AD 3.3- S9320-AM-PRO-030_MLDG REV 03.pdf

i ii iii

NAVSEA S9320-AM-PRO-030/MLDG REV 03

NSN 0910-LP-024-8470

TECHNICAL MANUAL

UNDERWATER CABLE ASSEMBLY AND

ENCAPSULATED COMPONENTS, FABRICATION,

REPAIR, AND INSTALLATION MANUAL

VOLUME III

PLASMA SPRAY PROCEDURE

DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIR

CONTRACTORS ONLY. OTHER REQUESTS FOR THIS DOCUMENT MUST BE

REFERRED TO: COMMANDER, NAVAL SEA SYSTEMS COMMAND (CODE 05Z),

1333 ISAAC AVE. SE, WASHINGTON NAVY YARD, DC, 20376-0001

PUBLISHED BY DIRECTION OF COMMANDER, NAVAL SEA SYSTEMS COMMAND

FEBRUARY 2005

iv

LIST OF EFFECTIVE PAGES

Dates of issue for revision 03 pages is February 2005

Page *Change No. No.

Title Page 0 List of Effective Pages 0 Revision Record 0 Table of Contents 0 Foreword 0 Section I 0 Section II 0 Section III 0 Section IV 0 Section V 0 Section VI 0

Appendix III-A Sample Plasma Spray Operator/Inspector 0 Test Questions

Appendix III-B Plasma Spray Operator/Inspector 0 Certification/Recertification Test Record

Appendix III-C Authorized Cleaning Solvents 0

Appendix III-D Plasma Spray Job Control Record 0

Appendix III-E Connector Plug Body Graphics (Typical) 0

Appendix III-F Grit Blast/Plasma Spray Metal Mask (Typical) 0

Appendix III-G Blank Table I and Equipment List 0

Appendix III-H Sample Audit 0

Appendix III-I List of Approved Vendors 0

Appendix III-J Sample Statistical Process Control Chart 0

Appendix III-K Connector Receipt Inspection and Post NCC 0 Application Report Form

*Zero in this column indicates an original page for revision 03 v

REVISION RECORD

REVISION

NO.

DATE

TITLE AND/OR BRIEF

DESCRIPTION

SIGNATURE

vi

TABLE OF CONTENTS

Page Issuance Letter ............................................................................................................... i Title Page ................................................................................................................. iii List of Effective Pages ................................................................................................... iv Revision Record ............................................................................................................ v Table of Contents .......................................................................................................... vi Foreword ................................................................................................................. x

SECTION I

1-0 INTRODUCTION

1-0.1 Applicability 1-0.2 Purpose 1-0.3 Scope 1-0.4 Assembly 1-0.5 Certification……………………………………………………………………. 1 1-0.6 Non-compliance

1-1 GENERAL

1-1.1 References 1-1.2 Appendices 1-1.3 Definitions

1-2 RESPONSIBILITIES

1-2.1 NAVSEA 05Z

1-2.2 NAVSEA O5M2

1-2.3 Performing Activity 1-2.3.1 Management 1-2.3.2 Quality Assurance (QA) Program

1-3 TRAINING AND CERTIFICATION

1-3.1 General 1-3.2 Process Certification 1-3.3 Operator Training and Certification 1-3.4 Maintenance of Operator Certification 1-3.5 Operator Certification Sample Preparation 1-3.5.1 Visual, Microscopic and Bend Test samples 1-3.5.2 Tensile Bond Strength Test samples 1-3.6 Operator Certification/Practical Tests 1-3.6.1 Visual Inspection 1-3.6.2 Microscopic Examination 1-3.6.3 Bend Tests 1-3.6.4 Tensile Bond Strength Test 1-3.7 Inspector Training and Certification 1-3.8 Maintenance of Inspector Certification 1-3.9 Facility Certification 1-3.10 Quality Conformance

1-4 RECORDS

1-4.1 Record Requirements vii

SECTION II

2-0 OCCUPATIONAL SAFETY AND ENVIRONMENTAL

2-1 EQUIPMENT/MATERIAL

2-1.1 Plasma Spray Hazards 2-1.2 Cleaning Solvents 2-1.3 Ventilation 2-1.4 Gas cylinders/gas supply systems 2-1.5 Electrical

2-2 PERSONAL PROTECTION EQUIPMENT (PPE)

2-2.1 Respiratory 2-2.2 Eye 2-2.3 Hearing 2-2.4 Protective Clothing 2-2.5 Personnel Requirement

2-3 WASTE DISPOSAL

SECTION III

3-0 MATERIALS

3-1 MATERIALS LIST

3-1.1 Base (base metal) Materials 3-1.2 Coating System Materials 3-1.2.1 Coating System Materials Storage 3-1.3 Plasma Gases 3-1.4 Grit Blasting Material 3-1.5 Masking 3-1.6 Cleaning Solvents

SECTION IV

4-0 EQUIPMENT

4-1 EQUIPMENT LIST

4-1.1 Plasma Spray System 4-1.2 Grit Blasting Equipment 4-1.3 Air Delivery Equipment 4-1.4 Spray Booth 4-1.5 Part Handling Equipment 4-1.6 Miscellaneous

4-2 PLASMA SPRAY EQUIPMENT MAINTENANCE

4-2.1 General 4-2.2 Plasma Spray Equipment 4-2.3 Ancillary Equipment viii

SECTION V

5-0 COATING PROCEDURE

5-0.1 Receipt Inspection 5-0.2 Lot Quality Assurance

5-1 SURFACE PREPARATION

5-1.1 Connector Plug Body Series machining (Typical) 5-1.2 Plasma Spray Area Machining 5-1.3 Solvent Cleaning 5-1.4 Masking Systems 5-1.4.1 Grit Blast Masking 5-1.5 Anchor-Tooth Blasting 5-1.6 Demasking 5-1.7 Machine Parameter Settings 5-1.8 Gun Fixturing

5-2 PLASMA SPRAY PROCEDURE

5-2.1 Plasma Spray Parameters 5-2.2 Connector Preheat 5-2.3 Masking Systems 5-2.3.1 Plasma Spraying Masking Materials 5-2.4 Coating System Application 5-2.4.1 Work In-Progress Testing 5-2.4.2 Powder Feed Rate 5-2.4.3 Bond (Primer) Coating 5-2.4.4 Non-Conductive (Ceramic) Coating 5-2.4.5 Temperature Monitoring 5-2.4.6 Thickness Monitoring

