TO 1-1-691- Attachment - 4.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

This publication supersedes Operational Supplement TO 1-1-691S-2, dated 17 May 2007 and Safety Supplement TO 1-1-691SS-4, dated 10 September 2007.

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited (WR-ALC/PA Public Affairs Certification Number PA04-11-96). Other requests for this document shall be referred to 584 CBSS/GBHDE, Robins AFB, GA 31098. Questions concerning technical content shall be referred to AFRL/MLS-OLR.

Published Under Authority of the Secretary of the Air Force

1 JULY 2003 CHANGE 2 - 19 OCTOBER 2007

BASIC AND ALL CHANGES HAVE BEEN MERGED

TO MAKE THIS A COMPLETE PUBLICATION

Dates of issue for original and changed pages are:

Original . . . . . . . .0 . . . . . . . .1 July 2003 Change. . . . . . . . 1 . . . . 15 October 2006

Change . . . . . . 2 . . . . . . 19 October 2007

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 358 CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Page *Change No. No.

Title A i ii - iv iv.1 Added iv.2 Blank v - vi vii viii Blank ix x xi xii xiii xiv Blank 1-1 1-2 2-1 2-2 - 2-20 2-21 2-22 3-1 3-2 - 3-6 3-7 - 3-8 3-9 3-10 - 3-12 3-13 - 3-14 3-15 - 3-28 3-28.1 Added 3-28.2 Blank 3-29 - 3-33 3-34 - 3-36 3-37 3-38 - 3-41 3-42 3-43 3-44 3-45 3-46 - 3-48 3-49 3-50 3-50.1 - 3-50.4 Added 3-51 3-52 3-53 - 3-61

3-62 4-1 - 4-2 4-3 - 4-4 4-5 - 4-6 4-7 - 4-8 4-9 4-10 - 4-13 4-14 - 4-15 4-16 - 4-18 5-1 - 5-2 5-3 - 5-11 5-12 5-13 5-14 5-15 - 5-16 5-17 - 5-23 5-24 5-25 5-26 5-27 - 5-29 5-30 5-31 - 5-40 5-41 5-42 5-43 - 5-44 5-45 - 5-46 5-47 5-48 5-49 - 5-51 5-52 Blank 6-1 6-2 - 6-10 6-11 6-12 - 6-16 6-17 - 6-18 6-18.1 Added 6-18.2 Blank 6-19 - 6-22 6-22.1 Added 6-22.2 Blank 6-23 - 6-27 6-28 6-29 - 6-30 6-31 - 6-33 6-34 Blank

7-1 - 7-15 7-16 - 7-19 7-20 Blank 8-1 - 8-3 8-4 8-5 8-6 - 8-13 8-14 Blank 9-1 - 9-3 Added 9-4 Blank A-1 - A-3 A-4 - A-5 A-6 - A-8 A-9 - A-10 A-11 A-12 - A-18 A-19 - A-21 A-22 - A-23 A-24 A-25 A-26 - A-46 B-1 B-2 - B-3 B-4 - B-5 B-6 - B-9 B-10 - B-15 B-16 B-17 B-18 - B-19 B-20 - B-22 B-23 B-24 - B-33 B-34 - B-39 B-40 - B-42 Glossary 1 Glossary 2 - Glossary 4 Index 1 Index 2 Index 3 Index 4 - Index 6 Index 6.1 Added Index 6.2 Blank Index 7 - Index 8

TO 1-1-691

LIST OF EFFECTIVE PAGES

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 DESTROY SUPERSEDED PAGES.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 margin 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.

