Atch_4_-_T.O._1-1-691.PDF

TO 1-1-691

TECHNICAL MANUAL

CLEANING AND CORROSION PREVENTION

AND CONTROL,

AEROSPACE AND NON-AEROSPACE EQUIPMENT

F42620-00-D-0038

FA8501-07-F-A080

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. PA Case Number PA04-11-96. Other requests for this document shall be referred to 406 SCMS/GUEE. Questions concerning technical content shall be referred to AFLCMC/EZPT-CPCO.

Published Under Authority of the Secretary of the Air Force

2 NOVEMBER 2009 CHANGE 12 - 1 JANUARY 2016

BASIC AND ALL CHANGES HAVE BEEN MERGED TO MAKE THIS A COMPLETE PUBLICATION.

Dates of issue for original and changed pages are:

Original. . . . . . . .0. . . .2 November 2009 Change . . . . . . . . 1. . . . . . .12 April 2010 Change . . . . . . . . 2 . . . . . . . 11 May 2011 Change . . . . . . . . 3. . . . .15 January 2013 Change . . . . . . . . 4. . . . . .14 March 2013 Change . . . . . . . . 5 . . . . . . 5 August 2013 Change . . . . . . . . 6 . . . . 17 February 2014

Change . . . . . . . . 7 . . . . . . . 29 May 2014 Change . . . . . . . . 8 . . . . . . . 11 July 2014 Change . . . . . . . . 9 . . . . 4 December 2014 Change . . . . . . . 10. . . . .14 January 2015 Change . . . . . . . 11 . . . . . . . . 2 July 2015 Change . . . . . . . 12. . . . . .1 January 2016

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 396, CONSISTING OF THE FOLLOWING:

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Title A - B C Blank i - iv v vi - ix x Blank xi - xv xvi - xvii Deleted xviii Blank 1-1 1-2 2-1 - 2-7 2-8 2-9 - 2-20 3-1 - 3-2 3-2.1 Added 3-2.2 Blank 3-3 3-4 - 3-5 3-6 3-7 - 3-8 3-9 - 3-11 3-12 3-13 3-14 3-15 3-16 3-17 - 3-19 3-20 3-21 - 3-24 3-25 - 3-28 3-29 3-30 - 3-36 3-37 3-38 - 3-39 3-40 3-41 3-42 - 3-43 3-44 - 3-46

3-47 3-48 3-48.1 - 3-48.2 Added 3-49 3-50 3-51 3-52 - 3-53 3-54 - 3-55 3-56 - 3-57 3-58 - 3-59 3-60 - 3-63 3-64 4-1 4-2 4-3 - 4-4 4-4.1 Added 4-4.2 Blank 4-5 - 4-14 4-15 4-16 - 4-18 5-1 - 5-11 5-12 5-13 - 5-15 5-16 5-17 - 5-26 5-27 5-28 5-29 5-30 5-31 - 5-41 5-42 - 5-44 5-45 - 5-46 5-46.1 Added 5-46.2 Blank 5-47 - 5-50 5-51 - 5-52 Added 6-1 6-2 6-3 - 6-5 6-6 - 6-31

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INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page. Changes to illustrations are indicated by shaded or screened areas, or by miniature pointing hands.

* Zero in this column indicates an original page.

A Change 12 USAF

A-13 A-14 A-15 A-16 - A-19 A-20 - A-21 A-22 - A-54 A-55 - A-57 A-58 Blank B-1 - B-18 B-19 - B-20 B-20.1 Added B-20.2 Blank B-21 - B-27 B-28 - B-30 B-30.1 - B-30.3 Added B-30.4 Blank B-31 - B-41 B-42 B-43 - B-45 B-46 Blank Glossary 1 - Glossary 4 Index 1 - Index 3 Index 4 Index 4.1 Added Index 4.2 Blank Index 5 Index 6 - Index 8 Index 8.1 - Index 8.2 Deleted Index 9 - Index 14 Deleted

