole) andup of the finish coatings, and also provide an indication as the other the cathode (positive pole). The anode is theto when the airplane should.be cleaned. Frequent portion of the metal which has greater electrical activitycleaning will retard the corrosion process. and is the portion which will disintegrate or corrode.Corrosion of airplane surfaces and parts has always been Four conditions must exist before electrochemicala problem, and can have a very serious effect upon the corrosion can proceed: (1) there must be something thatperformance of modern high speed airplanes. This is corrodes (the metal anode), (2) there must be a cathode titespecially true of airplanes which are based in areas may be either a more noble metal adjacent to the anode orwhere corrosive elements are present in the atmosphere. an area on the same metal which differs inAirplanes which are inaitive for extended periods alz microstructure, oxygen or metal ion concentration, oralso susceptible to corrosion. Corrosion control measures surface condition from the anode), ~3) there must be ashould not he relaxed because an airplane is inactive. continuous liquid path (electrolyte, usually condensate.

and salt or other contamination), and (4) there must be aAirplane parts are constructed of many different metals, conductor to carry the flow of electrons from the anode toand have various shapes, sizes and heat treatments. These the cathode ~this conductor is usually in the form of metai-surfaces and parts are constantly exposed to a corrosive to-metal contact such as rivets, bolts, and welds). The fourenvironment such as combustion gases from engines, conditions which are required before electrochemicalatmospheric moisture, condensation, salt spray, corrosion can proceed are illustrated in figure i.chemicals, dirt, dust, waste water, and fluid spillage.Also, metal fillings, tools, parts, or other metal objects lefton the interior or exterior surfaces of the airplane willcs~lse corrosion by dissimilar metal contact. Thus, all ofthe necessary factors are present throughout the life ofthe airplane to initiate corrosive attack on any metal partat any time. All types of metal used in the airplane aresubject to corrosion of some kind, but aluminum,magnesium, and steels not fully protected by adequatesurface treatment are ready prey to corrosion.

20-00-00Page 1

0 1984 BY SABRELINER CORPORATION Aug 17/84

SR 76-023CORROSION CONTROL MANUAL

STANDARD PRACTICES AIRFRAME (Continued)

CAUSES AND NATURE OF CORROSION (Contd) corrosion is first seen as a general dulling of the surfaceElimination of any one of the four conditions will stop

and if the attack is allowed to continue, the surfacecorrosion, e.g., an organic film on the surface of the metal becomes rough and possibly frosted in appearance.will prevent the electrolyte from connecting the cathode Discoloration or general dulling of metal created by

exposure to heat is not to be considered as uniform etchand anode, and the current cannot flow, therefore, nocorrosion.

corrosion. (See figure 2.)TYPES OF CORROSION Fitting Corrosion

Fitting is the most common corrosion on aluminum andCorrosion has been catalogued and typed in many ways.For descriptive purposes, the following types of corrosion magnesium alloys. It is first noticeable as a white or grayare discussed under what is considered the most powdery deposit similar to dust which blotches thecommonly accepted titles. surface. When the deposit is cleaned away, tiny pits orholes can be seen in the surface. Fitting corrosion mayUniform Etch Corrosion also occur in other types of metal alloys. (See figures 3, 4,

and 5.)The surface effect produced by most direct chemicalattack (e.g., as by an acid) is a uniform etching of themetal. (See figure 3.) On a polished surface, this type of

LlaUlDCURRENT FLOW PATH (ELECTROLYTE)

ANODIC CATHOD1C jAREA AREA

ELECTRON CONDUCTOR ELECTRON FLOW

METAL S265-23-20-9

Simplified Corrosion Ceil for Electro CorrosionFigure L

NO CONTACT BETWEENELECTROLYTE AND ANODE

,UNBROKEN ORGANICAND CATHODE BECAUSE OF FILMORGANIC FILM CONTINIIOUS LIQUID

PATH (ELECTROLYTE)

ANODIC CATHODICAREA AREA

ELECTRONCONDUCTOR METAL

5265-23-20-10

Corrosion Prevention Using an Organic FilmFigure 2

20-00-00Page 2Aug 17/84 a COPYRIGHT, 1984 a~ SABRELINER CUHPORATION


PITTINO CORROSION ON ALUMINUM SURFACE

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Effeets of Corrosion Removal Solutions on Fitted AluminumFigure3 20-00-00Page 3

0 COPYRIGHT, 1984 BY SABRELINER 2C~nPORATION Aug 17/84


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As Received ByATP

20-00-00Page 4Aug 17/84 o COPYRIGHT, 1984 BY SABRELINER CORPORATION



Intergranular Corrosion Exfoliation CorrosionIntergranular corrosion is an attack on the grain Exfoliation is a form of intergranular corrosion. It lifts upboundaries of a material. A highly magnified cross the surface grains of a metal by the force of expandingsection of any commercial alloy will show the granular corrosion products occurring at the grain boundariesjuststructure of the metal. This consists of quantities of below the surface. (See figures 7 and 8.) Lifting up orindividual grains, each of which has a clearly defined swelling is visible evidence of intergranular corrosion. Itboundary that differs chemically from metal in the grain is most often seen on extruded sections where graincenter. Frequently the grain boundaries are anodic to the thickness is usually less than in rolled forms.main body of the grain. When in contact with anelectrolyte, rapid selective corrosion of these anodic grainboundaries can occur. (See figure 6.)