USAFA Change 2

TABLE OF CONTENTS

Chapter Page Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . vi

LIST OF TABLES . . . . . . . . . . . . . . . . . . vii

FOREWORD . . . . . . . . . . . . . . . . . . . . . ix

SAFETY SUMMARY . . . . . . . . . . . . . . . xiii

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

1.1 CORROSION CONTROL PRO-

GRAM . . . . . . . . . . . . . . . . . . 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 CORROSION

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 CORRO-

SION . . . . . . . . . . . . . . . . . . . 2-2

2.5.1 Corrosion Under Painted Surfaces . . 2-2

2.6 FACTORS INFLUENCE CORRO-

SION . . . . . . . . . . . . . . . . . . . 2-2

2.6.1 Type of Metal . . . . . . . . . . . . . . . 2-3

2.6.2 Dissimilar Metal Coupling (Galvanic

Corrosion) . . . . . . . . . . . . . . . . 2-3

2.6.3 Anode and Cathode Surface Area . . 2-4

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

2.6.5 Heat Treatment and Grain Direc-

tion . . . . . . . . . . . . . . . . . . . . 2-4

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

2.6.7 Oxygen . . . . . . . . . . . . . . . . . . . 2-4

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

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 Corro-

sion . . . . . . . . . . . . . . . . . . . . 2-7

2.7.7 Corrosion Fatigue . . . . . . . . . . . . . 2-11

2.7.8 Filiform Corrosion . . . . . . . . . . . . 2-11

2.7.9 Fretting Corrosion . . . . . . . . . . . . 2-12

2.7.10 High Temperature Oxidation (Hot

Corrosion) . . . . . . . . . . . . . . . . 2-12

2.8 METALS AFFECTED BY CORRO-

SION . . . . . . . . . . . . . . . . . . . 2-12

2.8.1 Magnesium . . . . . . . . . . . . . . . . . 2-12

2.8.2 Steel . . . . . . . . . . . . . . . . . . . . . 2-13

2.8.3 Aluminum . . . . . . . . . . . . . . . . . . 2-13

2.8.4 Anodized Aluminum . . . . . . . . . . . 2-17

2.8.5 Titanium . . . . . . . . . . . . . . . . . . . 2-17

2.8.6 Copper and Copper Alloys . . . . . . . 2-17

2.8.7 Cadmium . . . . . . . . . . . . . . . . . . 2-17

2.8.8 CRES/Stainless Steel . . . . . . . . . . 2-17

2.8.9 Nickel and Chromium . . . . . . . . . . 2-18

2.8.10 Silver, Platinum, and Gold . . . . . . . 2-18

2.8.11 Graphite/Carbon Fiber Composites . 2-18

2.9 CORROSIVE ENVIRONMENTS . . 2-19

2.9.1 Moisture . . . . . . . . . . . . . . . . . . . 2-19

2.9.2 Temperature . . . . . . . . . . . . . . . . 2-19

2.9.3 Salt Atmospheres . . . . . . . . . . . . . 2-19

2.9.4 Ozone . . . . . . . . . . . . . . . . . . . . 2-19

2.9.5 Other Industrial Pollutants . . . . . . . 2-19

2.9.6 Sand, Dust, and Volcanic Ash . . . . 2-19

2.9.7 Solar Radiation . . . . . . . . . . . . . . 2-20

2.9.8 Climate . . . . . . . . . . . . . . . . . . . 2-20

2.9.9 Factors of Influence in Tropical En-

vironments . . . . . . . . . . . . . . . 2-20

2.9.10 Manufacturing . . . . . . . . . . . . . . . 2-20

2.9.11 Storage . . . . . . . . . . . . . . . . . . . . 2-21

2.9.12 Shipment . . . . . . . . . . . . . . . . . . 2-21

2.9.13 Industrial and Ship Emitted Air Pol-

lutants . . . . . . . . . . . . . . . . . . 2-21

2.9.14 Animal Damage . . . . . . . . . . . . . . 2-21

2.9.15 Micro-Organisms . . . . . . . . . . . . . 2-21

2.10 DEGRADATION OF NON-

METALS . . . . . . . . . . . . . . . . 2-22

2.11 PREVENTIVE MAINTENANCE . . 2-22

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

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

Change 1 i

3.1 PREVENTIVE MAINTENANCE

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