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TABLE OF CONTENTS

Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . vii

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . viii

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . xi

SAFETY SUMMARY . . . . . . . . . . . . . . . . . xv

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . 1-1

1.1 CORROSION CONTROL

PROGRAM. . . . . . . . . . . . . . . 1-1

1.1.1 Training . . . . . . . . . . . . . . . . . . . 1-1

1.1.2 Maintenance . . . . . . . . . . . . . . . . 1-1

1.1.3 Facilities . . . . . . . . . . . . . . . . . . . 1-1

1.2 SAFETY. . . . . . . . . . . . . . . . . . . 1-1

1.2.1 Responsibility of Supervisors . . . . . 1-1

1.2.2 Materials Handling . . . . . . . . . . . . 1-1

1.3 MATERIALS . . . . . . . . . . . . . . . 1-2

2 CORROSION THEORY . . . . . . . . . . . . . . . 2-1

2.1 INTRODUCTION TO CORRO-

SION THEORY . . . . . . . . . . . . 2-1

2.2 DEFINITION OF

CORROSION . . . . . . . . . . . . . 2-1

2.3 CHEMICAL DEFINITIONS . . . . . 2-1

2.3.1 Atom . . . . . . . . . . . . . . . . . . . . . 2-1

2.3.2 Electron . . . . . . . . . . . . . . . . . . . 2-1

2.3.3 Ions . . . . . . . . . . . . . . . . . . . . . . 2-1

2.3.4 Electrolyte. . . . . . . . . . . . . . . . . . 2-1

2.4 THEORY OF CORROSION . . . . . 2-1

2.4.1 Anode . . . . . . . . . . . . . . . . . . . . 2-1

2.4.2 Cathode . . . . . . . . . . . . . . . . . . . 2-1

2.4.3 Electrolyte. . . . . . . . . . . . . . . . . . 2-1

2.4.4 Electrical Contact . . . . . . . . . . . . . 2-1

2.5 DEVELOPMENT OF

CORROSION . . . . . . . . . . . . . 2-2

2.5.1 Corrosion Under Painted

Surfaces . . . . . . . . . . . . . . . . . 2-2

2.6 FACTORS INFLUENCE

CORROSION . . . . . . . . . . . . . 2-2

2.6.1 Type of Metal . . . . . . . . . . . . . . . 2-2

2.6.2 Dissimilar Metal Coupling (Galvanic

Corrosion). . . . . . . . . . . . . . . . 2-2

2.6.3 Anode and Cathode Surface

Area. . . . . . . . . . . . . . . . . . . . 2-3

2.6.4 Temperature . . . . . . . . . . . . . . . . 2-4

2.6.5 Heat Treatment and Grain

Direction. . . . . . . . . . . . . . . . . 2-4

2.6.6 Electrolytes . . . . . . . . . . . . . . . . . 2-4

2.6.7 Oxygen. . . . . . . . . . . . . . . . . . . . 2-5

2.6.8 Electrolyte Concentration. . . . . . . . 2-5

Chapter Page

2.6.9 Biological Organisms . . . . . . . . . . 2-5

2.6.10 Mechanical Stress. . . . . . . . . . . . . 2-5

2.6.11 Time . . . . . . . . . . . . . . . . . . . . . 2-5

2.7 TYPES OF CORROSION . . . . . . . 2-5

2.7.1 Uniform Surface Corrosion . . . . . . 2-5

2.7.2 Galvanic Corrosion. . . . . . . . . . . . 2-5

2.7.3 Pitting Corrosion . . . . . . . . . . . . . 2-6

2.7.4 Intergranular Corrosion . . . . . . . . . 2-6

2.7.5 Exfoliation Corrosion . . . . . . . . . . 2-6

2.7.6 Crevice/Concentration Cell

Corrosion . . . . . . . . . . . . . . . . 2-6

2.7.7 Corrosion Fatigue. . . . . . . . . . . . . 2-8

2.7.8 Filiform Corrosion . . . . . . . . . . . . 2-8

2.7.9 Fretting Corrosion . . . . . . . . . . . . 2-10

2.7.10 High Temperature Oxidation (Hot

Corrosion). . . . . . . . . . . . . . . . 2-11

2.8 METALS AFFECTED BY

CORROSION . . . . . . . . . . . . . 2-11

2.8.1 Magnesium . . . . . . . . . . . . . . . . . 2-11

2.8.2 Steel. . . . . . . . . . . . . . . . . . . . . . 2-12

2.8.3 Aluminum. . . . . . . . . . . . . . . . . . 2-12

2.8.4 Anodized Aluminum. . . . . . . . . . . 2-12

2.8.5 Titanium . . . . . . . . . . . . . . . . . . . 2-12

2.8.6 Copper and Copper Alloys. . . . . . . 2-13

2.8.7 Cadmium . . . . . . . . . . . . . . . . . . 2-16

2.8.8 CRES/Stainless Steel . . . . . . . . . . 2-16

2.8.9 Nickel and Chromium. . . . . . . . . . 2-16

2.8.10 Silver, Platinum, and Gold. . . . . . . 2-16

2.8.11 Graphite/Carbon Fiber

Composites . . . . . . . . . . . . . . . 2-16

2.9 CORROSIVE

ENVIRONMENTS. . . . . . . . . . 2-16

2.9.1 Moisture . . . . . . . . . . . . . . . . . . . 2-16

2.9.2 Temperature . . . . . . . . . . . . . . . . 2-17

2.9.3 Salt Atmospheres . . . . . . . . . . . . . 2-17

2.9.4 Ozone . . . . . . . . . . . . . . . . . . . . 2-17

2.9.5 Other Industrial Pollutants . . . . . . . 2-17

2.9.6 Sand, Dust, and Volcanic Ash. . . . . 2-18

2.9.7 Solar Radiation . . . . . . . . . . . . . . 2-18

2.9.8 Climate. . . . . . . . . . . . . . . . . . . . 2-18

2.9.9 Factors of Influence in Tropical

Environments . . . . . . . . . . . . . 2-18

2.9.10 Manufacturing . . . . . . . . . . . . . . . 2-19

2.9.11 Storage . . . . . . . . . . . . . . . . . . . . 2-19

2.9.12 Shipment . . . . . . . . . . . . . . . . . . 2-19

2.9.13 Industrial and Ship Emitted Air

Pollutants . . . . . . . . . . . . . . . . 2-19

2.9.14 Animal Damage . . . . . . . . . . . . . . 2-19

2.9.15 Microorganisms . . . . . . . . . . . . . . 2-19

2.10 DEGRADATION OF

NON-METALS . . . . . . . . . . . . 2-20

2.11 PREVENTIVE

MAINTENANCE. . . . . . . . . . . 2-20

Change 11 i

3 PREVENTIVE MAINTENANCE . . . . . . . . . 3-1

SECTION I INTRODUCTION. . . . . . . . . . . 3-1

3.1 PREVENTIVE MAINTENANCE

PROGRAM. . . . . . . . . . . . . . . 3-1

3.1.1 Preventive Maintenance. . . . . . . . . 3-1

SECTION II CLEANING . . . . . . . . . . . . . . 3-6

3.2 INTRODUCTION . . . . . . . . . . . . 3-6

3.2.1 Reasons for Cleaning . . . . . . . . . . 3-6

3.2.2 When to Accomplish Work . . . . . . 3-7

3.2.3 Aircraft Clear Water Rinse (CWR)

Requirements. . . . . . . . . . . . . . 3-7

3.2.4 Immediate Cleaning . . . . . . . . . . . 3-8

3.2.5 Deployed Aircraft Wash

Requirements. . . . . . . . . . . . . . 3-8

3.3 CLEANING COMPOUNDS . . . . . 3-9

3.3.1 Alkaline Cleaners . . . . . . . . . . . . . 3-9

3.3.2 Solvent Emulsion and Aqueous

Cleaners for Turbine Engine Gas Path and General Area Cleaning . . . . . . . . . . . . . . . . . 3-10