5-3 POST- APPLICATION PROCESSING

5-3.1 Cooling 5-3.2 Visual Inspection 5-3.3 Finishing and Dimensional Check 5-3.4 Sealing and Surface Resistivity Measurement 5-3.5 Final Inspection

SECTION VI

6-0 PACKAGING

6-0.1 Packaging 6-0.2 Marking ix

FIGURES

1 VISUAL, MICROSCOPIC AND BEND TEST SPECIMEN

2 ROTATING FIXTURE FOR SPRAYING TENSILE

AND BEND SPECIMENS (TYPICAL)

3 TENSILE BOND STRENGTH TEST SPECIMEN

4 TENSILE BOND SPECIMEN ALIGNMENT FIXTURE

5 SEALER APPLICATION

TABLES

I PLASMA SPRAY COATING PARAMETERS

II MATERIALS LIST

III 200 SURFACE FEET PER MINUTE PARAMETERS (Typical)

IV QUALITY CONFORMANCE CHART

V ALUMINA-TITANIA COATING PROPERTIES

APPENDICES

III-A SAMPLE PLASMA SPRAY OPERATOR/INSPECTOR

TEST QUESTIONS ............................................................................... A1

GENERAL PLASMA SPRAY QUESTIONS ........................................... A2

EQUIPMENT SPECIFIC QUESTIONS .................................................. A6 SAFETY QUESTIONS ........................................................................... A8 QUALITY ASSURANCE QUESTIONS .................................................. A9

III-B PLASMA SPRAY OPERATOR/INSPECTOR

CERTIFICATION/RECERTIFICATION TEST RECORD ....................... B1

III-C AUTHORIZED CLEANING SOLVENTS ................................................C1

III-D PLASMA SPRAY JOB CONTROL RECORD ........................................D1

INSTRUCTIONS FOR COMPLETING PSJCR AND ADDENDUM .. .....D3

DATA SHEET

PSJCR ADDENDUM DATA SHEET………………………………….. .....D4

III-E CONNECTOR PLUG BODY MACHINING (OPTIONAL - TYPICAL) ..... E1

III-F GRIT BLAST/PLASMA SPRAY METAL MASK (TYPICAL) ................... F1

III-G BLANK TABLE I AND EQUIPMENT LIST ......................................... .. G1 III-H SAMPLE AUDIT ....................................................................................H1

III-I LIST OF APPROVED VENDORS……………………………………......... I1

III-J SAMPLE STATISTICAL PROCESS CONTROL CHART…………... ..... J1

III-K CONNECTOR RECEIPT INSPECTION AND POST NCC

APPLICATION REPORT FORM……………………………………….. .... K1

x

FOREWORD

Due to patent 5,942,333 of 24 August 1999, use of this procedure is limited to Government agencies and companies that require it to fulfill contractual obligations.

Plasma spraying is a subset of the thermal spraying process. This procedure provides the minimum guidelines, technical references, forms, training and quality assurance requirements that are needed to certify a facility, operators, inspectors and equipment to plasma spray non-conductive ceramic coatings on submarine outboard connector metal plug bodies. The primary references used to assemble this process are MIL- STD-1687A, Thermal Spray Processes for Naval Ship Machinery Applications, MIL- STD-2138, Metal Sprayed Coatings for Corrosion Protection Aboard Naval Ships, MIL- STD-1916, Department of Defense Test Method Standard, and various Puget Sound Naval Shipyard Uniform Industrial Process instructions.

The purpose of applying non-conductive ceramic coatings to submarine outboard connector metal plug bodies is to reduce or eliminate cathodic delamination of the polyurethane overmolding from the connector metal plug body. Cathodic delamination, or galvanic action in this area, causes separation of the polyurethane overmolding/strain relief from the connector metal plug body. This delamination eventually provides an entry point for water to enter the connector causing premature connector failure. The cathodic delamination or galvanic action occurs when the connector metal plug body, attached to a hull fitting or an outboard component, becomes electrically active as a part of a galvanic couple. The presence of zinc anodes near the connector metal plug body may also increase the galvanic couple activity.

Plasma spraying a non-conductive ceramic coating onto a connector metal plug body is the latest, and perhaps best, effort to eliminate galvanic action at this interface area.

Additionally, plasma sprayed non-conductive ceramic coatings will not alter underwater connector metal plug body MIL-STD specifications to the point that the connector would require retesting per the applicable connector MIL-STD and will allow use of all previously used fabrication equipment and installation processes. NAVSEA 05Z has granted shock qualification to plasma sprayed, metal connectors conforming to MIL-C- 24231 and MIL-C-24217 per NAVSEA ltr. 3960 ser. 03Z61/001 of 16 January 1998.

SECTION I

1-0 INTRODUCTION

1-0.1 Applicability: This procedure is applicable to all government or commercial activities providing services for the specific purpose of applying non-conductive plasma sprayed ceramic coatings on submarine outboard connector metal plug bodies.

1-0.2 Purpose: The purpose of this procedure is to provide detailed, stand alone instructions and standards that contain the minimum training and certification requirements needed by a facility to become certified per NAVSEA 05M2 to produce acceptable non-conductive plasma sprayed ceramic coated submarine outboard connector metal plug bodies.

1-0.3 Scope: The ceramic plasma spray direction provided in this procedure applies only to submarine outboard connector metal plug bodies and does not apply to other thermal or plasma spray applications. The procedures, equipment and materials used in this instruction have been proven, through controlled testing and use, to produce optimum results for reducing or eliminating the galvanic action that causes polyurethane overmolding delamination at the connector plug body base metal interface area. Use of alternative equivalent equipment or materials shall be accepted only after proof of performance equivalency is demonstrated to the satisfaction of the NAVSEA 05M2 or authorized agents.

1-0.4 Assembly: This procedure was prepared by using applicable sections from the references listed in paragraph 1-1.1 to produce a stand alone, comprehensive procedure specifically for the application of non-conductive plasma sprayed ceramic coatings on submarine outboard connector metal plug bodies.

1-0.5 Certification: All activities that are engaged in the application of non-conductive ceramic coatings on submarine outboard connector metal plug bodies shall be certified in accordance with the requirements of this Technical Manual and shall be subject to re-certification on a biannual schedule. Further, all activities that are engaged in the application of non-conductive ceramic coatings on submarine outboard connector metal plug bodies shall certify each lot to be in compliance with the requirements of this manual. Signed copies of the certificates of compliance (C of C) shall be included in the shipment of each lot. Duplicate signed copies of the C of C’s shall be retained in the activity’s quality assurance files for a minimum of ten years.