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

SECTION II CLEANING . . . . . . . . . . . . 3-7

3.2 INTRODUCTION . . . . . . . . . . . . 3-7

3.2.1 Reasons for Cleaning . . . . . . . . . . 3-7

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

3.2.3 Aircraft Clear Water Rinse Require-

ments . . . . . . . . . . . . . . . . . . . 3-8

3.2.4 Immediate Cleaning . . . . . . . . . . . 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 So-

lutions . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . 3-30

3.4.4 Turbine Engine Compressor Clean-

ing Equipment . . . . . . . . . . . . . 3-34

3.4.5 Miscellaneous Large Cleaning

Equipment . . . . . . . . . . . . . . . 3-34

3.4.6 Spray Cleaning Guns for Solvents . 3-34

3.4.7 Pneumatic Vacuum Cleaner . . . . . . 3-34

3.4.8 Universal Wash Unit . . . . . . . . . . . 3-34

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

3.4.10 Miscellaneous Equipment . . . . . . . 3-36

3.5 CLEANING PROCEDURES . . . . . 3-37

3.5.1 Warnings and Cautions . . . . . . . . . 3-37

3.5.2 Cleaning Methods . . . . . . . . . . . . 3-40

3.5.3 Clear Water Rinsing of Aircraft . . . 3-47

3.5.4 Post Cleaning Procedures . . . . . . . 3-47

3.5.5 Treatment and Disposal of Wash

Rack Waste . . . . . . . . . . . . . . . 3-48

3.5.6 Fungus Growth Removal . . . . . . . . 3-48

3.5.7 Soil Barriers . . . . . . . . . . . . . . . . 3-49

3.5.8 Bird Strike Cleaning . . . . . . . . . . . 3-50

3.5.9 Bodily Fluids Contamination Clean-

up . . . . . . . . . . . . . . . . . . . . . 3-50.2

SECTION III LUBRICATION . . . . . . . . . 3-50.4

3.6 INTRODUCTION . . . . . . . . . . . . 3-50.4

3.6.1 Conventional Lubricants . . . . . . . . 3-50.4

3.6.2 Solid Film Lubricants . . . . . . . . . . 3-50.4

3.6.3 Application of Conventional Lubri-

cants . . . . . . . . . . . . . . . . . . . 3-51

SECTION IV PRESERVATION . . . . . . . . 3-53

3.7 INTRODUCTION . . . . . . . . . . . . 3-53

3.7.1 Operational Preservation . . . . . . . . 3-53

3.7.2 Non-Operational Preservation . . . . . 3-53

3.7.3 Types of CPC’s . . . . . . . . . . . . . . 3-53

3.7.4 Time Limitations of CPC’s . . . . . . 3-53

3.7.5 Description of CPC’s . . . . . . . . . . 3-56

3.7.6 Preservation of Specific Areas . . . . 3-61

3.7.7 Preservation Application Methods . . 3-61

3.8 APPLICATION OF POLISH AND

WAX . . . . . . . . . . . . . . . . . . . 3-62

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 . 4-4

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

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 . . . . . . . . . . . . . . . 4-8

4.4 DEGREES OF CORROSION . . . . 4-9

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

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

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

SECTION II CORROSION PRONE AR-

EAS . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

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

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

4.5.2 Faying Surfaces and Crevices . . . . 4-10

4.5.3 Spot-Welded Assemblies . . . . . . . . 4-10

4.5.4 Engine Exhaust and Gun Gas Im-

pingement Areas . . . . . . . . . . . 4-11

4.5.5 Wheel Wells and Landing Gear . . . 4-11

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

TO 1-1-691

TABLE OF CONTENTS - CONTINUED

ii Change 2

4.5.7 Engine Frontal Areas and Air Inlet

Ducts . . . . . . . . . . . . . . . . . . . 4-12

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 . . . . . . . . . . . . . 5-9