3.3.3 Aqueous Parts Washer Cleaning

Solutions. . . . . . . . . . . . . . . . . 3-10

3.3.4 Solvents . . . . . . . . . . . . . . . . . . . 3-11

3.3.5 Miscellaneous Cleaning Agents . . . 3-11

3.3.6 Steam Cleaning . . . . . . . . . . . . . . 3-12

3.3.7 Dilution . . . . . . . . . . . . . . . . . . . 3-12

3.4 CLEANING EQUIPMENT . . . . . . 3-29

3.4.1 High Pressure/Hot Water Wash

Equipment. . . . . . . . . . . . . . . . 3-29

3.4.2 Portable, 15 Gallon, Foam Generat-

ing, Cleaning Unit . . . . . . . . . . 3-29

3.4.3 Portable, 45 Gallon, Foam Generat-

ing Cleaning Unit. . . . . . . . . . . 3-32

3.4.4 Turbine Engine Compressor Clean-

ing Equipment . . . . . . . . . . . . . 3-33

3.4.5 Miscellaneous Large Cleaning

Equipment. . . . . . . . . . . . . . . . 3-33

3.4.6 Spray Cleaning Guns for

Solvents . . . . . . . . . . . . . . . . . 3-33

3.4.7 Pneumatic Vacuum Cleaner . . . . . . 3-33

3.4.8 Universal Wash Unit . . . . . . . . . . . 3-33

3.4.9 Aqueous Parts Washers . . . . . . . . . 3-34

3.4.10 Miscellaneous Equipment . . . . . . . 3-35

3.5 CLEANING PROCEDURES . . . . . 3-36

3.5.1 Warnings and Cautions . . . . . . . . . 3-36

3.5.2 Cleaning Methods . . . . . . . . . . . . 3-39

3.5.3 Clear Water Rinsing of Aircraft . . . 3-46

3.5.4 Post Cleaning Procedures . . . . . . . 3-46

3.5.5 Treatment and Disposal of Wash

Rack Waste . . . . . . . . . . . . . . . 3-47

3.5.6 Fungus Growth Removal . . . . . . . . 3-47

Chapter Page

3.5.7 Soil Barriers . . . . . . . . . . . . . . . . 3-48.2

3.5.8 Bird Strike Cleaning . . . . . . . . . . . 3-49

3.5.9 Bodily Fluids Contamination

Cleanup . . . . . . . . . . . . . . . . . 3-51

SECTION III LUBRICATION . . . . . . . . . . . 3-53

3.6 INTRODUCTION . . . . . . . . . . . . 3-53

3.6.1 Conventional Lubricants . . . . . . . . 3-53

3.6.2 Solid Film Lubricants . . . . . . . . . . 3-54

3.6.3 Application of Conventional

Lubricants . . . . . . . . . . . . . . . . 3-54

SECTION IV PRESERVATION . . . . . . . . . . 3-56

3.7 INTRODUCTION . . . . . . . . . . . . 3-56

3.7.1 Operational Preservation . . . . . . . . 3-56

3.7.2 Non-Operational Preservation. . . . . 3-56

3.7.3 Types of CPC’s . . . . . . . . . . . . . . 3-56

3.7.4 Time Limitations of CPC’s . . . . . . 3-57

3.7.5 Description of CPC’s . . . . . . . . . . 3-57

3.7.6 Preservation of Specific Areas . . . . 3-64

3.7.7 Preservation Application

Methods . . . . . . . . . . . . . . . . . 3-64

3.8 APPLICATION OF POLISH AND

WAX . . . . . . . . . . . . . . . . . . . 3-64

4 INSPECTION AND CORROSION PRONE

AREAS. . . . . . . . . . . . . . . . . . . . . . . . . 4-1

SECTION I INSPECTION . . . . . . . . . . . . . 4-1

4.1 Purpose . . . . . . . . . . . . . . . . . . . 4-1

4.1.1 Responsibility . . . . . . . . . . . . . . . 4-1

4.1.2 Frequency of Inspections . . . . . . . . 4-1

4.1.3 General Inspections . . . . . . . . . . . 4-1

4.1.4 Detailed Inspections . . . . . . . . . . . 4-1

4.2 INSPECTION METHODS. . . . . . . 4-1

4.2.1 Visual inspection . . . . . . . . . . . . . 4-1

4.2.2 Depth Gauge . . . . . . . . . . . . . . . . 4-2

4.2.3 Visual Inspection with a

Borescope/Videoscope. . . . . . . . 4-3

4.2.4 Optical Depth Micrometers . . . . . . 4-3

4.2.5 Fluorescent Penetrant

Inspection . . . . . . . . . . . . . . . . 4-5

4.2.6 Eddy Current Inspection . . . . . . . . 4-6

4.2.7 Ultrasonic Inspection . . . . . . . . . . 4-6

4.2.8 Radiographic Inspection . . . . . . . . 4-6

4.3 EVALUATION OF CORROSION

DAMAGE. . . . . . . . . . . . . . . . 4-6

4.4 DEGREES OF CORROSION . . . . 4-6

4.4.1 Light Corrosion . . . . . . . . . . . . . . 4-9

4.4.2 Moderate Corrosion . . . . . . . . . . . 4-9

4.4.3 Severe Corrosion . . . . . . . . . . . . . 4-9

TO 1-1-691

TABLE OF CONTENTS - CONTINUED

ii Change 11

SECTION II CORROSION PRONE AREAS . 4-9

4.5 COMMON AREAS . . . . . . . . . . . 4-9

4.5.1 Fasteners. . . . . . . . . . . . . . . . . . . 4-9

4.5.2 Faying Surfaces and Crevices. . . . . 4-9

4.5.3 Spot Welded Assemblies . . . . . . . . 4-9

4.5.4 Engine Exhaust and Gun Gas Im-

pingement Areas . . . . . . . . . . . 4-10

4.5.5 Wheel Wells and Landing Gear . . . 4-10

4.5.6 Flap and Slat Recesses . . . . . . . . . 4-11

4.5.7 Engine Frontal Areas and Air Inlet

Ducts . . . . . . . . . . . . . . . . . . . 4-11

4.5.8 Wing/Fin-Fold Joints and Wing and

Control Surface Leading Edges . . . . . . . . . . . . . . . . . . . 4-14

4.5.9 Hinges . . . . . . . . . . . . . . . . . . . . 4-14

4.5.10 Control Cables. . . . . . . . . . . . . . . 4-14

4.5.11 Relief Tube Outlets. . . . . . . . . . . . 4-14

4.5.12 Water Entrapment Areas . . . . . . . . 4-14

4.5.13 Bilge Areas . . . . . . . . . . . . . . . . . 4-14

4.5.14 Battery Compartments and Battery

Vent Openings . . . . . . . . . . . . . 4-14

4.5.15 Magnesium Parts . . . . . . . . . . . . . 4-15

4.5.16 Electrical Connectors and Other

Components . . . . . . . . . . . . . . 4-15

5 CORROSION REMOVAL AND SURFACE

TREATMENT . . . . . . . . . . . . . . . . . . . . 5-1

SECTION I CORROSION REMOVAL . . . . . 5-1

5.1 PURPOSE. . . . . . . . . . . . . . . . . . 5-1

5.2 RESPONSIBILITY. . . . . . . . . . . . 5-1

5.3 CORRECTIVE ACTIONS. . . . . . . 5-1

5.4 PAINT REMOVAL. . . . . . . . . . . . 5-1

5.5 CORROSION REMOVAL. . . . . . . 5-1

5.5.1 Mechanical Methods . . . . . . . . . . . 5-2

5.5.2 Non-Powered Tools and

Materials. . . . . . . . . . . . . . . . . 5-2

5.5.3 Power Tools and Materials. . . . . . . 5-4

5.5.4 Abrasive Blasting . . . . . . . . . . . . . 5-7

5.6 SURFACE FINISH. . . . . . . . . . . . 5-11

5.7 PITTING ON CRITICAL

STRUCTURE . . . . . . . . . . . . . 5-11

5.8 CORROSION REMOVAL

PROCEDURES-MECHANICAL 5-11

5.8.1 Warnings and Cautions . . . . . . . . . 5-11

5.8.2 Non-Powered Mechanical Corrosion

Removal . . . . . . . . . . . . . . . . . 5-14

5.8.3 Powered Mechanical Corrosion

Removal . . . . . . . . . . . . . . . . . 5-15

5.8.4 Abrasive Blasting Corrosion

Removal . . . . . . . . . . . . . . . . . 5-15

5.9 CORROSION

REMOVAL-CHEMICAL. . . . . . 5-17

Chapter Page

5.9.1 Aluminum Alloys . . . . . . . . . . . . . 5-17

5.9.2 Magnesium Alloys . . . . . . . . . . . . 5-20

5.9.3 Ferrous Metal (Steel) Alloys Other

Than Stainless Steels

(CRES). . . . . . . . . . . . . . . . . . 5-21

5.9.4 Stainless Steel (CRES) and Nickel

Based Alloys . . . . . . . . . . . . . . 5-26

5.9.5 Copper and Copper Based

Alloys . . . . . . . . . . . . . . . . . . 5-30

5.9.6 Titanium and Titanium Based

Alloys . . . . . . . . . . . . . . . . . . 5-32

5.9.7 Plated and Phosphated Surfaces . . . 5-33

SECTION II SURFACE TREATMENT . . . . . 5-36

5.10 PURPOSE. . . . . . . . . . . . . . . . . . 5-36

5.10.1 Chemical Prepaint Treatments . . . . 5-36

5.10.2 Surface Preparation. . . . . . . . . . . . 5-38

5.10.3 Precautions . . . . . . . . . . . . . . . . . 5-38

5.10.4 Application of Surface

Treatments . . . . . . . . . . . . . . . 5-39

5.10.5 Notes on Conversion Coating/Sur-

face Treatment . . . . . . . . . . . . . 5-40

5.10.6 Post Treatment. . . . . . . . . . . . . . . 5-40

5.10.7 Temporary Preservation. . . . . . . . . 5-41

SECTION III SHOT

PEENING/ROTO-PEENING . . . . . . . . . . . 5-42

5.11 PEENING OF METAL

SURFACES. . . . . . . . . . . . . . . 5-42

5.11.1 Types of Peening . . . . . . . . . . . . . 5-43

5.11.2 Roto-Peening (Rotary Flap Peening)

Procedures . . . . . . . . . . . . . . . 5-44

5.11.3 Determining Peening/Intensity . . . . 5-45

5.11.4 Peening Process Preparation. . . . . . 5-45

5.11.5 Post Peening Surface Finish . . . . . . 5-46

6 SEALANTS . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.1 PURPOSE. . . . . . . . . . . . . . . . . . 6-1

6.2 APPLICATIONS . . . . . . . . . . . . . 6-1

6.3 SEALING COMPOUNDS. . . . . . . 6-1

6.3.1 Sealant Packaging . . . . . . . . . . . . 6-1

6.3.2 Polysulfide, Polyurethane, and Poly-

thioether Sealing Compounds . . . . . . . . . . . . . . . 6-1

6.3.3 Silicone Sealing Compounds . . . . . 6-2

6.3.4 Adhesion Promoters . . . . . . . . . . . 6-2

6.3.5 SAE AMS 3255 Oil and Water Re-

sistant, Expanded Polytetrafluoro-ethylene Sealing Tape (EPTFE) Skyflex . . . . . . . . . . . . . . . . . . 6-2

TO 1-1-691

Change 11 iii

6.3.6 Av-Dec® Polyurethane Sealant

Tapes and Two Component Sealants . . . . . . . . . . . . . . . . . 6-2

6.4 EQUIPMENT . . . . . . . . . . . . . . . 6-2

6.4.1 Sealant Gun. . . . . . . . . . . . . . . . . 6-2

6.4.2 Application Nozzles . . . . . . . . . . . 6-3

6.4.3 Injection Gun . . . . . . . . . . . . . . . 6-3

6.4.4 Sealant Kits (Semkits®) . . . . . . . . 6-3

6.4.5 Sealant Removal and Application

Tools . . . . . . . . . . . . . . . . . . . 6-3

6.5 SEALANT MIXING. . . . . . . . . . . 6-3

6.5.1 Application Life. . . . . . . . . . . . . . 6-3

6.5.2 Storage Instructions . . . . . . . . . . . 6-4

6.5.3 Mixing MIL-PRF-81733, Type III

Sprayable Sealant Coating . . . . . 6-5

6.6 SEALANT APPLICATION

PROCEDURES . . . . . . . . . . . . 6-22

6.6.1 Cleaning . . . . . . . . . . . . . . . . . . . 6-22

6.6.2 Masking . . . . . . . . . . . . . . . . . . . 6-22

6.6.3 Adhesion Promoters . . . . . . . . . . . 6-25

6.6.4 Brush Spatula or Caulking Gun

Application . . . . . . . . . . . . . . . 6-25

6.6.5 Spray Gun Application . . . . . . . . . 6-26

6.6.6 Peel and Stick Application; SAE

AMS 3255 EPTFE Skyflex® and Av-Dec® HT3935-7 and HT3000 Sealing Tapes . . . . . . . . . . . . . 6-26