1-0.6 Non-compliance: In the event of non-compliance with the requirements of this instruction, all work by the non-compliant activity(s) will be suspended until the non-compliance is resolved. All non-compliant parts shall be reworked to comply with this procedure.

1-1 GENERAL

1-1.1 References

(a) MIL-STD-1687A, Thermal Spray Processes for Naval Ship Machinery Applications

(b) MIL-STD-2138, Metal Sprayed Coatings for Corrosion Protection Aboard Naval

Ships (Metric)

(c) Uniform Industrial Process Instruction 0074-903, Thermal Spray, Machinery Repair, Puget Sound Naval Shipyard (PSNS), of 25 Aug 89

(d) MIL-C-24231 Connectors, Plugs, Receptacles, Adapters, Hull Inserts, and Hull

Insert Plugs, Pressure-Proof, General Specifications for

(e) MIL-C-24217, Connectors, Electrical, Deep Submergence, Submarine

(f) NAVSEA ltr. 3960 ser. 05Z61/001 of 16 January 1998

(g) Chapter 29 Code of Federal Regulations (OSHA Safety Standards)

(h) American Welding Society (AWS) C2.1, Spraying, Thermal, Recommended Safe

Practices for

(i) OPNAVINST 5100.23, Navy Occupational Safety and Health Program Manual

(j) NAVSEA S9086-CH-STM-030, Chapter 074, Volume 3, Naval Ship’s Technical

Manual, Gas Free Engineering

(k) OPNAVINST 5100.19, Navy Occupational and Health (NAVOSH) Program Manual for Forces Afloat

(l) National Fire Protection Agency (NFPA) 50A, Standard for Gaseous Hydrogen

Systems at Consumer Sites (National Fire Codes, Volume 2) (m)Submarine Maintenance Standard, TRS No. 2040-086-010, Inspect Electrical Cable

Connectors and Hull Inserts/Holes

(n) MIL-STD-2073/1, DoD Standard Practice for Military Packaging

(o) MIL-STD-129, Standard Practice for Military Marking

(p) AWS, Thermal Spraying - Practice, Theory and Application

(q) NAVSEA S9086-KC-STM-000/CH300, Technical Manual

(r) MIL-STD-1916, Department of Defense Test Method Standard (DoD Preferred methods for Acceptance of Product)

1-1.2 Appendices

Appendix III-A, SAMPLE PLASMA SPRAY OPERATOR/INSPECTOR TEST

QUESTIONS

Appendix III-B, PLASMA SPRAY OPERATOR/INSPECTOR CERTIFICATION/TEST

RECORD

Appendix III-C, AUTHORIZED CLEANING MATERIALS

Appendix III-D, PLASMA SPRAY JOB CONTROL RECORD

Appendix III-E, CONNECTOR PLUG BODY MACHINING (OPTIONAL - TYPICAL)

Appendix III-F, GRIT BLAST/PLASMA SPRAY METAL MASK (TYPICAL)

Appendix III-G, BLANK TABLE I AND EQUIPMENT LIST

Appendix III-H, SAMPLE AUDIT

Appendix III-I, LIST OF APPROVED VENDORS

Appendix III-J, SAMPLE STATISTICAL PROCESS CONTROL CHART

Appendix III-K, CONNECTOR RECEIPT INSPECTION AND POST NCC

APPLICATION REPORT FORM

1-1.3 Definitions

1. Anchor Tooth Profile: The condition of the base metal after abrasive blasting for surface roughening.

2. Acceptable: Acceptable items conform to the applicable standard or specification.

3. Approval (Approved): Approved items under consideration have been sanctioned in writing by the Commander, NAVSEA or his authorized agent.

4. Authorized Agent: An authorized agent is any Government representative specifically authorized to approve use of equipment and material or to perform inspections and audits within the scope of this procedure. The authorized agent must have the appropriate training and experience to implement and evaluate inspection functions of this procedure. Agent authority will be designated in writing.

Agents are designated by NAVSEA 05M2 or as follows:

(1) For Government Shipyards, the agent is the authorized agent of the Shipyard Commander.

(2) For commercial shipyards, the agent is the authorized agent of the Supervisor of Shipbuilding Conversion and Repair.

(3) Naval Ship Systems Engineering Station (NAVSSES) Philadelphia is also authorized to provide field support for Naval activities.

(4) For fleet units or activities, the agent is the authorized agent of the Type Commander.

5. Base metal (Substrate): Any material upon which a thermal sprayed coating is deposited.

6. Blasting (Grit Blasting): A method of cleaning or surface roughening by a forcibly projected stream of sharp angular abrasive.

7. Bond Coat: A preliminary (or prime) coat of material that improves adherence of the subsequent thermal spray deposit.

8. Certified: A certified facility, operator or inspector that has been approved to the requirements of this procedure.

9. Coating System: One or more thermal spray coatings that are qualified for use singly or in combination.

10. Composite Powder: Powder particles that are formed by physically combining two or more materials in intimate contact, such that the end particles function as a unit.

11. Inspector: An inspector is an employee of a contractor, Naval shipyard or

Government agency designated to accept or reject materials or workmanship on the basis of the results of specified tests.

12. Interpass Temperature: The allowed temperature range of the component to be sprayed prior to depositing a spray coating pass.

13. Interface: The contact surface between the spray deposit and the base metal or two different types of sprayed materials.

14. Lot: A lot is considered to be a quantity of one or more connector plug bodies sprayed during a shift by an individual operator using materials from the same batch numbers. If operators or material batch numbers change, the Lot Number shall change.

15. Masking: The method of protecting areas adjacent to the surface to be plasma sprayed or blasted to prevent coating adherence or surface roughening to those areas.

16. Plasma Spraying: A thermal spraying process wherein a non-transferred constricted electric arc-gas mixture (called a plasma) is utilized as the source of heat for melting and propelling the coating material to the work piece.

17. Operator: An employee of a contractor, Naval Shipyard or Government agency that has satisfactorily completed the specified training, practical tests and has been designated by an authorized agent to perform plasma spraying for the purpose of applying ceramic coatings on connector metal plug bodies. An operator may also be required to perform various inspections during the plasma spraying process.

18. Procedure: An approved written instruction that contains all the applicable essential elements required to perform a given function.

19. Seal Coat: Seal coats are applied as a post treatment to the plasma sprayed coatings to fill pores and maintain the ceramic coating dielectric constant.