5.6 SURFACE FINISH . . . . . . . . . . . 5-13

5.7 PITTING ON CRITICAL STRUC-

TURE . . . . . . . . . . . . . . . . . . 5-13

5.8 CORROSION REMOVAL

PROCEDURES-

MECHANICAL . . . . . . . . . . . . 5-13

5.8.1 Warnings and Cautions . . . . . . . . . 5-13

5.8.2 Non-Powered Mechanical Corrosion

Removal . . . . . . . . . . . . . . . . . 5-16

5.8.3 Powered Mechanical Corrosion Re-

moval . . . . . . . . . . . . . . . . . . . 5-17

5.8.4 Abrasive Blasting Corrosion Re-

moval . . . . . . . . . . . . . . . . . . . 5-17

5.9 CORROSION REMOVAL-

CHEMICAL . . . . . . . . . . . . . . 5-18

5.9.1 Aluminum Alloys . . . . . . . . . . . . . 5-18

5.9.2 Magnesium Alloys . . . . . . . . . . . . 5-22

5.9.3 Ferrous Metal (Steel) Alloys Other

Than Stainless Steels (Cres) . . . . 5-23

5.9.4 Stainless Steel (Cres) And Nickel

Based Alloys . . . . . . . . . . . . . . 5-27

5.9.5 Copper And Copper Based Alloys . . 5-31

5.9.6 Titanium and Titanium Based Al-

loys . . . . . . . . . . . . . . . . . . . . 5-33

5.9.7 Plated And Phosphated Surfaces . . . 5-35

SECTION II SURFACE TREATMENT . . . 5-37

5.10 PURPOSE . . . . . . . . . . . . . . . . . 5-37

5.10.1 Chemical Prepaint Treatments . . . . 5-37

5.10.2 Surface Preparation . . . . . . . . . . . 5-39

5.10.3 Precautions . . . . . . . . . . . . . . . . . 5-40

5.10.4 Application of Surface Treatments . 5-40

5.10.5 Notes on Conversion Coating/Sur-

face Treatment . . . . . . . . . . . . . 5-41

5.10.6 Post Treatment . . . . . . . . . . . . . . . 5-42

5.10.7 Temporary Preservation . . . . . . . . . 5-42

SECTION III SHOT PEENING/ROTO-

PEENING . . . . . . . . . . . . . . . . . . . . . . 5-44

5.11 PEENING OF METAL SUR-

FACES . . . . . . . . . . . . . . . . . . 5-44

5.11.1 Types of Peening . . . . . . . . . . . . . 5-44

5.11.2 Roto-Peening (Rotary Flap Peening)

Procedures . . . . . . . . . . . . . . . 5-45

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 . . . . . . . . . . . 6-11

6.3.5 SAE AMS 3255 Oil and Water Re-

sistant, Expanded Polytetrafluoro-ethylene Sealing Tape (EPTFE) Skyflex . . . . . . . . . . . . . . . . . . 6-11