6.7 SEALING OF SPECIFIC

AREAS . . . . . . . . . . . . . . . . . 6-27

6.7.1 Faying Surface Sealing . . . . . . . . . 6-27

6.7.2 Fillet Sealing . . . . . . . . . . . . . . . . 6-28

6.7.3 Injection Sealing . . . . . . . . . . . . . 6-28

6.7.4 Fastener Sealing. . . . . . . . . . . . . . 6-29

6.7.5 Integral Fuel Cells/Tanks and Re-

movable Fuel Tanks . . . . . . . . . 6-29

6.7.6 Form-In-Place (FIP) Gasket Sealant

Repair . . . . . . . . . . . . . . . . . . 6-29

6.7.7 SAE AMS 3255 EPTFE (Skyflex®)

and Av-Dec® HT3000 and HT3935-7 Sealing Tape Gasket Repair . . . . . . . . . . . . . . . . . . 6-30

6.7.8 External Aircraft Structure . . . . . . . 6-31

6.7.9 Depressions . . . . . . . . . . . . . . . . . 6-31

6.7.10 Damaged Sealant . . . . . . . . . . . . . 6-31

6.7.11 Extensive Repair . . . . . . . . . . . . . 6-32

6.7.12 High Temperature Areas . . . . . . . . 6-32

6.7.13 Low Temperature Curing. . . . . . . . 6-32

6.8 STORAGE/SHELF LIFE CON-

TROL OF SEALANTS . . . . . . . 6-32

7 TREATMENT OF SPECIFIC AREAS . . . . . . 7-1

7.1 INTRODUCTION . . . . . . . . . . . . 7-1

Chapter Page

7.2 BATTERY COMPARTMENTS,

BOXES, AND ADJACENT

AREAS . . . . . . . . . . . . . . . . . 7-1

7.2.1 Preparation of Solutions for Clean-

ing and Neutralizing Battery Electrolytes . . . . . . . . . . . . . . . 7-1

7.2.2 Cleaning and Neutralizing

Procedures . . . . . . . . . . . . . . . 7-2

7.2.3 Paint Systems . . . . . . . . . . . . . . . 7-2

7.3 RELIEF TUBE AREAS . . . . . . . . 7-2

7.4 CORROSION TREATMENT FOR

STEEL CABLES . . . . . . . . . . . 7-3

7.5 PIANO TYPE HINGES . . . . . . . . 7-3

7.6 INTEGRAL AND EXTERNAL

FUEL TANKS AND DROP

TANKS . . . . . . . . . . . . . . . . . 7-3

7.6.1 Corrosion Removal and Rework of

Pitted Areas of Integral Fuel Tanks . . . . . . . . . . . . . . . . . . . 7-3

7.6.2 Removal of Corrosion and Rework

of Aluminum External Fuel Tanks/Drop Tanks. . . . . . . . . . . 7-4

7.7 FAYING SURFACES AND AT-

TACHMENT POINTS . . . . . . . 7-5

7.7.1 Faying Surfaces, Joints, and

Seams . . . . . . . . . . . . . . . . . . 7-5

7.7.2 Attaching Parts and Hardware . . . . 7-5

7.7.3 Severely Corroded (Rusted)

Hardware . . . . . . . . . . . . . . . . 7-6

7.8 NATURAL AND SYNTHETIC

RUBBER PARTS. . . . . . . . . . . 7-7

7.9 POTABLE WATER TANKS . . . . . 7-7

7.10 SURFACES AND COMPONENTS

EXPOSED TO EXHAUST

GASES, GUN GASES, AND

ROCKET BLAST . . . . . . . . . . 7-7

7.11 ELECTRICAL AND ELECTRONIC

EQUIPMENT . . . . . . . . . . . . . 7-7

7.11.1 Grounding and Bonding

Connections. . . . . . . . . . . . . . . 7-7

7.11.2 Conduit and Junction Boxes. . . . . . 7-7

7.11.3 Wires and Cables . . . . . . . . . . . . . 7-7

7.11.4 Deleted. . . . . . . . . . . . . . . . . . . . 7-7

7.11.5 Moisture and Fungus Proofing of

Electrical and Electronic Equipment. . . . . . . . . . . . . . . . 7-7

7.11.6 Antennas. . . . . . . . . . . . . . . . . . . 7-7

7.12 STRUCTURAL TUBING MEM-

BERS AND ASSEMBLIES . . . . 7-8

7.12.1 Structural Aluminum Alloy

Tubing . . . . . . . . . . . . . . . . . . 7-8

7.12.2 Structural Magnesium Alloy

Tubing . . . . . . . . . . . . . . . . . . 7-8

TO 1-1-691

iv Change 11

7.12.3 Structural Copper Alloys, Stainless

Steel (CRES) Alloys, and Heat Resistant Alloy Tubing . . . . . . . 7-8

7.12.4 Structural Carbon Steel Tubing. . . . 7-8

7.13 NON-STRUCTURAL TUBING

MEMBERS AND

ASSEMBLIES. . . . . . . . . . . . . 7-8

7.13.1 Aluminum Alloy Tubing . . . . . . . . 7-8

7.13.2 Stainless Steel (CRES) Tubing . . . . 7-9

7.13.3 Cadmium Plated Steel Tubing . . . . 7-10

7.13.4 Special Instructions for Tubing Fit-

tings and Sleeves . . . . . . . . . . . 7-10

7.13.5 Removable Installations. . . . . . . . . 7-10

7.14 CORROSION REMOVAL FROM

THIN METAL (0.0625 INCH

THICKNESS AND LESS). . . . . 7-11

7.15 AIR INTAKE DUCTS FOR JET

AIRCRAFT. . . . . . . . . . . . . . . 7-11

7.16 CLOSELY COILED SPRINGS . . . 7-11

7.17 CORROSION PREVENTION ON

ASSEMBLIES AND PARTS RE-

MOVED FROM AIRCRAFT

DURING MAINTENANCE, 30

DAY SHORT TERM STORAGE,

AND OVER 30 DAY LONG

TERM STORAGE

REQUIREMENTS . . . . . . . . . . 7-11

7.17.1 Short Term Storage. . . . . . . . . . . . 7-11

7.17.2 Long Term Storage. . . . . . . . . . . . 7-12

7.18 DEPLETED URANIUM

COUNTERWEIGHTS. . . . . . . . 7-12

7.18.1 Corrosion and Finish Damage Treat-

ment Procedures. . . . . . . . . . . . 7-13

7.19 MONEL RIVETS. . . . . . . . . . . . . 7-14

7.20 BERYLLIUM-COPPER ALLOYS,

BERYLLIUM-ALUMINUM AL-

LOYS, AND BERYLLIUM

OXIDE. . . . . . . . . . . . . . . . . . 7-14

7.20.1 Corrosion Removal and

Treatment . . . . . . . . . . . . . . . . 7-14

7.20.2 Depot Maintenance. . . . . . . . . . . . 7-14

7.21 EMI SEALS AND GASKETS . . . . 7-15

7.21.1 Treatment of EMI Seals and

Gaskets. . . . . . . . . . . . . . . . . . 7-15

8 EMERGENCY PROCEDURES . . . . . . . . . . 8-1

8.1 PURPOSE. . . . . . . . . . . . . . . . . . 8-1

8.2 RESPONSIBILITY. . . . . . . . . . . . 8-1

8.3 EMERGENCY

PREPARATIONS . . . . . . . . . . . 8-1

8.3.1 Priority Removal List of Equipment

and/or Components. . . . . . . . . . 8-1

8.3.2 Emergency Reclamation Team . . . . 8-2

Chapter Page

8.3.3 Emergency Reclamation

Equipment. . . . . . . . . . . . . . . . 8-2

8.3.4 Production Planning . . . . . . . . . . . 8-2

8.4 GENERAL PROCEDURES . . . . . . 8-2.1

8.4.1 Removal of Contaminated Installed

Equipment. . . . . . . . . . . . . . . . 8-8

8.4.2 Disassembly/Removal of

Components . . . . . . . . . . . . . . 8-8

8.4.3 Clean . . . . . . . . . . . . . . . . . . . . . 8-8

8.4.4 Tagging . . . . . . . . . . . . . . . . . . . 8-8

8.5 GENERAL CLEANING

PROCEDURES . . . . . . . . . . . . 8-8

8.5.1 Primary Method . . . . . . . . . . . . . . 8-9

8.5.2 Alternate Methods . . . . . . . . . . . . 8-9

8.5.3 Removing Fire Extinguishing Pow-

der (O-D-1407 Potassium Bicar-bonate [Purple K{PKP}], Sodium Bicarbonate, Ammonium Phos-phate Monobasic) and/or Other Dry Chemical Agents . . . . . . . . 8-10