ELECTROLYTE ENTERS,PAINT

THROUGH CRACKS IN FILMPAINT FILM

CLADDING (ANODE)(CATnODE)

INTERGRANULAR FASTENER 1075 T6

CORROSION ALUMINUM

Interffranular CorrosionFigure 6

se

9265-23-20-21jExtreme Exfoliation Corrosion at Nutplates

ORIGIFIAL Figure 7As Received Sy

ATP 20-00-00Page 5




Galvanic Corrosion Metals grouped together in table 1 have little tendency toGalvanic corrosion occurs when dissimilar metals are in produce galvanic corrosion and are relatively safe to usein contact with each other. Coupling of metals fromcontact and an external circuit is provided by the different groups and distant from each other in the tablepresence of moisture. It is usually recognizable by the will usually result in galvanic or accelerated corrosion ofpresence of a build-up of corrosion at the joint between themetals. For example, aluminum and magnesium skins the metal higher on the list. The farther apart the metalsriveted together form a galvanic couple if moisture and are in table i, the greater the galvanic tendency will becontamination are present. When magnesium is attached because of the greater electrical potential differencebetween them.with steel fasteners, galvanic corrosion can occur. (Seefigures ff and 10.)

slc~1-i

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L 1~

a

-:,~ka a I -r-.-- ,r-. ;iSr

i

S265-23-20-24

Extreme Exfoliation CorrosionFigure 8

ORIGINALAs Received BY

ATP

20-00-00Page 6Aug 17/84 o COPYRIGHT, 1984 BY SABkeLINER CORPORATION

SR-76-023ORIGINAL CORROSION CONTROL MANUAL

As Received DyATP

~e ~O

cJ~

i9

as

~i

laa:g

Li3t1

*-3,,.::r

4M:1 5265-23-20-26

Extreme Case of Surface Corrosion and Dissimilar Metal CorrosionFigure 9

ELECTROLYTE

CORROSION

(CATHODE)(ANODE)PRODUCTS

STEEL MAGNESIUMFASTENER ALLOY

S265-23-20-15

Galvanic Corrosion of ~Iagnesium Adjacent to Steel FastenerFigure 10

20-00-00Page 7


SR-76-023CORKOSION CONTROL MANUAL

STANDARD PRACTICES AIRFRAME ~Continued)Galvanic Corrosion (Contd) small(more active) member will be severe and extensive

when insulation breaks down. If the cathode or less activeTable i, Metals in Galvanic Series member is small compared with the anode, anodic attack

ANODIC METALS will be superficial or general. An aluminum fastener incontact with a relatively inert Monel structure maycorrode severely, while a Monel bracket secured to a large

Magnesium 6i Magnesium Alloys aluminum member would result in a relativelyAluminum Alloys 5052, 5056, 5356, 6061 6063 superficial attack on the aluminum sheet. (See figure 11.)

All commonly used metals will cause corrosion of(;loul, 11magnesium in a strong salt environment. Cadmium orAluminum Aluminum Alloys

Carlmium zinc plating on the more cathodic metals such as iron andsteel will greatly reduce galvanic corrosion. It has beenNickel Zinc Alloy found that tin plated metal, when connected toZinc B Zinc Alloymagnesium, causes less corrosion than cadmium or zinc

~roup ill plated metal. This happens because, in this unusualIron circumstance, the tin polarizes and acts as an insulator.Leatl This is a contradiction of table i. (The galvanic series ofTin metals and alloys is to be used for general information andAnrl Their Alloys Except Stainless Yteels exceptions do exist.) Aluminum alloys containing

magnesium such as 5052 and 50fj~ reduce galvanic(;roup IVUhromium corrosion of magnesium alloys and also reduce

simultaneous corrosion of the aluminum. Under severeCobaltexposure, when the contact of magnesium alloys and(.opl~er