20. Spalling: The flaking or separation of a sprayed coating.

21. White Metal Surface: A white metal blast cleaned surface finish is defined as a base metal surface with a gray-white, uniform metallic color, slightly roughened to form a suitable anchor pattern for coatings. The surface shall be free of oil, grease, dirt, mill scale, rust, corrosion products, oxides, paint, or any other foreign matter.

1-2 RESPONSIBILITIES

1-2.1 NAVSEA 05Z: NAVSEA 05Z or authorized agent is the primary administrative and coordination authority for maintenance of this procedure. NAVSEA 05Z or authorized agent will work with NAVSEA 05M (Welding Engineers) to ensure that any recommended changes or modifications to this procedure are within the intended scope of the procedure.

1-2.2 NAVSEA 05M2: NAVSEA 05M2 is to provide technical resolution and act as approval authority for any recommended changes or modifications to this procedure.

NAVSEA 05M2 or authorized agent will certify facilities as qualified to perform the requirements of this procedure.

1-2.3 Performing Activity: The performing activity shall be responsible and accountable for assuring that all plasma spray functions and inspections within this procedure are performed per the requirements of this procedure.

1-2.3.1 Management: In accordance with NAVSEA direction, the authority and responsibility to assure quality control of all plasma spray applications supported in this procedure will be a performing activity management function.

1-2.3.2 Quality Assurance (QA) Program: All MIL-STD- 1916 and MIL-STD-1687A QA Program requirements necessary to insure submarine outboard connector metal plug body plasma spray quality requirements are written into this procedure for ease of implementation. The performing activity shall cause to be implemented, per the QA requirements of this procedure, a Quality Assurance Program adequate to assure NAVSEA that all quality requirements are met or exceeded. Performing activity personnel conducting acceptance inspections shall be trained and certified in writing by the performing activity or authorized agent for the work they perform. Performing activity plasma spray program internal audits shall be conducted semi-annually as a part of the performing activity QA Program. A sample audit is included in Appendix III-H.

1-3 TRAINING AND CERTIFICATION

1-3.1 General: This procedure is one of several thermal spray processes in the MIL- STD-1687 thermal spray standard. The intent of the training and certification direction presented in this procedure is to meet the requirements of MIL-STD-1687 while limiting the training and certification to that required by facilities, operators and inspectors to become proficient in applying acceptable plasma sprayed ceramic coatings on the metal plug body component of molded submarine outboard connectors. Sample questions are contained in Appendix III-A. This training or certification is not intended to prepare or certify operators and inspectors in other thermal spraying disciplines. Each spray facility shall contact SUBMEPP, Code 1843WN, B-85/Third Floor, McDonough Ave., Portsmouth, NH 03804-5000 to arrange funding and schedule for facility certification. Facility level qualification records shall be sent to W. Nichols at the address listed above.

1-3.2 Process Certification: The initial process certification plasma spray coating parameters, included in Puget Sound Naval Shipyard (PSNS), Bremerton, WA, Uniform Industrial Process Instruction 0074-903, were approved for use by NAVSEA 05Z and NAVSEA 05M2 for a METCO Plasma Spray System and the parameters in TABLE I of this procedure. If other plasma spray systems or plasma spray materials are used, the parameters may vary from TABLE I parameters and the plasma spray process must be certified, per this procedure, and accepted by NAVSEA 05M2 or authorized agent.

Complete Appendix III-G Table I and Equipment List for all Plasma Spray Systems.

1-3.3 Operator Training and Certification: To become certified to plasma spray submarine outboard connector metal plug bodies an operator trainee must receive a minimum of 40 hours classroom training on the general theory of plasma spraying, safety, equipment and tool handling, equipment maintenance and repair, base metal surface preparation, plasma spray and sealer application and quality control in the diagnosis of good and degraded coatings. At the completion of classroom training, the trainee will satisfactorily complete a NAVSEA 05M2, or authorized agent, approved written test (see Appendix III-A). The test will be “open book” and will cover material presented in class. Upon satisfactory completion of classroom training, the operator trainee shall receive 80 hours of hands-on plasma spray equipment and coating processes training and shall successfully prepare, test and inspect samples required for operator certification (in-house training purposes only). The certification samples will include two visual, microscopic and bend tests and five tensile bond tests. Final operator certification approval is the responsibility of the site welding engineering division or other organization as designated by NAVSEA 05M2 or authorized agent (see Appendix III-B). Training and certification for other thermal spraying procedures in References (a) or (b) may, dependent on NAVSEA 05M2 or authorized agent approval, qualify an operator in this procedure.

NOTE: Both operators and inspectors must pass an annual eye examination for visual acuity such that the individual (corrected vision) is capable of reading JI letters on the standard Jaegar, or equivalent, type chart for near vision.

1-3.4 Maintenance of Operator Certification: Operator certification shall be maintained unless a period of 6 months has elapsed since the last production and use of the plasma spray process. Operators whose certification has lapsed may be re-certified by satisfactorily completing the Operator Certification/Practical Tests, paragraph 1-3.6. Practical qualification testing may also be required at any time an operator’s performance is questionable as evidenced by documented data or as requested by NAVSEA 05Z or its authorized agent.

TABLE I - PLASMA SPRAY COATING PARAMETERS

ITEM BOND COAT

PARAMETERS:

CERAMIC COAT

PARAMETERS:

BASE METAL: MONEL

316 SS

NITRONIC 50

TITANIUM

EUTETIC 21021

EUTETIC 21031 (preferred), METCO 43C

EUTETIC 21031 (preferred), METCO 43C

NO BOND COAT or METCO

METCO 130, Norton 107 or

METCO 130 or Norton 107

GRIT TYPE AND SIZE AL2 03 16-30 MESH N/A

ANCHOR TOOTH PROFILE 0.002-0.004 INCHES N/A

BLAST NOZZLE TO WORK

DISTANCE

2-4 INCHES N/A

BLAST NOZZLE TO WORK ANGLE 90° (MINIMUM 75°) N/A

PRIMARY GAS TYPE ARGON ARGON

PRIMARY GAS PRESSURE (PSI) 75 @ BOOTH; 100 @ BOTTLE 75 @ BOOTH; 100 @ BOTTLE

PRIMARY GAS FLOW (CFH) 80 80

SECONDARY GAS TYPE HYDROGEN HYDROGEN

SECONDARY GAS PRESSURE (PSI) 50 @ BOOTH; 100 @ BOTTLE 50 @ BOOTH; 100 @ BOTTLE

SECONDARY GAS FLOW (CFH) 25 25

OPERATING VOLTAGE RANGE DL 64-70 70-80

AMPERAGE RANGE DC 500 500

GUN TRAVERSE SPEED See Table III See Table III

POWDER CARRIER GAS TYPE ARGON ARGON

CARRIER GAS FLOW 13 13

METER WHEEL TYPE METCO R2 METCO S

METER WHEEL (RPM) 18 35

SPRAY RATE (LB./HR) 5 5

GUN TO BASE METAL DISTANCE

(IN)