8.5.4 Removing MIL-F-24385 Aqueous

Film Forming Foam (AFFF) Fire Extinguishing Agent and Other Synthetic Based Foaming Agents Including High-Expansion (Hi- Ex) Foams . . . . . . . . . . . . . . . 8-10

8.5.5 Removal of Carbon Dioxide (CO2), HFC-125, Halon and 3M NOVEC 1230 Fire Extinguishing Agents . . . . . . . . . . . . . . . . . . 8-11

8.5.6 Removal of Protein Type Foam and

Soda-Acid Fire Extinguishing Agents . . . . . . . . . . . . . . . . . . 8-11

8.5.7 Treatment After Landing on a

Foamed Runway . . . . . . . . . . . 8-11

8.5.8 Treatment After Exposure to Volca-

nic Ash. . . . . . . . . . . . . . . . . . 8-11

8.6 SPECIFIC INTERNAL

AREAS . . . . . . . . . . . . . . . . . 8-12

8.6.1 Aircraft Cockpit Area . . . . . . . . . . 8-12

8.6.2 Aircraft Ejection Seats . . . . . . . . . 8-12

8.6.3 Avionic, Electronic, and Electrical

Equipment. . . . . . . . . . . . . . . . 8-13

8.6.4 Photographic Equipment . . . . . . . . 8-13

8.6.5 Graphite or Carbon Fiber/Epoxy, Boron Fiber/Epoxy, and Tungsten Fiber/Epoxy Composite Materials. . . . . . . . . . . . . . . . . 8-13

8.7 SPECIFIC EXTERNAL AREAS OF

AIRCRAFT. . . . . . . . . . . . . . . 8-14

8.7.1 Airframes . . . . . . . . . . . . . . . . . . 8-14

8.7.2 Antennas. . . . . . . . . . . . . . . . . . . 8-14

8.7.3 Reciprocating Engines. . . . . . . . . . 8-14

TO 1-1-691

Change 12 v

8.7.4 Turbine Engines . . . . . . . . . . . . . . 8-15

8.7.5 Treatment for Engines Which Have

Ingested Fire Extinguishing Pow-der (Potassium Bicarbonate [Purple K{PKP}], Sodium Bicar-bonate, Ammonium Phosphate Monobasic) and/or Synthetic Foaming Agents (AFFF, Hi-Ex, AR) . . . . . . . . . . . . . . . . . . . . 8-15

8.7.6 Helicopter Transmission, Rotor

Head, and Rotor Hub . . . . . . . . 8-16

8.7.7 Helicopter Main and Tail Rotor

Blades . . . . . . . . . . . . . . . . . . 8-16

8.7.8 Armament . . . . . . . . . . . . . . . . . . 8-16

8.7.9 Aircraft Fuel Systems . . . . . . . . . . 8-17

9 SOUTHWEST ASIA ENVIRONMENTS . . . . 9-1

9.1 INTRODUCTION . . . . . . . . . . . . 9-1

9.1.1 Climatic Conditions . . . . . . . . . . . 9-1

9.1.2 Aircraft Wash . . . . . . . . . . . . . . . 9-1

9.1.3 Aircraft Clear Water Rinse

(CWR) . . . . . . . . . . . . . . . . . . 9-1

9.1.4 Effects of Desert Environment . . . . 9-1

9.2 PRE-DEPLOYMENT

RECOMMENDATIONS . . . . . . 9-1

9.3 RECOMMENDED ACTIONS

WHILE DEPLOYED . . . . . . . . 9-2

9.3.1 High Efficiency Particulate Air

(HEPA) Filtration . . . . . . . . . . . 9-2

9.3.2 Areas to be Checked and

Cleaned . . . . . . . . . . . . . . . . . 9-2

9.4 POST DEPLOYMENT . . . . . . . . . 9-3

9.5 CORROSION PREVENTIVE

COMPOUNDS (CPC’s) . . . . . . 9-3

9.5.1 Recommended CPC’s . . . . . . . . . . 9-3

10 REMOTELY PILOTED AIRCRAFT CORRO-

SION PREVENTION . . . . . . . . . . . . . . . 10-1

10.1 REMOTELY PILOTED AIRCRAFT

(RPA). . . . . . . . . . . . . . . . . . . 10-1

10.1.1 Definition . . . . . . . . . . . . . . . . . . 10-1

10.2 CORROSION CONTROL

PROGRAM. . . . . . . . . . . . . . . 10-1

Chapter Page

10.3 CARBON FIBER COMPOSITES

AND CORROSION . . . . . . . . . 10-1

10.3.1 Corrosion Concerns . . . . . . . . . . . 10-1

10.3.2 Moisture Absorption . . . . . . . . . . . 10-2

10.4 CORROSIVE

ENVIRONMENTS. . . . . . . . . . 10-2

10.5 APPROVED CLEANING

COMPOUNDS . . . . . . . . . . . . 10-2

10.5.1 MIL-PRF-87937, Type IV and MIL-

PRF-85570, Type II . . . . . . . . . 10-2

10.5.2 MIL-PRF-87937, Type III and MIL-

PRF-85570, Type V . . . . . . . . . 10-2

10.5.3 A-A-59921 (Formerly MIL-C-

43616), Class 1A Emulsion Cleaner. . . . . . . . . . . . . . . . . . 10-2

10.6 AIRCRAFT CLEANING. . . . . . . . 10-2

10.6.1 Frequency of Cleaning . . . . . . . . . 10-3

10.6.2 Wipe Down or Spot Cleaning. . . . . 10-3

APPENDIX A CONSUMABLE

MATERIALS. . . . . . . . . . . . . . . . . . . . . . A-1

A.1 INTRODUCTION . . . . . . . . . . . . A-1

A.1.1 Shelf Life . . . . . . . . . . . . . . . . . . A-1 A.1.2 Consumable Materials

Containers. . . . . . . . . . . . . . . . A-1 A.1.3 Local Purchase . . . . . . . . . . . . . . A-1 A.1.4 Local Environmental Laws and

Regulations . . . . . . . . . . . . . . . A-1 A.1.5 Unit of Issue Codes . . . . . . . . . . . A-1

APPENDIX B EQUIPMENT FOR CLEAN-

ING AND CORROSION PREVENTION

AND CONTROL . . . . . . . . . . . . . . . . . . . B-1

B.1 INTRODUCTION . . . . . . . . . . . . B-1

B.1.1 Unit of Issue Codes . . . . . . . . . . . B-1

GLOSSARY . . . . . . . . . . . . . . . . . . . . . Glossary 1

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . Index 1

TO 1-1-691

vi Change 11

LIST OF ILLUSTRATIONS

Number PageTitle

2-1 Simplified Corrosion Cell . . . . . . . . . . . 2-2 2-2 Elimination of Corrosion by Application of an Organic Film to a Metal Surface . . . . . . . . . . . . . . . . . . . . . . 2-3

2-3 Effect of Sea Water on Galvanic Corrosion . . . . . . . . . . . . . . . . . . . . 2-3

2-4 Galvanic Corrosion in a Flashlight Battery . . . . . . . . . . . . . . . . . . . . . . 2-4

2-5 Effect of Area Relationship in Dissimilar Metal Contacts . . . . . . . . . . . . . . . . . 2-4

2-6 Galvanic Corrosion of Magnesium Adja-cent to a Steel Fastener . . . . . . . . . . . 2-5

2-7 Pitting of an Aluminum Wing Assembly . . . . . . . . . . . . . . . . . . . . 2-6

2-8 Cross-Section of Corrosion Pits . . . . . . . 2-6 2-9 Cross-Section of 7075-T6 Aluminum

Alloy . . . . . . . . . . . . . . . . . . . . . . . 2-7 2-10 Grain Structure of a Corroding Aluminum

Surface . . . . . . . . . . . . . . . . . . . . . . 2-7 2-11 Intergranular Corrosion of 7075-T6 Alumi-num Adjacent to Steel Fastener. . . . . . 2-7 2-12 Example of Exfoliation . . . . . . . . . . . . . 2-7 2-13 Another Example of Exfoliation . . . . . . . 2-7 2-14 Concentration Cell Corrosion . . . . . . . . . 2-9 2-15 Stress Corrosion Cracking . . . . . . . . . . . 2-9 2-16 Galvanic Series of Metals and Alloys in