(;old plated steel bolts is necessary, the use of 6052 aluminumGi.aphiir ~ulshers may prevent seiere gnlvznic attack. ContinuityNickel of the liquid path may also be broken by the use of vinyl orSilvel polyester tapes. When conditions favorable to galvanicPlatinum corrosion are u navoidable, always p rotect both Dortio ns ofRhodium a couple. A break in the protective coating on the anodic~tainless Steel c~ Stainless Steel Allovs surface will cause severe pitting if the cathodic ~iurface isTitanium c~ Titanium hllovs not protected. This is because of the concentration of

current upon the relatively jmall area e~posed. WhenCXTHODIC ~VIET.-\LS practical, rivets. bolts, and other fasteners should be che

same material as the main structure. When not practical,Ithen tuc, dissimilar metals are used where contact may they should be selected from materials nearei thedevelop. if the more active member of the pair is small cathodic end of table 1 in order to distribute the anodiccompared with the less active member, attack on the

MONEL RIVET

HEAVY (SMALL CATHODE)CORROSIVEATTACK ALUMINUM RIVET

(SMALL ANODE)

RELATIVELY

LITTLECORROSIVEATtACK

ALUMINUM SIIIETMONEL SHEET tLARGE ANODE)(LARGE CATnODE)

5265-?3-a0-16

Area Relatinship in Dissimilar Metal ContactFigure 11

20-00-00Page 8Aug r 1/84 o COPYRIGHT, 1984 BY SABRELINER CORPORATION



Galvanic Corrosion (Contd) Oxygen Concentration Cellsattack over the larger of the two coupled metals. This is A solution in contact with a metal surface will normallyparticularly important where the fasteners are subjected contain dissolved oxygen. An oxygen cell can develop atto high stress and when the safety factor is low. The any point where the oxygen in the air is not allowed tostructural strength of the aircraft must not be diffuse into the solution, thereby creating a difference inendangered by substituting incorrect parts, oxygen concentration between two points. Typical

locations of oxygen concentration cells are under eitherConcentration Cell Corrosion metallic or non-metallic deposits (dirt) an the metalConcentration cell corrosion occurs when two or more

surface and under faying surfaces such as riveted lapareas of a metal surface are in contact with different joints. Oxygen cells can also develop unde r gaskets, wood.concentrations of the same solution. There are three rubber, plastic tape, and other materials in contact withthe metal surface. Corrosion will occur at the area of lowgeneral types of concentration cell corrosion:

oxygen concentration (anode) as illustrated in figure 12.i. Metal ion concentration cells view B.

2. Oxygen concentrationceils Active-Passive Cells8. Active-passive cells Metals which depend on a tightly adhering passive film

Metal ion Concentration Cells usually an oxide, for corrosion protection, e.g., austeniticcorrosion resistant steel, are prone to rapid corrosive

The solution may consist of water and ions of the metal in attack by active-passive cells. The corrosive actioncontact with the water. A high concentration of metal ions usually starts as an oxygen concentration cell, e.g., saltwill normally exist under faying surfaces where the deposits on the metal surface in the presence of watersolution is stagnant, and a low concentration of metal ions con tain i n g oxygen can create the oxygen cell. The passivewill exist adjacent to the crevice which is created by the film will be broken beneath the dirt particle. Once thefaying surface. An electrical potential will exist between passive film is broken the active metal beneath the film.the iwo points; the area of metal in contact with the low will be exposed to corrosive attack. An electrical potentialconcentration of metal ions will be cathodic and be will develop between the large area of the cathodeprotected; the area in contact with the high metal ion (passive film) and the small area of the anode tactiveconcentration will be anodic and will be corroded. Figure metal). Rapid pitting of the active metal will result as12. view A illustrates metal ion concentration cell illustrated in figure 12, view C.corrosion.

HIGH OXYGENLOW METAL ION CONCENTRATION CONCENTRATION

HIGH METAL IONCONCENTRATION

LOW OXYGEN CONCENTRATION

A. METAL 10N CONCENTRATIO~ CELL B. OXYGEN CONCENTRATION CELLRIVETED LAP JOINT

FOREIGN MATERIAL CREATESLOW OXYGEN REGION WnlCHPREVENTS THE RE-FORMAtlONOF PASSIVE FILM

ACTIVE PASSIVE FILMMETAL PROTECTS EXPOSED

SURFACEC. ACTIVE PASSIVE CELL

Concentration Cell CorrosionFigure 12

20-00-00Page 9

0 COPYRIGHT, l"nr BY SABRELINER CORPORATION Aug 17/84



Stress Corrosion CrackingStress corrosion cracking is caused by the simultaneouseffects of constant tensile stress and corrosion. Stressmaybe internal or applied. Internal stresses are produced bynon-uniform deformation during cold working, by unequalcooling from high temperatures, and by internal struc-tu ral rearrangements involving volume changes. Stressesinduced when a piece is deformed, those induced by pressand shrink fits, and those in rivets and bolts are internalstresses. Concealed stress is more important than designstress, especially because stress corrosion is difficult torecognize before it has overcome the design safety factor.The magnitude of the stress varies from point to pointwithin the metal. Stresses in the neighborhood of the yieldstrength are generally necessary to promote stress corro-sion cracking, but failures may occur at lower stresses.Specific environments have been identified which willcause stress corrosion cracking of certain alloys. Salt solu-ti o ns and seawater may cause stress corros ion cracking ofheat treatable aluminum alloys. Methyl alcohol-hydro-chloric acid solutions will cause stress corrosion crackingof some titanium alloys. Magnesium alloys may stresscorrode in moist air. Stress corrosion may be prevented byremoving the corrosive environment. This may be done byapplying protective coatings, using corrosion inhibitors,or controlling the environment. Stress relieving treat-ment can also be effectively used.