4 - 5 INCHES 4-5 INCHES

GUN ANGLE 90° 90°

PREHEAT TEMPERATURE (°F) 200-225 200-225

INTERPASS TEMPERATURE (°F) 200-350 200-350

MAX. BASE METAL TEMP (°F) 350 350

MIN. PART SURFACE SPEED (FPM) 80 150

MAX. PART SURFACE SPEED (FPM) 150 200

MIN, COATING THICKNESS/PASS 0.001 INCHES 0.0003 INCHES

MAX. COATING THICKNESS/PASS. 0.002 INCHES 0.0005 INCHES

MIN. APPLIED COATING THICKNESS 0.003 INCHES 0.008 INCHES

MAX. APPLIED COATING

THICKNESS

0.005 INCHES 0.010 INCHES

SEALER TYPE N/A See Table II

TYPE OF FINISHING N/A N/A

Note: Each bond coat/ceramic coat must meet process Quality Conformance listed in Table IV. Equivalent equipment information must be submitted for approval with listing of similar parameters. Equivalent ceramics from other vendors may be used after review/approval from NAVSEA.

1-3.5 Operator Certification Sample Preparation:

1-3.5.1 Visual, Microscopic and Bend Test Samples: Visual, microscopic and bend test samples shall be prepared per Figure 1 by spraying one side of a 3 inch (approximate) x 1.75 inch (approximate) x 0.050 (+ 0.013, - 0.000) inch coupon fabricated from base metals of connector plug bodies as listed in TABLE II. Single coat samples shall have a 2-mils to 3-mils bond coating and at least a 5-mils ceramic coating. Microscopic test samples shall have a coating thickness of 5 mils (minimum).

The test samples may be sprayed in a rotating fixture such as shown in Figure 2.

Sprayed coatings shall be applied using TABLE III parameters as specified for the connector metal plug bodies. Coatings shall be tested in the as applied condition.

1-3.5.2 Tensile Bond Strength Test Samples: Five samples will be prepared to test tensile bond strength. Each sample will consist of two identical pieces fabricated per the dimensions provided in Figure 3. By masking the piece outer diameter and abrasive blasting the piece face, five of the pieces will be prepared for plasma spray coating the piece face. Plasma spray coat the piece face to a single ceramic coating thickness of 9 mils ± 1 mil and a two coating thickness, including bond coat, of 13 mils ± 2 mils. The pieces may be sprayed in a rotating fixture such as is shown in Figure 2.

The sprayed and unsprayed piece face shall be cleaned with an approved degreaser from Appendix III-C. The unsprayed piece face shall be lightly grit blasted. Any grit that adheres to the piece may be removed with clean, dry air. If clean dry air will not remove embedded grit blast particles, they may be removed by picking them off with a clean, degreased knife blade or similar tool.

Figure 1: Visual, Microscopic and Bend Test Specimen

TABLE II - MATERIALS LIST

MATERIAL FUNCTION SPECIFICATION

MONEL CONNECTOR PLUG BODY QQ-N-281, Class A

316 STAINLESS STEEL CONNECTOR PLUG BODY QQ-S-723

NITRONIC 50 CONNECTOR PLUG BODY QQ-S-723

TITANIUM 6A1 4V CONNECTOR PLUG BODY MIL-T-9047

METCO 130 POWDER or

NORTON 107

ALUMINA-TITANIA COATING MIL-STD-1687A

METCOLITE C, or equivalent ALUMINUM OXIDE BLASTING

GRIT (16 – 30 MESH)

MIL-STD-1687A

EUTECTIC 21021 (preferred), or equivalent

BOND COAT (MONEL)

EUTECTIC 21031 (preferred), METCO 43C, or equivalent

BONDCOAT (316 STAINLESS

STEEL AND NITRONIC 50)

*METCO AP or CHEMLOK 219

SEALER

HYDROGEN PLASMA GAS BB-H-886 PREPURIFIED

TO 99.5 PERCENT

ARGON PLASMA GAS MIL-A-18455 HIGH

PURITY – MAXIMUM

DEWPOINT @ MINUS

76°F

SHADOW SPRAYING FIXTURES GRIT BLAST AND PLASMA

SPRAYING MASKS

LOCAL MFG. OR

COMMERCIAL

EPOXY ADHESIVE

(NON-METALLIC)

3M SCOTCHWELD 2214NMF,

or equivalent

TENSILE BOND STRENGTH

TEST

NSN8040-XX-HML- 6731

MSDS 6731XA

FIBERGLASS TAPE (heat resistant) MASK FOR BLASTING COMMERCIAL

• NOTE: Sealer parameters: high resistivity, long after-application shelf life and must be compatible with the primers or polyurethanes used for underwater connector/electrical component molded backshells/stain reliefs. Sealer MSDS must be available to shops applying the sealer.

Figure 2: Rotating Fixture for Spraying Tensile and Bend Specimens (Typical)

Figure 3: Tensile Bond Strength Test Specimen

TABLE III: 200 SURFACE FEET PER MINUTE PARAMETERS (TYPICAL)

CONNECTOR TYPE

(A) CONN.

PLUG BODY

ORIGINAL

DIA. (IN)

HEAD

STOCK

(RPM)

TRAVERSE

TRAVEL

RATE

(IN/MIN)

(D) FINAL

COAT DIA.