Sea Water . . . . . . . . . . . . . . . . . . . . 2-10 2-17 Filiform Corrosion Found Under Paint

Coating on a Magnesium Panel. . . . . . 2-11 2-18 Schematic of the Development of Filiform

Corrosion on an Aluminum Alloy . . . . 2-11 2-19 Magnesium Corrosion Products. . . . . . . . 2-12 2-20 Steel Corrosion Products (Rust) . . . . . . . 2-13 2-21 Aluminum Surface Corrosion

Products . . . . . . . . . . . . . . . . . . . . . 2-14 2-22 Cadmium Plated Surface Conditions . . . . 2-15 2-23 Failed Chromium Plating . . . . . . . . . . . . 2-17 3-1 Foam Generating Cleaning Unit (15

Gallons) . . . . . . . . . . . . . . . . . . . . . 3-30 3-2 Foam Generating Cleaning Unit (45

Gallons) . . . . . . . . . . . . . . . . . . . . . 3-31 3-3 Universal Wash Unit . . . . . . . . . . . . . . . 3-32 3-4 Top Loading Type . . . . . . . . . . . . . . . . 3-36 3-5 Front Loading Type . . . . . . . . . . . . . . . 3-36 3-6 Use of Aircraft Washing Applicator . . . . . 3-40 3-7 Aircraft Cleaning Procedure . . . . . . . . . . 3-41 3-8 Automatic Water Spray Nozzle . . . . . . . . 3-44 4-1 Depth Dimension of Corrosion Pits . . . . . 4-4 4-2 Fiber Optic Borescope. . . . . . . . . . . . . . 4-4 4-3 Optical Depth Micrometer (Analog Me-chanical Read Out Type) . . . . . . . . . . 4-7 4-4 Optical Depth Micrometer (Digital Read

Out Type) . . . . . . . . . . . . . . . . . . . . 4-8

Number PageTitle

4-5 Typical Use of a Straight Edge to Deter-mine if Suspect Areas Have Been Pre-viously Reworked . . . . . . . . . . . . . . . 4-9

4-6 Corrosion Around Fasteners . . . . . . . . . . 4-10 4-7 Galvanic Corrosion of Aluminum Adjacent to Steel Fasteners . . . . . . . . . . . . . . . 4-10 4-8 Spot Weld Corrosion . . . . . . . . . . . . . . . 4-11 4-9 Spot Welded Skin Corrosion

Mechanism . . . . . . . . . . . . . . . . . . . 4-11 4-10 Gun Blast Area Corrosion Points. . . . . . . 4-12 4-11 Exhaust Trail Area Corrosion Points . . . . 4-12 4-12 F-15 Nose Landing Gear Wheel Well . . . 4-12 4-13 Flaps Lowered to Expose Recess

Areas . . . . . . . . . . . . . . . . . . . . . . . 4-12 4-14 Reciprocating Engine Frontal Area Corro-sion Points. . . . . . . . . . . . . . . . . . . . 4-13 4-15 Jet Engine Frontal Area Corrosion

Points . . . . . . . . . . . . . . . . . . . . . . . 4-13 4-16 Corrosion Prone Point of Air Inlet. . . . . . 4-13 4-17 Corrosion in Air Intake Duct . . . . . . . . . 4-14 4-18 Wing Fold Joint . . . . . . . . . . . . . . . . . . 4-15 4-19 Hinge Corrosion Points . . . . . . . . . . . . . 4-16 4-20 Piano Hinge Lugs . . . . . . . . . . . . . . . . . 4-16 4-21 Control Cables . . . . . . . . . . . . . . . . . . . 4-16 4-22 Personnel Relief Tube Vent . . . . . . . . . . 4-16 4-23 Common Water Entrapment Areas. . . . . . 4-17 4-24 Bilge Areas . . . . . . . . . . . . . . . . . . . . . 4-17 4-25 Battery Compartment . . . . . . . . . . . . . . 4-18 5-1 3M Co. Scotch-BriteTM Flap Brush and

Mandrel . . . . . . . . . . . . . . . . . . . . . 5-4 5-2 Abrasive Flap Wheels with Spindle

Mount. . . . . . . . . . . . . . . . . . . . . . . 5-4 5-3 3M Co. Radial Bristle Disc . . . . . . . . . . 5-5 5-4 3M Co. Roloc Discs . . . . . . . . . . . . . . . 5-6 5-5 3M Co. Inline Bristle Disc . . . . . . . . . . . 5-7 5-6 Abrasive Blasting Equipment . . . . . . . . . 5-10 5-7 Shaping Reworked Areas . . . . . . . . . . . . 5-13 5-8 Acceptable Clean-Up of Pitting Corrosion on Critical Structure . . . . . . . . . . . . . 5-13 5-9 Limited Clearance. . . . . . . . . . . . . . . . . 5-14 5-10 A Water-Break Free Surface Compared with One with Breaks . . . . . . . . . . . . 5-40 5-11 Magnetic Almen Strip Holder . . . . . . . . . 5-46.1 5-12 “A” Test Strip Magnetic to SAE J442 Stri-pholder Arc Height Conversion Graph . . . . . . . . . . . . . . . . . . . . . . . 5-47

5-13 “A” Test Strip Arc Height Magnetic to SAE J442 Stripholder Conversion Chart, 0.001 Inch . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

5-14 “N” Arc Height Magnetic to SAE J442 Stripholder Conversion Graph. . . . . . . 5-49

Change 11 viiAll data on pages viii through ix deleted

5-15 “N” Arc Height Magnetic to SAE J442 Stripholder Conversion Chart, 0.001 Inch . . . . . . . . . . . . . . . . . . . . . . . . 5-50

5-16 First Trial Estimate of Intensity for “A” Test Strip . . . . . . . . . . . . . . . . . . . . 5-51

5-17 Example of Coverage . . . . . . . . . . . . . . 5-52 6-1 Pneumatic Sealant Gun . . . . . . . . . . . . . 6-6 6-2 Sealant Application Nozzles . . . . . . . . . . 6-7 6-3 Countersink Application Nozzles. . . . . . . 6-8 6-4 Rivet Application Nozzles . . . . . . . . . . . 6-9 6-5 Sealant and Adhesive Smoothing

Tools . . . . . . . . . . . . . . . . . . . . . . . 6-10 6-6 Sealant Injection Guns. . . . . . . . . . . . . . 6-11 6-7 Injection Style Semkit®. . . . . . . . . . . . . 6-12 6-8 Non-Metallic Spatula . . . . . . . . . . . . . . 6-26 6-9 Faying Surface Sealing . . . . . . . . . . . . . 6-28 6-10 Typical Fillet Seal. . . . . . . . . . . . . . . . . 6-29 6-11 Typical Injection Seal . . . . . . . . . . . . . . 6-30 6-12 Typical Methods of Sealing Fasteners . . . 6-31 6-13 Typical Lap Skin Sealing . . . . . . . . . . . . 6-33

Number PageTitle

6-14 Sealing Procedures for Typical Aircraft Fitting. . . . . . . . . . . . . . . . . . . . . . . 6-34

6-15 Typical Spar Cap Sealing. . . . . . . . . . . . 6-35 6-16 Sealing of Access Doors . . . . . . . . . . . . 6-36 7-1 Beryllium-Copper Spiral Contact with En-vironmental Fluorosilicone Seal . . . . . 7-16 7-2 Dorsal Longeron EMI Seal . . . . . . . . . . 7-17 7-3 Stainless Steel (CRES) EMI Screen. . . . . 7-17 7-4 Bonding Cable from Airframe to Graphite/

Epoxy Avionics Bay Door . . . . . . . . . 7-18 7-5 EMI Bonding Washers in an Avionics

Bay . . . . . . . . . . . . . . . . . . . . . . . . 7-19 9-1 Soil Makeup in the SWA Area . . . . . . . . 9-2 9-2 Global Dust Producing Regions . . . . . . . 9-2 9-3 Open Circuit Board. . . . . . . . . . . . . . . . 9-3 B-1 Back Mounted Full Facepiece

Respirator . . . . . . . . . . . . . . . . . . . . B-43 B-2 Front Mounted Full Facepiece

Respirator . . . . . . . . . . . . . . . . . . . . B-44 B-3 Hooded Air Respirator System . . . . . . . . B-45