Filiform Corrosion

5letals with organic coatings tend to undergo a type ofcotrosion resulting in numerous threadlike filaments ofcorrosion products under the coating. (See figures 1Sand 14).Filiform corrosion is caused by the diffusion of oxygenand water through the coating and is considered a specialtype of oxygen concentration cell corrosion. This type ofcorrosion can be prevented by storing the aircraftecluipment in a low humidity environment (below 65%relxtive humidity). The progress can be markedlydecreasetl by the use of coatings which have a highresistance to diffusion by water.

20-00-00Page 10Aug 17/84 o COPYRIGHT, 1984 BY CORPORATION


:"-~-i

B

S265-23-20-19

Filiform Corrosion at Lap JointFigure L3

S265-23-20-25

Filliform Corrosion at Fastener HeadFigure 14

ORIGINALAs Received By

ATP 20-00-00Page 11/12 Blank

0 COPYRIGHT, 1984 BY SABRELINER CORPORA I 10N Aug 17/84


CORROSION ON AIRFRAME

CORROSION PRONEAREAS

To prevent corrosion on the aircraft, appropriateinspection and maintenance of corrosion prone areasmust be performed at scheduled intervals, The aircraftmust be carefully inspected for signs of corrosion at eachscheduled inspectibn. Under certain atmosphericconditions, such as high humidity, high temperature, andsalt water, it may be necessary to increase the frequencyofcorrosion inspections.Principal metals used on the exterior surface of theairplane are on figures 1 thru i. Areas of the airplanewhich should be examined periodically for corrosion areshown in table I. Specific corrosion prone areas asapplicable to each series of airplanes are shown in figurestj thru 9.Corrosion prone areas are on unpainted surfaces(actuating mechanisms or painted areas that have peeledor chipped), skin seams, lap joints, and areas where dirtanti ~rime collect. Other areas, such as rub strips, accessdoors, and crevices are corrosion prone because of theaccumulation of salt water and cleaning compounds.Moisture in these locations does not evaporate as rapidlyas in other locations more direcfly exposed to sun and air,such as the upper wing and Fuselage surfaces, Areassubjected to frequent contact of fluids, such as hydraulicdrains, fuel drains, water drain holes, and ahy otheroverboard drain, will require closer attention. There willbe less corrosion on painted, aluminum-coated, oraluminum-plated surfaces; however, corrosion willatt:lck protected metal, as moisture may penetrate theprc,tectecl surface. Palticular attention must be given toareas where drain holes may become clogged andmoisture may accumulate. Areas where dissimilarrnetal~ are in contact must be closely inspected. Whenappreciable moisture is present between dissimilarmetals, corrosion is accelerated. Leather, neoprene,soundproofing, and insulating materials can pick up andhold moisture, thus c~using corrosion.

LOC:I-\TION OF IMACNESIUAI PARTS

Tile location of all maffnesium components is shown infigure 1U. These components are highly durable andcor~rosion resistant when the protective finishes areintact. IMagnesium parts are considered corrosion pronesi nce a slight break or scratch through the primary finishma\l tesult in corrosion which could penetrate anddearade a mar5nesium part in a relatively short time.

20-00-10Page 1



I I ALUMNUM ALLOYS

t~j LAMINATED FIBREGLASS~i_i ij.il:l::/q HONEYCOMB88111711111111mn GLASSOR PLASTIC

CORROSION RESISTANTSTEEL

OP

g d~rj00 BVt~

oo

SIDE S265-23-20-25

20-00-10 Exterior Surface Materials Model NA 265-40Fiffure 1

Pa)SeAu~S 1T/X4 o COPYRIGHT, 1984 BY SABRELINER CORPORATION


I I ALUMINUM ALLOYS

LAMINATED FIBREOLASS

ii -;ii :-I HONEYCOMB

mmmmmmm

tJ~l CORROSION RESISTANT STEEL

773M

~ai-

ci

SIDE9265-23-20-6

EKteliol Sulface Materials Model ruA 2fi~-60Figure2 20-00-10Page 8

S3PYRIGHT, 1984 BY SABRELINER CORPORATION Aug 17/84


I 1~LUMINUMPILLOYS

LelMINITEDFIBREOLISs

I::.:::::::i:l:l ::::::I:::~ HONEYCOMB

GLASS OR PLASTIC

~j CORROSION RESISTLNTSTEEL

TOP

ii I I-T-

~i -e=iL~L! c o

~a\ Bro ~a ~sl a~

BOTTOM

SIDE

20-00-10 Exterior Surface Materials Model NA 2(iS-65Figure3Page 4Aug 17/84 o COPYRIGHT, 1984 BY SABRELINER CORPORATION