(IN)

(MAXIMUM)

M24231/1-001 (CPG-1027/1-100)

M24231/1-002 (CPG-1027/1-101)

1.031 756 189 1.041

M24231/3-002 (CPG-1027/1-102)

M24231/3-003 (CPG-1027/1-103)

1.343 577 144 1.353

M24231/4-001 (CPG-1027/1-104)

M24231/4-002 (CPG-1027/1-105)

M24231/4-003 (CPG-1027/1-106)

M24231/4-004 (CPG-1027/1-107)

1.811 427 107 1.821

M24217/7-001 M24217/7-002

0.874 895 224 0.884

M24217/7-003 M24217/7-004

1.061 734 183 1.071

M24217/7-005 M24217/7-006 M24217/7-015

1.186 655 164 1.196

M24217/7-007 M24217/7-008 M24217/7-016 M24217/7-018

1.501 516 129 1.511

M24217/7-009 M24217/7-010 M24217/7-017 M24217/7-019 M24217/7-020

1.874 412 103 1.884

M24217/7-011 M24217/7-012 M24217/7-021

2.314 333 83 2.324

M24217/7-013 M24217/7-014

2.749 280 70 2.7594

M24217/8-002 0.874 892 223 0.884 M24217/8-005 1.186 655 164 1.196 M24217/8-007 1.501 516 129 1.511 M24217/8-009 1.874 412 103 1.884 M22539 1.000 780 195 1.010 M22539 1.497 517 129 1.517 M22539 1.687 458 115 1.697 EB3325/2-010 remove material as shown on the EB SPEC 3325/2- 010 Appendix D Worksheet)

1.937 399 100 1.947

FORMULAS:

R=S x 12 WHERE: R=HEADSTOCK RPM π x D S=200 SURFACE FEET/MIN

D=CONNECTOR PLUG BODY DIAMETER

T=R T= TRAVERSE RATE (IN/MIN)

NOTE: TABLE III is intended only as a general guideline for starting parameters.

Actual RPM and traverse rate (in/min.) may vary from TABLE III parameters during operation to achieve desired coating thickness per pass. If the actual headstock RPM and traverse rate vary from the values provided in TABLE III, repeat the spraying operation at least once to confirm the values and record them in TABLE III under the provided rates and on the Plasma Spray Job Control Record (PSJCR). Use those rates for future starting parameters.

1-3.6 Operator Certification/Practical Tests. These practical tests shall be satisfactorily completed prior to operator certification and on an annual recertification basis. NAVSEA can require these tests at any time during an audit of the facility.

1-3.6.1 Visual Inspection: Each as-sprayed sample will be visually inspected with tools such as a 10X magnifier, coating thickness gauge, profile tape, etc. Surface inspection will be made at 10 - 20 magnifications for a uniform appearance with surface defects limited to nodules not to exceed 0.45 mils in diameter and 0.25 mils above the surface.

The coating shall not contain any of the following:

a. Blisters

b. Cracks

c. Chips or loosely adhering particles

d. Evidence of oil or other contamination

e. Pits exposing the bond coat or base metal

f. Coating/substrate separation

g. Spatter or unmelted particles

1-3.6.2 Microscopic Examination: A microscopic examination shall be conducted at 200X to inspect for uniform coating distribution with no coating or base metal separation, a base metal anchor-tooth profile of 2 to 4 mils and less than 10 percent bond line contamination (such as grit, debonds and oxidation). Unreacted globular particles shall be less than 10 percent of the coating cross-sectional area with the average diameter of the particle not exceeding 0.002 inch.

1-3.6.3 Bend Tests: Bend Tests will be visually inspected without magnification aids.

The sprayed coupons shall be bent 180 degrees on a 0.50-inch diameter rod. The coating shall be on the tensile side of the bend and show no evidence of flaking, delamination or gross cracking due to bending. Small hairline cracks or alligator cracks in the coating near the bend are permissible. Ceramic coatings may exhibit flaking at the sample edges.

1-3.6.4 Tensile Bond Strength Test: The sprayed and unsprayed pieces prepared per paragraph 1-3.5.2 are then cemented together with a non-metallic epoxy adhesive (Table II), taking care to avoid entrapment of air bubbles. The cemented pieces are placed in an alignment fixture similar to figure 4 and cured in an oven at 350° F +/-25° F for one hour. After the specimens have cooled, the excess adhesive is removed from the periphery of the joints manually or by belt sanding, taking care to minimize grinding marks. Pull test the specimens using a tensile testing machine equipped with a universal joint arrangement for each end of the joined specimens (conducted at room temperature). A constant rate of cross head travel of between .030 and .050 inches per minute shall be applied until joint rupture occurs. When applied over a bond coat, the tensile bond strength of a ceramic coating must meet or exceed minimum average bond strength of 3500 lb/square inch and minimum single specimen bond strength of 2500 lb/square inch. If the bond fails to meet minimum requirements because fracture occurs at the coating-epoxy interface, the test shall be considered invalid and shall be repeated.

Figure 4: Tensile Bond Specimen Alignment Fixture (Typical)

1-3.7 Inspector Training and Certification: To become certified to inspect plasma sprayed submarine outboard connector metal plug bodies, the prospective inspector must have a minimum of 6 hours classroom instruction on plasma spraying general theory, application, coating processes and quality assurance. The training shall include hands-on training with inspection tools such as a 10X magnifier, coating thickness gauge, profile tape, etc. on good and bad coatings on representative parts. Upon completion of training an inspector must satisfactorily complete a NAVSEA 05Z approved written test covering both the operator and inspector training materials (see Appendix III-A). Final inspector certification approval is the responsibility of NAVSEA 05M2 or authorized agent (see Appendix III-B). Training and certification for other thermal spraying procedures in References (a) or (b) may, dependent on NAVSEA 05M2 or authorized agent approval, qualify an inspector in this procedure.

NOTE: Both operators and inspectors must pass an annual eye examination for visual acuity such that the individual (corrected vision) is capable of reading JI letters on the standard Jaegar, or equivalent, type chart for near vision.

1-3.8 Maintenance of Inspector Certification: Inspector certification shall be maintained unless a period of 6 months has elapsed since the last production and use of the plasma spray process. Inspectors, whose certification has lapsed, must demonstrate the ability to inspect all areas of the plasma spray process and the Plasma Spray Job Control Record (PSJCR) shown in Appendix III-D.

1-3.9 Facility Certification: Any facility, government or commercial, applying plasma sprayed non-conductive coatings to submarine outboard connector metal plug bodies shall be certified by NAVSEA 05M2 or their authorized agent in accordance with the requirements of this procedure. Prior to production implementation, the performing activity shall submit a request to NAVSEA 05M2 requesting certification of their facility.

The request shall contain written evidence that the facility meets the requirements of this standard. Facilities shall perform semi-annual internal audits to determine the status and adequacy of their quality program and shall re-certify annually.