6.3.6 Av-Dec® Polyurethane Sealant

Tapes and Two Component Seal-ants . . . . . . . . . . . . . . . . . . . . 6-11

6.4 EQUIPMENT . . . . . . . . . . . . . . . 6-11

6.4.1 Sealant Gun . . . . . . . . . . . . . . . . 6-11

6.4.2 Application Nozzles . . . . . . . . . . . 6-11

6.4.3 Injection Gun . . . . . . . . . . . . . . . 6-11

6.4.4 Sealant Kits (Semkits®) . . . . . . . . 6-17

6.4.5 Sealant Removal and Application

Tools . . . . . . . . . . . . . . . . . . . 6-18

6.5 SEALANT MIXING . . . . . . . . . . 6-18

6.5.1 Application Life . . . . . . . . . . . . . . 6-19

6.5.2 Storage Instructions . . . . . . . . . . . 6-22.1

6.5.3 Mixing MIL-PRF-81733, Type III

Sprayable Sealant Coating . . . . . 6-22.1

6.6 SEALANT APPLICATION PROCE-

DURES . . . . . . . . . . . . . . . . . 6-22.1

6.6.1 Cleaning . . . . . . . . . . . . . . . . . . . 6-23

6.6.2 Masking . . . . . . . . . . . . . . . . . . . 6-23

6.6.3 Adhesion Promoters . . . . . . . . . . . 6-23

6.6.4 Brush Spatula or Caulking Gun Ap-

plication . . . . . . . . . . . . . . . . . 6-23

TO 1-1-691

TABLE OF CONTENTS - CONTINUED

Change 2 iii

6.6.5 Spray Gun Application . . . . . . . . . 6-24

6.6.6 Peel and Stick Application; AMS

3255 EPTFE Skyflex® and Av- Dec® HT3935-7 and HT3000 Sealing Tapes . . . . . . . . . . . . . 6-24

6.7 SEALING OF SPECIFIC AREAS . 6-25

6.7.1 Faying Surface Sealing . . . . . . . . . 6-25

6.7.2 Fillet Sealing . . . . . . . . . . . . . . . . 6-26

6.7.3 Injection Sealing . . . . . . . . . . . . . 6-26

6.7.4 Fastener Sealing . . . . . . . . . . . . . . 6-26

6.7.5 Integral Fuel Cells/Tanks and Re-

movable Fuel Tanks . . . . . . . . . 6-27

6.7.6 Form-In-Place (FIP) Gasket Sealant

Repair . . . . . . . . . . . . . . . . . . 6-27

6.7.7 SAE AMS 3255 EPTFE (Skyflex®)

and Av-Dec® HT3000 and HT3935-7 Sealing Tape Gasket Repair . . . . . . . . . . . . . . . . . . 6-27

6.7.8 External Aircraft Structure . . . . . . . 6-29

6.7.9 Depressions . . . . . . . . . . . . . . . . . 6-29

6.7.10 Damaged Sealant . . . . . . . . . . . . . 6-29

6.7.11 Extensive Repair . . . . . . . . . . . . . 6-30

6.7.12 High Temperature Areas . . . . . . . . 6-30

6.7.13 Low Temperature Curing . . . . . . . . 6-30

6.8 STORAGE/SHELF LIFE CON-

TROL OF SEALANTS . . . . . . . 6-30

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

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

7.2 BATTERY COMPARTMENTS,

BOXES, AND ADJACENT AR-

EAS . . . . . . . . . . . . . . . . . . . . 7-1

7.2.1 Preparation of Solutions for Clean-

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

7.2.2 Cleaning and Neutralizing Proce-

dures . . . . . . . . . . . . . . . . . . . 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) Hard-

ware . . . . . . . . . . . . . . . . . . . . 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 Connec-

tions . . . . . . . . . . . . . . . . . . . . 7-7

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

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

7.11.4 Corrosion Protection for Electrical

Connectors, Lead-ins, etc . . . . . 7-7

7.11.5 Moisture and Fungus Proofing of

Electrical and Electronic Equip-ment . . . . . . . . . . . . . . . . . . . 7-7

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

7.12 STRUCTURAL TUBING MEM-

BERS AND ASSEMBLIES . . . . 7-7

7.12.1 Structural Aluminum Alloy Tubing . 7-7

7.12.2 Structural Magnesium Alloy Tub-

ing . . . . . . . . . . . . . . . . . . . . . 7-8

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 ASSEM-

BLIES . . . . . . . . . . . . . . . . . . 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 . . . . 7-9