I I ALUMINUM ALLOYS

F~ LAMINATED FIBREGLASSnolcrcama

mmmmmmR GLASS OR PLASTIC

~I CORROSION RESISTANT STEEL

iY

BOTTOM

SIDE S265-23-20-7

Exterior Surface Materials Model NA 265-70Figure4 20-00-10Page 5



I ALUMINUM ALLOYS

LAMINATED FIBREGLASS

HONEYCOMB

mmmmmmn GLASS OR PLASTIC

CORROSION RESISTANTSTEEL

TOP

/d

x i

BOTTOM

mni an mn;_=

SIDE 5265-23-20-8

20-00-10 E?rterior Surface Materials Model NA 26.5-80Figure5Page tiAua 17/84 o COPYRIGHT, 1984 BY SABRELINER CORPORATION


CORROSIONON AIRFRAME (Continued)

Table 1. Periodic Corrosion Inspection

AREA ACTION

i. FuselageAccess doors panels Check mating edges for chafing, paint, and sealing.

Check for corrosion in areas surrounding fasteners.Areas where paint has been chipped or damaged Check for traces of surface corrosion.Bolt and fastener heads Check for exfoliation-type corrosion and rust.Countersinks in exterior skins Check for exfoliation-type corrosion and damaged paint.Drain holes Check for cleanness and for corrosion and paint.Entry door Check for sealing, painting, and corrosion.Ground escape hatch Check for sealing, painting, and corrosion.In-flight escape hatch-duter door (inactive) Check for sealing, painting, and corrosion.~IaKnesium control support castings I Check for galvanic action.Nose wheel well Check for corroded tubing and debris.Nose gear strut Check for corroded bolts, tubing, and rusted parts.Nose geal actuating cylinders Check for rust or corrosion on all components.Screw-attacheci dears Check for painting, sealing, and corrosion around

fastener heads.

Speed brake, speed brake well, and Check far painting and corrosion.actuating cylinders Check for rusted or corroded components.Wintlshieltl retaining strips Check sealing, and for corrosion anti aaivanice action

on all edges.~leas along fuselage lower centerline where Check for evidence of interaranular corrosion.moisture collects and tioes not evaporate tapidlyBattery bay I Check for corrosion and that acid-resistant paint

is intact.

Control cables Check for damageu protective film and corrosion.Dissimilar metal contacts Check for galvanic-tyDp corrosion.,-\nv area where paint has been chipped Check fol traces i~f surface corrosion.ol~

2 WingGroup~Access doors Check for painting, sealing, and corrosion.Xilelon balance weight attachment fasteners Check for signs of galvanic corrosion.Aileron hinge and actuator fittings Check hinge pins and bearings for corrosion.Bolt and fastener heads Check for galvanic and exfoliation-type corrosion.Countersinks in exterior skins Check for exfoliation-type corrosion and damaged paint.Dissimilar metal contact iStainless-steel screws Check for galvanic-type corrosion.surrounding compass in left wing tip)

20-00-10Page 7


SR-76-OL3C()RR()SION CONTROL MANUAL

CORROSION ON AIRFRAME~Continued)

Table i. Periodic Corrosion Inspection (Continued)

AREA ACTION

2. Wing Group(Contd)Flap actuator fittings Check pins and bearings for corrosion.Flap tracks and flap track fittings and rollers Check flap tracks for flaking of chrome plating

and corrosion.Check flap fittin)gs and rollers for corrosion and rust.

Exposed areas of wing rear spar Check for damaged paint films and evidence of corrosion.Main landing gear door actuating cylinders Check for intergranular corrosion on exterior surfaces.Main landing gear st~ut and actuators Check for corroded or rusted areas, bolts, and tubing.Main gear wheel well Check for corroded tubing and Fittings.

Check for cleanness.Slat tracks and slat track fittings and rollers Check slat tracks for flaking of chrome plating

and corrosion.Check slat track fittings and rollers for corrosionand rust.

Machined land on wing upper and lower skins Check for intergranular types of corrosion onat wing tip attach area, machined area.Close out doors on wing leading edge skins Check for intergranular and galvanic corrosionAft portion of wing leading edge skins adjacent Check for damaged paint films and/or evidenceto front spar where slats rub of corrosion.