1-3.10 Quality Conformance: The performing activity is required by MIL-STD-1916 to submit products that meet all contract and specification requirements. The application of the quality plans or procedures of this standard does not relieve the performing activity of responsibility for meeting all contract product requirements. The performing activity’s quality program, including manufacturing processes and quality control measures, will be established and operated to consistently produce products that meet all requirements. To that end, performing activities will employ a Statistical Process Control (SPC) system as a means to ensure 100% conformance of the final product to specifications, and to provide, for the record, objective quality evidence of the adequacy of the industrial process to produce conforming product as well as documentation of the conformance of the product. Table IV provides a list of the minimum process certification and work in-progress quality conformance requirements necessary to provide a satisfactory end product. The work in-progress requirements are included on the Plasma Spray Job Control Record (PSJCR), block 22, and amplified on the PSJCR addendum sheet as quality acceptance checkpoints to support future problem resolution. The coating thickness records shall be initially recorded on the Connector Body Worksheet and entered into the SPC system. The final record shall be maintained on the addendum data sheets that are appended to the PSJCR. A sample addendum sheet is shown on page III-D4.

TABLE IV - QUALITY CONFORMANCE CHART

TEST

STEP

PROCESS CERTIFICATION/INSPECTION REQUIREMENT

PROCESS

CERTIFICATION

OPERATOR

CERTIFICATION

INSPECTOR

CERTIFICATION

WORK

IN-PROGRESS

INSPECTION

VISUAL

INSPECTION

1-3.5.1 X X X X

MICROSCOPIC

INSPECTION

1-3.5.1 X X

BEND TEST (1)

1-3.5.1 X X X X

COATING

DIMENSION

1-3.5.1 1-3.5.2

X X X

TENSILE/BOND

STRENGTH

TEST

1-3.5.2 X X

RECEIPT

INSPECTION

5-0.1 X X X

PLUG BODY

DIAMETER

5-1.2 X X

GRIT BLAST

SURFACE

5-1.5 X X X X

BLASTED

SURFACE

DIAMETER

X

TEMP. (°F)

5-2.4.5 X X X

PREHEATED

PLUG BODY

DIAMETER

X

BOND COAT

DIAMETER

5-2.4.3 X

CERAMIC

COAT

DIAMETER

5-2.4.4 X

COATING

DIMENSION

5-2.4.6 X

FINISHING AND

DIMENSIONAL

5-3.3 X

SEALING/

SURFACE

RESISTIVITY

5-3.4 X

FINAL

INSPECTION

5-3.5 X

Notes: (1) Tests referencing this note shall be accomplished prior to commencement of each lot.

1-4 RECORDS

1-4.1 Record Requirements: As a minimum, the following records shall be prepared and maintained by the performing activity:

a. Plasma Spray Job Control Record (PSJCR), with appended addendum data sheets, shall be established for each lot (see definitions) of connectors coated. A copy of the PSJCR and the associated addendum data sheets for each item coated shall be sent to the procuring activity along with the coated item(s). A typical PSJCR with minimum requirements is shown in Appendix III-D. A typical addendum sheet is shown in Appendix III-D4. PSJCRs shall be maintained by the performing activity for a minimum of 10 years. If a performing activity ceases to function as an authorized plasma spraying facility, all PSJCRs shall be forwarded to NAVSEA 05Z or authorized agent.

b. Plasma Spray Operator/Inspector Qualification Test Record shall be maintained by the performing activity training organization responsible for the plasma spraying function for each operator or inspector qualified to perform or inspect plasma spray operations. Appendix III-B provides an example of a typical Plasma Spray Operator/Inspector Certification/Test Record.

c. Performing Activity audits, audit discrepancies and corrections shall be maintained by the performing activity for a period of five years after the performing activity facility certification lapses.

SECTION II

2-0 OCCUPATIONAL SAFETY AND ENVIRONMENTAL

2-1 EQUIPMENT/MATERIAL

2-1.1 Plasma Spray Hazards: Potential plasma spray hazards include exposure to hazardous materials, vapors, dusts and fumes, compressed gases, combustible gasses, the plasma spray gun, noise, rotating machinery and arc ultraviolet radiation.

Proper safety and hazardous material precautions, as defined in applicable local activity and state and federal guidelines/instructions, such as Chapter 29 Code of Federal Regulations (OSHA Safety Standards); AWS C2.1, Recommended Safe Practices for Thermal Spraying; OPNAVINST 5100.23 Naval Occupational and Health (NAVOSH) Program Manual for Shore Facilities; NAVSEA S9086-CH-STM-030, Chapter 074, Volume 3; and OPNAVINST 5100.19 Navy Occupational and Health (NAVOSH) Program Manual for Navy afloat activities shall be strictly adhered to. The Safety instruction will be included in required certification training curriculum.

2-1.2 Cleaning Solvents: Only those cleaning solvents in Appendix III-C shall be used.

2-1.3 Ventilation: Proper ventilation for solvent cleaning, grit blasting, plasma spraying, and seal coat application is mandatory. All ventilation requirements defined by local, state, federal, including 29 CFR OSHA Safety Standards, and Material Safety Data Sheets (MSDS) shall be met before any plasma operations can commence.

Insure that the ventilation system is running and operating per design requirements before opening any gas valve.

2-1.4 Gas cylinders/gas supply systems: Examine all gas equipment regularly for leaks and loose connections, replacing or repairing failed equipment as necessary.

Gas cylinders shall always be secured to keep them from falling. Cylinders in use shall be kept away from the plasma spray operation so that molten spray will not reach them.

If this is not possible, fire resistant shields shall be provided. When not in use for an extended period of time shut off the gas, remove regulators and place valve caps on cylinders. All gas systems that support plasma-spraying operations shall comply with NFPA 50A standards and the local safety officials shall approve the system.

2-1.5 Electrical: Electrical equipment at Navy plasma spray facilities shall be checked in accordance with OPNAVINST 5100.23B, Navy Occupational and Health (NAVOSH) Safety Program Manual for Shore Activities or OPNAVINST 5100.19, Navy Occupational and Health (NAVOSH) Safety Program Manual for Afloat Activities and NAVSEA Technical Manual S9086-KC-STM-000/CH 300 for afloat activities. Electrical equipment at commercial plasma spray facilities shall conform to OSHA safety requirements. The plasma spray equipment shall be equipped with Emergency Stops on, at a minimum, the plasma spray gun and the control console.

2-2 PERSONAL PROTECTION EQUIPMENT (PPE)

2-2.1 Respiratory: All operators shall be respirator qualified and wear approved respirators while plasma spraying. Training and qualification cards are required before an operator is approved to wear a respirator. A positive exhaust water wash, HEPA filter or other NAVSEA 05Z authorized filtration equipped spray booth shall be used to remove the toxic or irritation effects of dust and fumes generated by the plasma spraying operation.