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) . . . . . 7-10

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 REQUIRE-

MENTS . . . . . . . . . . . . . . . . . 7-11

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

7.17.2 Long Term Storage . . . . . . . . . . . . 7-11

TO 1-1-691

TABLE OF CONTENTS - CONTINUED

iv Change 2

7.18 DEPLETED URANIUM

COUNTER-WEIGHTS . . . . . . . 7-12

7.18.1 Corrosion and Finish Damage Treat-

ment Procedures . . . . . . . . . . . 7-12

7.19 MONEL RIVETS . . . . . . . . . . . . . 7-13

TO 1-1-691

TABLE OF CONTENTS - CONTINUED

Change 2 iv.1/(iv.2 blank)

7.20 BERYLLIUM-COPPER ALLOYS,

BERYLLIUM-ALUMINUM AL-

LOYS, AND BERYLLIUM OX-

IDE . . . . . . . . . . . . . . . . . . . . 7-13

7.20.1 Corrosion Removal and Treatment . 7-13

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

7.21 EMI SEALS AND GASKETS . . . . 7-14

7.21.1 Treatment of EMI Seals and Gas-

kets . . . . . . . . . . . . . . . . . . . . 7-14

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

8.3.3 Emergency Reclamation Equip-

ment . . . . . . . . . . . . . . . . . . . 8-2

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

8.4 GENERAL PROCEDURES . . . . . . 8-2

8.4.1 Removal of Contaminated Installed

Equipment . . . . . . . . . . . . . . . 8-5

8.4.2 Disassembly/Removal of Compo-

nents . . . . . . . . . . . . . . . . . . . 8-5

8.4.3 Clean . . . . . . . . . . . . . . . . . . . . . 8-5

8.4.4 Tagging . . . . . . . . . . . . . . . . . . . 8-5

8.5 GENERAL CLEANING PROCE-

DURES . . . . . . . . . . . . . . . . . 8-5

8.5.1 Primary Method . . . . . . . . . . . . . . 8-5

8.5.2 Alternate Methods . . . . . . . . . . . . 8-6

8.5.3 Removing O-D-1407 Potassium Bi-

carbonate (Purple K Powder/PKP or Other Dry Chemical Fire Ex-tinguishing Agents . . . . . . . . . . 8-6

8.5.4 Removing MIL-F-24385 Aqueous

Film Forming Foam (AFFF) Fire Extinguishing Agent . . . . . . . . . 8-7

8.5.5 Removal of Carbon Dioxide (CO2), HFC-125, or Halon Fire Extin-guishing Agents . . . . . . . . . . . . 8-7

8.5.6 Removal of Protein Type Foam and

Soda-Acid Fire Extinguishing Agents . . . . . . . . . . . . . . . . . . 8-7

8.5.7 Treatment After Landing on a

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

8.5.8 Treatment After Exposure to Volca-

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

8.6 SPECIFIC INTERNAL AREAS . . . 8-8

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

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

8.6.3 Avionic, Electronic and Electrical

Equipment . . . . . . . . . . . . . . . 8-9

8.6.4 Photographic Equipment . . . . . . . . 8-9

8.6.5 Graphite or Carbon Fiber/Epoxy, Boron Fiber/Epoxy, and Tungsten Fiber/Epoxy Composite Materi-als . . . . . . . . . . . . . . . . . . . . . 8-9

8.7 SPECIFIC EXTERNAL AREAS OF

AIRCRAFT . . . . . . . . . . . . . . . 8-10

8.7.1 Airframes . . . . . . . . . . . . . . . . . . 8-10

8.7.2 Antennas . . . . . . . . . . . . . . . . . . 8-10

8.7.3 Reciprocating Engines . . . . . . . . . 8-10

8.7.4 Turbine Engines . . . . . . . . . . . . . . 8-11

8.7.5 Treatment for Engines Which Have

Ingested Fire Extinguishing Pow-der (Purple K/PKP, Aqueous Film Forming Foam (AFFF), and/or Sodium Bicarbonate) . . . . . . . . 8-11