LIST OF TABLES

Number PageTitle

2-1 Corrosion of Metals - Type of Attack and Appearance of Corrosion Products . . . 2-15

3-1 Aircraft Wash Intervals . . . . . . . . . . . . . 3-2 3-2 Cleaning of Specific Areas and

Components. . . . . . . . . . . . . . . . . . . 3-12 3-3 Deicing/Anti-Icing Fluid Residue Inspec-tion and Cleaning Procedures . . . . . . . 3-28 3-4 Recommended Dilution of Low Tempera-ture Cleaner . . . . . . . . . . . . . . . . . . . 3-45 3-4.1 Fungus Growth Removal from Organic

Materials . . . . . . . . . . . . . . . . . . . . . 3-47 3-5 Common Military Greases and Their

Uses . . . . . . . . . . . . . . . . . . . . . . . . 3-55 3-6 Time Limitations for CPC’s . . . . . . . . . . 3-57 3-7 Corrosion Preventive Compounds . . . . . . 3-57 3-8 Preservation of Specific Areas and

Components. . . . . . . . . . . . . . . . . . . 3-60 4-1 NDI Inspection Tools for Various Types of

Corrosion . . . . . . . . . . . . . . . . . . . . 4-2 5-1 Grades of Abrasive Mats . . . . . . . . . . . . 5-3 5-2 Grades of Steel Wool . . . . . . . . . . . . . . 5-3 5-3 Recommended Powered Abrasives for

Corrosion Removal . . . . . . . . . . . . . . 5-8 5-4 Recommended Non-Powered Abrasives for

Corrosion Removal . . . . . . . . . . . . . . 5-10 5-5 Typical Chemical Corrosion Removal Pro-cedures for Aluminum Alloy Parts and Assemblies . . . . . . . . . . . . . . . . . . . 5-18

Number PageTitle

5-6 Typical Chemical Corrosion Removal Pro-cedures for Magnesium Alloys . . . . . . 5-22

5-7 Typical Chemical Corrosion Removal Pro-cedures for Ferrous Metals Other Than Stainless Steel (CRES) . . . . . . . . . . . 5-26

5-8 Typical Chemical Corrosion Removal Pro-cedures for Stainless Steel (CRES) and Nickel Based Alloys . . . . . . . . . . . . . 5-28

5-9 Control of Corrosion Removal/Pickling Action of Nitric-Acid-Hydrofluoric Solutions . . . . . . . . . . . . . . . . . . . . . 5-30

5-10 Typical Chemical Corrosion Removal Pro-cedures for Copper and Copper Alloys. . . . . . . . . . . . . . . . . . . . . . . 5-32

5-11 Typical Chemical Corrosion Removal of Titanium and Titanium Base Alloys. . . . . . . . . . . . . . . . . . . . . . . 5-34

5-12 Typical Chemical Corrosion Removal Pro-cedures for Plated and Phosphated Surfaces . . . . . . . . . . . . . . . . . . . . . 5-36

5-13 Prepaint Treatments for Metal Surfaces . . . . . . . . . . . . . . . . . . . . . 5-41

5-14 Tool Speed Operation Requirements . . . . 5-44 5-15 Standard Peening Intensity (Isp) for Com-plete Coverage Arc-Height in Inches. . . . . . . . . . . . . . . . . . . . . . . 5-45

6-1 Sealing Compounds . . . . . . . . . . . . . . . 6-13

TO 1-1-691

LIST OF ILLUSTRATIONS - CONTINUED

viii Change 11

6-2 Time Requirements for Sealants When Used at 75° F (24° C) and 50%

RH. . . . . . . . . . . . . . . . . . . . . . . . . 6-22

8-1 Priority Guide for Emergency Treatment of Aircraft, Missiles, and Equipment . . . . . . . . . . . . . . . . . . . . 8-3

8-2 Suggested List of Emergency Reclamation Items . . . . . . . . . . . . . . . . . . . . . . . 8-3

Number PageTitle

10-1 Air Force RPA Tiers . . . . . . . . . . . . . . . 10-1 A-1 Unit of Issue Codes . . . . . . . . . . . . . . . A-1 A-2 Consumable Materials . . . . . . . . . . . . . . A-2 B-1 Unit of Issue Codes . . . . . . . . . . . . . . . B-1 B-2 Equipment for Cleaning and Corrosion

Prevention and Control . . . . . . . . . . . B-2

TO 1-1-691

LIST OF TABLES - CONTINUED

Change 11 ix/(x blank)

FOREWORD

1 PURPOSE.

The purpose of this manual is to provide information on materials and procedures for the prevention and repair of corrosion damage to aircraft and missile weapon systems and related equipment. Supervisory and maintenance personnel shall use this manual as a guide for all corrosion control and maintenance efforts. Contractors who maintain and repair corrosion of aircraft, missiles, and related equipment shall also use this manual. Use this manual in conjunction with and in support of the appropriate systems specific aircraft, missile, or equipment technical orders (TO’s). In the case of a conflict between this manual and a systems specific air-craft, missile, or equipment manual, the system specific manual shall take precedence over this manual. Paragraph 6 lists related technical publications used by personnel in-volved in cleaning and corrosion control.

2 SCOPE.

The material in this manual provides basic cleaning, corro-sion prevention and control, and corrective maintenance in-formation to be used at organizational, intermediate, and de-pot levels. This manual is divided into eight chapters, two appendices, a glossary, and an alphabetical index. Chapter 1 explains the appropriate usage of this manual. Chapter 2 ex-plains what corrosion is, why it occurs, the various forms it can take, and how to recognize it. Chapter 3 outlines ac-cepted procedures, methods, and materials to be used in maintenance cleaning in Section I, lubrication in Section II, and preservation in Section III of aircraft, missiles, and re-lated equipment. Chapter 4 describes inspection techniques for detecting corrosion in Section I and discusses corrosion prone areas in Section II. Chapter 5 outlines the approved methods for the removal of corrosion damage in Section I and the application of surface treatments in Section II. Chap-ter 6 covers recommended materials and procedures for the application of sealing compounds to aircraft, missile, and related equipment structures. Chapter 7 describes the recom-mended procedures for treating and protecting against corro-sion in specific areas. Chapter 8 outlines emergency proce-dures to be followed after exposure of aircraft to salt water, fire extinguishing chemicals, etc., Appendix A lists the rec-ommended materials for cleaning, corrosion prevention, sur-face treatment, and preservation of aircraft, missiles, and re-lated equipment. Appendix B lists equipment used for cleaning, corrosion removal, conversion coating, and sealing of aircraft, as well as associated safety equipment including personal protective equipment (PPE) for these operations.

3 LIST OF ABBREVIATIONS AND ACRONYMS.

All abbreviations used in this manual are in accordance with

ASME Y14.38.

AFCPCO Air Force Corrosion Prevention and Con-trol Office

AFFF Aqueous Film Forming Foam AFPHIS Animal and Plant Health Inspection Ser-vices AISI American Iron and Steel Institute AOR Area of Responsibility BOD Biological Oxygen Demand CaCO3 Calcium Carbonate CaSO4.2H2O Anhydrous Calcium Sulfate CBR Chemical, Biological, Radiological CC Cubic Centimeters CFM Cubic Feet Per Minute CPC Corrosion Preventive Compounds CRES Corrosion Resistant Steels CrO3 Chromic Acid CWR Clear Water Rinse °C Degrees Celsius °F Degrees Fahrenheit DFT Dry Film Thickness DI Deionized DTIC Defense Technical Information Center EA Each EPA Environmental Protection Agency EPTFE Expanded Polytetrafluoroethylene ft Foot/Feet FIP Form-In-Place HAP Hazardous Air Pollutants HCFC Hydrochlorofluorocarbon HEPA High Efficiency Particulate Air ID Inside Diameter in Inch IVD Ion Vapor Deposited KSI Kilograms per Square Inch LG Landing Gear LOX Liquid Oxygen MEK Methyl Ethyl Ketone

Change 11 xi mg/L Milligrams per Liter mm Hg Millimeters of Mercury MOS Maximum Operating Speed MSDS Material Safety Data Sheet NDI Non-Destructive Inspection NRA Nuclear Regulatory Agency NSN National Stock Number OD Outside Diameter ODC Ozone Depleting Compounds ODS Ozone Depleting Substances PDM Program Depot Maintenance pH Potential of Hydrogen PMB Plastic Media Blast PMF Pre-Mixed and Frozen PN Part Number PPE Personal Protective Equipment ppm Parts Per Million PSI Pounds Per Square Inch QPD Qualified Products Database QPL Qualified Products List RH Relative Humidity RPM Rotations Per Minute RTU Ready-To-Use SE Support Equipment SLED Shelf Life Extension Document SPD System Program Director SPM System Program Manager SWA Southwest Asia TDS Total Dissolved Solids TNP Touch-N-PrepTM

TO Technical Order TPH Total Petroleum Hydrocarbon TSS Total Suspended Solids VOC Volatile Organic Compound

4 RESPONSIBILITY FOR CHANGES TO THIS

MANUAL.