2-2.2 Eye: Helmets, face shields or goggles shall be used to protect the eyes during plasma spray operations. Lens shade shall be 10 - 12. All personnel in the viewing vicinity shall have the proper protection. Covers shall be placed over windows of the plasma spray facility when spraying to protect the eyes of personnel working outside or passing by.

2-2.3 Hearing: Plasma spraying can generate noise levels in excess of 120 dB.

Double hearing protection is required. Earmuffs and properly fitted soft rubber earplugs shall be used.

2-2.4 Protective Clothing: Flame-resistant clothing and leather or rubber gauntlets shall be worn during plasma spraying to keep harmful flying particles from thermal sprayed materials from skin contact. Aluminized clothing may be used, taking care to insure that radiation and ultraviolet light are not reflected onto unprotected skin areas.

Care shall also be taken as aluminized clothing may present a danger from electric shock.

2-2.5 Personnel Requirement: Government facilities shall have two persons present at all times during the spraying operations; one inside the booth and one outside.

Should the spraying operation be automated to the point that an operator need not be in the spray booth during gun ignition, then only one operator need be present outside the booth during spray operations. Commercial facilities shall comply with local, state and federal regulations.

2-3 WASTE DISPOSAL: All requirements of local, state and federal hazardous material control and hazardous waste (HMC/HW) programs will be adhered to for the protection of the safety and health of those involved with the plasma spraying process and to ensure the environment is protected from HM and the HW produced from plasma spraying.

SECTION III

3-0 MATERIALS

3-1 MATERIALS LIST

3-1.1 Base (base metal) Materials: See TABLE II - MATERIALS LIST for the list of underwater electrical connector metal plug body materials for which this instruction is approved.

3-1.2 Coating System Materials: Coating system materials and specifications are listed in TABLE II - MATERIALS. The electrical and physical requirements of the aluminum oxide/titanium oxide composite ceramic powder (METCO 130 or NORTON

107) component of the coating system are listed in TABLE V - ALUMINA-TITANIA COATING PROPERTIES. Substitution of equivalent spray materials is prohibited under this instruction unless tested and approved for this application per NAVSEA 05Z instruction.

3-1.2.1 Coating System Materials Storage: Stored spray materials shall be protected from environments that can harm the sprayed coating quality. Powder suspected of being contaminated by foreign matter shall not be used. Storage recommendations of the powder manufacturers shall be followed. Powders shall be shaken before use to break up any segregation or aggregation that may have occurred during storage. The contents of powder containers shall be identified.

3-1.3 Plasma Gases: See TABLE II - MATERIALS LIST.

3-1.4 Grit Blasting Material: Abrasive particles shall be clean, dry, sharp, and free of excess fines. Only aluminum oxide grit, mesh size 16-30 (Metcolite C or equivalent), shall be used for abrasive blasting during final surface preparation (anchor-tooth profile) of the base metal. The abrasive grit shall be kept clean from oil and other foreign contaminants. Grit must be replaced if when compared with new grit under a magnification of 10X it is noticeably worn or dull. Prior to reuse, aluminum oxide grit shall be screened using a 30 mesh screen, visually inspected for debris and oil contamination and shall pass the following oil contamination test:

(a) Fill a clean 150-milliliter (ml) (5 ounce) vial or bottle half full of screened abrasive particles.

(b) Fill the remainder of the vial or bottle with clean water.

(c) Cap and shake the vial or bottle.

(d) Inspect the water for oil sheen.

(e) If any oil is observed, the abrasive particles shall not be used.

(f) Clean the blasting equipment, replace the blasting material and retest.

TABLE V - ALUMINA-TITANIA COATING PROPERTIES (TYPICAL)

COMPOSITION

87% ALUMINUM OXIDE/13% TITANIUM OXIDE

MESH SIZE -270 MICRON + 15µ -53 MICRON + 15µ

SURFACE FINISH

AS-SPRAYED

HARDNESS R15N

DPH300 850

DC INSULATION

RESISTANCE

≥ 1 MOhms @ 500VDC

3-1.5 Masking: Heat resistant fiberglass tape may be used for masking for grit blasting operations. Metal tape, heat resistant fiberglass tape, metal shadow fixtures or high temperature plugs shall be used for plasma spraying operations.

3-1.6 Cleaning Solvents: Only those cleaning solvents in Appendix III-C shall be used.

SECTION IV

4-0 EQUIPMENT

4-1 EQUIPMENT LIST: Enter the plasma spray system and equipment being certified in Appendix III-G, Equipment List.

4-1.1 Plasma Spray System: Any plasma spray system that will produce the standards required by this Procedure and MIL-STD-1687A.

4-1.2 Grit Blasting Equipment: Grit Blasting equipment is used to provide a clean metal surface and to produce an anchor-tooth profile on the connector plug body to increase bond coating (primer) and non-conductive coating adhesion to the connector metal plug body. Dedicated pressure type glove box blasting equipment, equipped with a blast nozzle dead man switch shall be used. The blasting unit shall not be used for anything other than connector metal plug body, or equivalent work for plasma spray preparation.

4-1.3 Air Delivery Equipment: The air equipment for abrasive blasting shall provide air having a maximum of five milligrams condensed hydrocarbons per cubic meter and a dew point of +14 °F or lower at standard temperature and pressure (68 °F and 14.7 PSI absolute) prior to the final filtering and moisture separation unit. For abrasive blasting, the equipment shall be capable of maintaining a minimum air pressure of 50 PSI. In-line water and oil filters shall be located between the compressor air dryer after the cooler and before the grit-blasting unit. These filters shall be inspected and serviced to assure delivery of uncontaminated dry air. An air contamination test shall be conducted at the blast booth at least monthly prior to spraying to insure that the compressed air delivery equipment is meeting the requirements of this instruction.

4-1.4 Spray Booth: Plasma spraying shall be accomplished in a booth equipped with a filtration system that complies with AWS, Thermal Spraying - Practice, Theory and Application and CFR 29, part 1910.107. Two systems that meet those requirements are the positive exhaust and water wash dust collector system and a HEPA filter system that provides a minimum of 200 feet per minute airflow.

CAUTION

The plasma spray gun has an electrical potential to ground and must be insulated from ground when attached to the mechanical positioning device. Damage to the equipment could occur.

4-1.5 Part Handling Equipment: Fixtures for mechanical positioning shall be used to support the work piece and plasma…