EmpennageBalance weight attachment fasteners Check for galvanic corrosion.Bolt and fastener heads Check for galvanic and exfoliation-type corrosion.Countersinks in exterior skins Check For exfoliation-type corrosion and damaged paint.Dissimilar metal contact Check for signs of galvanic-type corrosion.Dt:lin holes in lowel sutfaceu Check for e?tfoliation-type corrosion and that all cirain

holes are open.Hinge and actuator fittings Check hinge pins and bearings for corrosion.Horizontal and vertical stabii;zer attach fittings Check for all types of corrosion.

4. Pylonsand EngineNn~zlles~il. intake ctuct Checl< interior c,f duct fot surface corrosion.Bolt anct Fastener heads Check for galvanic and exfoliation-type colrosion.Dissimilar metal contact Check for. galvanic-type corrosion.Engine attach mounts Check for corrosion and rusted areas.Engine nacelle door hooks and latches Check for corrosion and rust.

Check for damaged paint.Steel lines and f;ttings Check for signs of rust and corrosion.Pylon firewall FS 5.57 to 384.5 Check for signs of rust and/or corrosion and also for

indications of excessive heat.Pvion and engine air intake duct leading edge skins Check for damaged paint films and evidence of corrosion.Close-out doors and covers and related attach Check for damaged paint films and evidence of corrosion.angles in pylon lower skin

20-00-10Page 8Aug 17/84 o COPYRIGHT, 1984 BY SABRELINER CORPORATION

SR-76-O2.3CORROSION CONTROL 1MANUAL

8

t ir, 4

10

26--:=1

1112

13

14

18 17 1619 15

21 20

22

23

24

25

1. GALLEYAREA2. ENGINE AIR INTAKE3. BATTERYAREA4. HORIZONTAL STABILIZER TO FUSELAGE RUB AREA5. RUDDER HINGES5. TAIL CONE INTERIOR7. RUDDER POSTFITTING8. HORIZONTAL STABILIZER HINGES9. AFTFUSELAGEDRAIN HOLES

10. FUSELAGE SKINS THRUST REVERSER IMPINGEMENT AREA11. CENTER SECTION UPPER SKINS12. FLAPTRACKS13. AILERONTRIMTAB MINCES14. AILERON HINGES15. LOWER SURFACE SKINS16. MAIN LANDING GEAR CHASSIS ASSEMBLY17. WING ATTACH FITTINGS18. WING LEADING EDGE TO FUSELAGE RUB AREA19. INFLIGHtESCAPE HATCH20. MAIN ENTRYDOOR21. SPEED BRAKEWELL22. FLOOR AREA INBOARD OF MAIN ENTRY DOOR23. INTERIOR AREA BELOW PILOTS SLIDING WINDOW24. NOSE GEAR CHASSIS ASSEMBLY25. BULKHEADATFS1326. PYLON FIREWALL FS 357 TO 384.5 5285-23-20-1

Corrosion Prone Areas Model NA 265-40 20-00-10Figure 6Paffe 9

B COPYRIGHT, 1984 BY SA=DTTLINER CORPORATION Aug 17/84

SR-7(i-02:3C()KK()SI()N CONTROL MANUAL

,li

a i4 /13

15

32

17

Is

J

25 2426 23 22 21

27 2028

29

30

31

WINDSHIELD RETAINING STRIPS 17. FLAP TRACKS 8 FLAP TRACK ROLLERS2. GALLEY 18. AILERON TRIM TAB HINGESi. SL~T TRACKS 5 SLAT TRACK ROLLERS 19. L\ILERON HINGESJ~ ADF L\NTENNAMOUNT 20. LOWER SURFACE SKINS5. WINOOWPANS 21. MAIN LANDING GEAR CHASSIS ASSEMBLY6. ENGINEAIR INTAKE 22. MAIN LANDING GEAR WHEEL WELLS7. LAVATORY 23. WING ATTACH FITTINGS3. SATTERYAREA 24. WING LEADING EDGE TO FUSELAGE RUB AREA9. HORIZONTAL STABILIZER TO FUSELAGE RUB AREA 25. SPEED BRAKEWELL

lO. RUDDER HINGES 26. MAIN ENTRY DOOR FLOOR STRUCTURE AREA11. RUDDER POSTFITTING 27. INTERIOR AREA BELOW PILOTS SLIDING WINDOW12. TAIL CONE INTERIOR 28. NOSE GEARWHEEL13. HORIZONTAL STABILIZER HINGES 29. NOSE GEAR CHASSIS ASSEM 8 WHEELS14. AFTFUSELAGEDRAIN HOLES 30. ELECTRONIC COMPARTMENT15. FUSELAGE SKINS THRUST REVERSER IMPINGEMENT AREAS 31. BULKHEAD ASSY AT FS 1316. CENTER SECTION UPPER SKINS 32. PYLON FIREWALL FS 357 TO 384.5