This manual is maintained for technical content by the Air Force Corrosion Prevention and Control Office (AFCPCO), AFRL/RXSSR, 325 Richard Ray Blvd., Robins AFB, GA 31098-1639, Tel: (478) 926-3284 (DSN 468-3284), Fax:

(478) 926-6619 (DSN 468-6619), email:

afcorr@robins.af.mil; and for TO administration by WR- ALC/LESGI, 460 Richard Ray Blvd., Robins AFB, GA 31098-1640, Tel: (478) 926-7046 x122 (DSN 468-7046 x122), email: wralc.lesgi.industrialbackhop@robins.af.mil.

5 CHANGE RECOMMENDATIONS.

Recommendations concerning changes to this manual shall be submitted in accordance with TO 00-5-1.

6 LIST OF RELATED PUBLICATIONS.

List of Related Publications

Number Title AFI 20-114 Air and Space Equipment

Structural Management AFI 32-1067 Water Systems AFI 32-7080 Pollution Prevention Pro-gram AFI 40-201 Managing Radioactive Mate-rials in the U.S. Air Force AFMAN 23-110 CD Basic USAF Supply

Manual AFMAN 24-204-IP Preparing Hazardous Materi-als for Military Air Ship-ments

AFMAN 91-223 Aviation Safety Investiga-tions and Reports

AF-PAM 91-212 Bird/Wildlife Aircraft Strike Hazard (BASH) Manage-ment Techniques

AFI 91-203 Air Force Consolidated Oc-cupational Safety Instruc-tion

ASME Y14.38 Abbreviations and Acronyms for Use on Drawings and Related Documents

DOD 4140.27-M Shelf Life Management Manual

DOD 6050.5LR Hazardous Material Control and Management

(HMC&M)

MIL-HDBK-729 Corrosion and Corrosion Prevention-Metals

TO 00-5-1 AF Technical Order System TO 00-20-1 Aerospace Equipment Main-tenance Inspection, Docu-mentation, Policy and Pro-cedures

TO 00-20-2 Maintenance Data Documen-tation

TO 00-25-107 Maintenance Assistance TO 00-25-172 Ground Servicing of Aircraft and Static Grounding/ Bonding

TO 00-25-234 General Shop Practice Re-quirements for the Repair, Maintenance, and Test of Electronic Equipment

TO 00-25-235 Safety Procedures and Equipment for Confined Space Entry (Including Missile Propellant Tanks) xii Change 11

List of Related Publications - Continued

Number Title TO 00-35D-54 USAF Material Deficiency

Reporting and Investigat-ing System

TO 00-85A-03-1 Preservation, Packaging and Packing - External Aircraft Fuel Tanks, Fuel Cells

TO 00-110A-1 Guidelines for Identification and Handling of Aircraft and Material Contami-nated with Radioactive Debris (Fallout)

TO 1-1-3 Inspection and Repair of Aircraft Integral Tanks and Fuel Cells

TO 1-1-8 Application and Removal of Organic Coatings, Aero-space and Non-Aerospace Equipment

TO 1-1-17 Storage of Aircraft and Mis-siles Systems

TO 1-1-24 Maintenance Repair and Electrical Requirements for Fiberglass Airborne Radomes

TO 1-1-689-1 Cleaning and Corrosion Control, Volume I, Corro-sion Program and Corro-sion Theory

TO 1-1-689-3 Cleaning and Corrosion Control, Volume III, Avi-onics and Electronics

TO 1-1-689-5 Cleaning and Corrosion Control, Volume V, Con-sumable Materials and Equipment for Avionics

TO 1-1-690 General Advanced Compos-ite Repair Processes

TO 1-1A-1 Engineering H/B Series for Aircraft Repair - General Manual for Structural Re-pair

TO 1-1A-8 Engineering Manual Series for Aircraft and Missiles Repair Structural Hard-ware

TO 1-1A-9 Engineering Series for Air-craft Repair Aerospace Metal General Data and Usage Factors

TO 1-1A-12 Fabrication, Maintenance and Repair of Transparent Plastic

TO 1-1A-14 Installation Practices for Air-craft Electric and Elec-tronic Wiring

List of Related Publications - Continued

Number Title TO 1-1A-15 General Maintenance In-structions for Support Equipment (SE)

TO 2-1-111 Standard Maintenance Prac-tices, Navy, USAF and Army, P&W Aircraft En-gines

TO 2J-1-13 Cleaning of Gas Turbine Aircraft Engines and Parts

TO 2J-1-18 Preparation for Shipment and Storage of Gas Tur-bine Engines

TO 2J-1-32 Standard Maintenance Prac-tice Instructions - GE Air-craft Engines, Model TF-

34-GE-100, A, -400, A, B,

TF58-GE-3, -5, -8B, -10,

-16, -100 (USCG), -400B,

-402, T64-GE-6B, -7, A,

100, -413, -415, -416, -416A, F404-GE-400,

YF404-GE-400, F110-GE-

400, YT700-GE-401,

T700-GE-401, 4

TO 4B-1-32 Maintenance and O/H In-structions - All Type Air-craft Brakes

TO 4S-1-182 General O/H & Maintenance Instr. All FSC 1620 Land-ing Gear & Components

TO 4W-1-61 Operation, Service, and Maintenance Instructions- All Aircraft Wheels

TO 10-1-179 Corrosion Control Manual for Photographic Equip-ment

TO 13A1-1-1 Repair, Cleaning, Inspection and Testing Aircraft Safety Belts, Shoulder Harness, and Miscellaneous Person-nel Restraint Equipment

TO 31-1-221 Field Instructions for Paint-ing and Preserving Elec-tronics Command Equip-ment

TO 33B-1-1 Nondestructive Inspection Methods

TO 34-1-3 Inspection and Maintenance of Machinery and Shop Equipment

TO 35-1-3 Corrosion Prevention, Paint-ing, and Marking of USAF Support Equipment

(SE)

Change 11 xiii

List of Related Publications - Continued

Number Title TO 35-1-4 Processing and Inspection of

Support Equipment for Storage and Shipment

TO 36-1-191 Technical and Managerial Reference for Motor Ve-hicle Maintenance

TO 42A1-1-1 Evaluation and Service Test-ing of Materials - Clean-ing, Painting, Sealing, Pro-tective Treating, Anti- Corrosion, Inspection Materials, and Related Items

TO 42A3-1-2 General Use of Cements, Sealants, and Coatings

List of Related Publications - Continued

Number Title TO 42B-1-6 Corrosion Preventive Lubri-cants and Anti-Seize Com-pounds

TO 42C-1-2 Anti-Icing, Deicing, and De-frosting of Parked Aircraft

TO 42C-1-12 Quality Control of Chemi-cals

TO 42C2-1-7 Electro Deposition of Metals and Metal Surface Treat-ments to Meet Air Force Maintenance Requirements xiv Change 11

SAFETY SUMMARY

1 GENERAL SAFETY INSTRUCTIONS.

This manual describes physical and chemical processes which may cause injury or death to personnel, or damage to equipment if not properly followed. This safety summary includes general safety precautions and instructions that must be understood and applied during operation and maintenance to ensure personnel safety and protection of equipment. Prior to performing any task, the WARNINGs, CAUTIONs and NOTEs included in that task shall be reviewed and under-stood.

2 WARNINGS, CAUTIONS, AND NOTES.

WARNINGs and CAUTIONs are used in this manual to highlight operating or maintenance procedures, practices, conditions or statements which are considered essential to protection of personnel (WARNING) or equipment (CAU- TION). NOTEs are used in this manual to highlight operat-ing or maintenance procedures, practices, conditions or state-ments which are not essential to protection of personnel or equipment. The headings used and their definitions are as follows:

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in in-jury to, or death of, personnel or long term health hazards.

Highlights an essential operating or maintenance procedure, practice, condition,…