5265-23-20-2

20-00-10 Colrosion Prune Areas Model NA 865-60Figure7Paae 10Aug 17/84 o COPYRIGHT, 1984 BY SABRELINER CORPORATION

SR-76-02YCORROSION CONTROL MANUAL

3

4~67

119Il

11

23

,13

14

15

21 ;o 1922

17

1. WINDSHIELD RETAININGSTRIPS2. GALLEY

3. SLAT TRACKS 8 SLAT TRACK ROLLERSj~ ENGINEAIR INTAKE5. LAVATORY6. BATTERYAREA7. HORIZONTAL STABILIZER TO FUSELAGE RIJB AREA5. RUDDER HINGES9. HORIZONTAL STABILIZER HINGES

10. AFTFUSELAGEDRP~IN HOLES!1 FUSELAGE SKINS THRUST RE\/ERSER IMPINGEMENT ~REA12. MAIN LANDING GEAR WHEEL WELLS13. MAIN LANDING GEAR CHASSIS ASSEMBLY14. FLAP TRACKS 4 FLAP TRACK ROLLERS15. AILERON TRIM TAB HINGES16. AILERON HINGES17. LOWER SURFACESKINS18. WING LEADING EDGE TO FUSii~GE RUB AREA19. MAIN ENTRY DOOR FLOOR Si r;UCTURE AREA20. SPEED BRAKEWELL21. NOSE GEAR WELL22. NOSE GEAR CHASSIS ASSEMBLY23. PYLON FIREWALL FS 357 TO 384.5

5265-23-20-3

Colrosion Prone Areas Model NA 865-70 20-00-10Figure 8Page 11


SR-7fi-02~C()KH()SI()N CONTROL IMANUAL

3~ 1! 6

1

.J ii 1023

X?12

i 13

19 1817

20 1522 21

16

i. WINDSHIELD RETAINING STRIPS2. GALLEY3. SLAT TRACKS 8 SLAT TRACK ROLLERS4. ENGINEAIR INTAKE5. LAVATORY8. HORIZONTAL STABILIZER TO FUSELAGE RUB AREA7. RUDDER HINGES8. HORIZONTAL STABILIZER HINGES9. dFT FUSELAGE DRAIN HOLES

10. FUSELAGE SKINS THRUST REVERSER IMPINGMENT AREA11. MAIN GEAR WHEEL WELLS12. MAINLANDINGGEAR CHASSISASSEMBLY13. FLAP TRACKS 8 FLAP TRACK ROLLERS14. AILERONTRIMTAB HINGES15. L\ILEAON MINCES16. LOWER SURFACESKINS17. WING LEADING EDGE TO FUSELAGE RUB AREA18. MAIN ENTRY DOOR FLOOR STRUCTURE AREA19. SPEED BRAKEWELL20. NOSE GEAR WELL21. NOSE GEAR CHASSIS ASSEMBLY22. BATTERYBAY23. PYLON FIREWALL IrS 357 TO 384.5

S265-23-20-J

20-00-10 Corrosion Prone Ateas Model ruA 265-80Figure9Pane 1~Aug 17/e o COPYRIGHT, 1984 BY SABRELINER CORPORATION


1 13

5

2 210

19

6

4

12

7 9 8 9 7 8 11 14 15 17 20

i. 265-430003 SUPPORT--ENGINE THROTTLE QUADRANT AND AILERON BELLCRANK ASSEMBLY2. 265-524079 PCDAL--PILOTS BRAKE AND DIF\ECTIONAL CONTROL ASSEMBLY3. 265-334007 SUPPORT--LEFT BRAKE BELLCRANK, FS 76J. 265-334022 HOUSING--PRESSURE BOX SEALING--PILOTS BRAKE CONTROL SYSTEM5. 265-437028-1. -2. -11. -12 SUPPORT--TORQUE TUBE--THROTTLE CONTROL SYSTEM. FS 79.5i. :65-524031 KNOB--PEDAL ADJUSTMENT-CONTROL COLUMN ASSEMBLY7. 265-521017-1 &2 PEDESTAL--RUDDER PEDAL AND CONTROL COLUMN3. 265-522020 SUPPORT--TORQUE TUBE--LONGITUDINAL CONTROL SYSTEM, FS 104.844

265-5220239. 265-524057 SUPPORT--RUDDER TORQUE TUBE--CONTROL COLUMN ASSEMBLY

10. 246-52231-i 8 9 SUPPORT-LONGITUDINAL CONTROL SYSTEM BELLCRANK, FS 176.511. 265-522037 BELLCLlANK-BOBWEIGHT BALANCE BUNGEE--LONGITUDINAL CONTROL SYSTEM12. 265-334006 SUPPORT-BELLCRANK RIGHT-HAND BRAKE, FS 7613. 265-524032 LINK--IDLER--RUDDER CONTROL PEDAL FWD AND APT-CONTROL COLUMN ASSEMBLY

265-52403314. 265-300242-1 HANDLE--FUSELAGE ENTRY DOOR-INSIDE15. 246-52418 SUPPORT--DIRECTIONAL CONTROL SYSTEM, FS 116.5 (BELLCRANK)16. 246-52218-11 &12 SUPPORT-LONGITUDINAL CONTROL SYSTEM BELLCRANK. FS 176.5 (UPPER)ti. 246-33731 SUPPORT-LANDING GEAR EMERGENCY AFT CONTROL18. 265-522026 SUPPORT-LONGITUDINAL CONTROL SYSTEM BELLCRANK, FS 36319. 265-524004 SUPPORT--DIRECTIONAL CONTROL BELLCRANK SYSTEM, FS 457.87520. 265-523048 BELLCRANK--LATERAL CONTROL SYSTEM TRIM ACTUATOR

S265-23-20-(2

Location of Magnesium Parts 20-00-10Figure 10Page in/14 Blank



CLEANING AIRFRAME

CLEANING MATERIALS, METHODS, AND ToiueneAPPLICATIONS Toluene is flammable. Keep away from heat and openTable 701 provides a listing of the areas and types of soils flame. Vapors are harmful. Use only with adequatewhich may be encountered during the preventive ventilation or respirator. Avoid prolonged or repeatedmaintenance phase of a corrosion control inspection breathing of vapor. Avoid contact with skin and eyes. Doprogram and of the materials and methods necessary to not take internally, Comply with air pollution controladequately remove any accumulated soils. rules concerning photochemically reactive solvents.

Conditions Requiring Immediate Cleaning SealantsUnder certain conditions, the need for the immediate Sealants are irritating to the skin and eyes upon contact,cleaning of an area may arise. When any of these and may emit harmful vapors. Use only with adequateconditions do arise, cleaning of the affected areas should ventilation. Avoid all skin and eye contact, Use protectivenot be delayed any longer than is absolutely necessary, clothing such as rubber gloves, apron and eye protection.The longer the cleaning process is delayed, the greater the Wash off immediately any accidentally contaminatedchance of serious damage being caused by the corrosion- skin area. Do not take internally.inducing condition.

Epoxy Polyamide PrimerImmediate cleaning should be accomplished any time theairplane has been subjected to any of the following Epoxy polyamide primer emits harmful vapors, whichconditions: may be flammable, especially during mixing, curing, andi. spray application. Perform these operations only withSpi lied electrolyte or corrosive deposits in vicinity of

batteries. adequate ventilation or respirator protection. Epoxyresins, especially the uncured resins and curing agents

2. Exposure to fire extinguishing agents other than are irritating to the skin and eyes. Avoid all skin and eyecarbon dioxide (CO~). contact. Use protective clothing such as rubber gloves,

apron, and eye protection. Wash off immediately any3. Operation in low-level ocean flight. accidentally contaminated skin area. Do not take4. Exposure to saltwater spray during adverse internally. Comply with air pollution control rules

weather conditions. concerning photochemically reactive solvents.

Hazardous Materials Polyurethane Paint~lethvl ethyl ketone(MEK). nliphatic naphtha, toluene, Polyurethane paint contains flammable solvents andsealants, epoxy polyttmide primer. polyurethane paint, toxic diisocyantes. Keep away from heat and open flame.anti eposy filler are materials which could be injurious to Vapors or mists are harmful! Complete body protection.the health of persons using them unless the applicable including entire head, is required, to prevent skin or eyesafety precautions are observed, irritation from contact with the paint or its vapors or

mists. Respirator protection is required, usually an air-Methyl Ethyl Ketone (IMEK) supplied hood, during mixing, curing and application.

Suitable facilities should be provided for immediateMEK is flammable. Keep away from heat and open flame. clean water flushing of any accidental skin or eye contact.Vapors may be harmful. Use with adequate ventilation. Do not take internally.~void ptolon~ged or repeated breathing of vapor. Avoidcontact ~ith skin and e~es. Do not take internally. Epoxy Filler

;\liphatic Naphtha Epoxy emits harmful vapors, especially during mixingand curing. Use only with adequate ventilation orNaphtha, aliphatic is flammable. Keep away from heat respirator. Epoxy resins, especially the uncured resins

and open flame. Vapors may be harmful. Use with and curing agents, are irritating to the skin and eyes.adequate ventilation. Avoid prolonged or repeated Avoid all skin and eye contact. Use protective clothingbreathing of vapor. Avoid contact with skin and eyes. Do such as rubber gloves, apron and eye protection. Wash offnot take internally. Comply with air pollution control immediately any accidentally contaminated skin area.rules concerning photochemically reactive solvents, Do not take internally.

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SR-76-023CORROS

Corocion Control Manual

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