8.7.6 Helicopter Transmission, Rotor

Head, and Rotor Hub . . . . . . . . 8-11

8.7.7 Helicopter Main and Tail Rotor

Blades . . . . . . . . . . . . . . . . . . 8-12

8.7.8 Armament . . . . . . . . . . . . . . . . . . 8-12

8.7.9 Aircraft Fuel Systems . . . . . . . . . . 8-13

9 SOUTHWEST ASIA ENVIRONMENTS . . . 9-1

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

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

9.1.2 Aircraft Wash . . . . . . . . . . . . . . . 9-2

9.1.3 Aircraft Clear Water Rinse (CWR) . 9-2

9.1.4 Effects of Desert Environment . . . . 9-2

9.2 PRE-DEPLOYMENT RECOM-

MENDATIONS . . . . . . . . . . . . 9-2

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 . . 9-3

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

9.5 CORROSION PREVENTIVE COM-

POUNDS (CPC’s) . . . . . . . . . . 9-3

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

APPENDIX A CONSUMABLE MATERI-

ALS . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

APPENDIX B EQUIPMENT FOR

CLEANING AND CORROSION PRE-

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

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

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

TO 1-1-691

TABLE OF CONTENTS - CONTINUED

Change 1 v

LIST OF ILLUSTRATIONS

Figure Title Page Figure Title Page

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

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 Adjacent 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

Aluminum Adjacent to Steel Fastener . . . . . . . . . . . . . . . . . . . . 2-7

2-12 Example of Exfoliation . . . . . . . . . . . 2-7 2-13 Another Example of Exfoliation . . . . . 2-8 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 . . . . . . . . . . . . . . . . . . . . . 2-12

2-19 Magnesium Corrosion Products . . . . . . 2-13 2-20 Steel Corrosion Products (Rust) . . . . . . 2-14 2-21 Aluminum Surface Corrosion Products . 2-15 2-22 Cadmium Plated Surface Conditions . . 2-16 2-23 Failed Chromium Plating . . . . . . . . . . 2-18 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 . . . . . . . . . . . . . 3-33 3-4 Top Loading Type . . . . . . . . . . . . . . . 3-36 3-5 Front Loading Type . . . . . . . . . . . . . . 3-37 3-6 Use of Aircraft Washing Applicator . . . 3-41 3-7 Aircraft Cleaning Procedure . . . . . . . . 3-42 3-8 Automatic Water Spray Nozzle . . . . . . 3-45 4-1 Depth Dimension of Corrosion Pits . . . 4-3 4-2 Fiber Optic Borescope . . . . . . . . . . . . 4-4 4-3 Optical Depth Micrometer (Analog

Mechanical Read Out Type) . . . . . . 4-7 4-4 Optical Depth Micrometer (Digital Read

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

4-5 Typical Use of a Straight Edge to Determine if Suspect Areas Have Been Previously 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 . . . . . . . . . . . . . . . . . 4-12 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 . . 4-13 4-13 Flaps Lowered to Expose Recess

Areas . . . . . . . . . . . . . . . . . . . . . 4-13 4-14 Reciprocating Engine Frontal Area

Corrosion 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 . . . . . . . . . . . . . . . . . . . . 5-5 5-2 Abrasive Flap Wheels with Spindle

Mount . . . . . . . . . . . . . . . . . . . . . 5-5 5-3 3M Co. Radial Bristle Disc . . . . . . . . . 5-6 5-4 3M Co. Roloc Discs . . . . . . . . . . . . . 5-6 5-5 3M Co. Inline Bristle Disc . . . . . . . . . 5-8 5-6 Abrasive Blasting Equipment . . . . . . . 5-10 5-7 Shaping Reworked Areas . . . . . . . . . . 5-15 5-8 Acceptable Clean-up of Pitting

Corrosion on Critical Structure . . . . 5-15 5-9 Limited Clearance . . . . . . . . . . . . . . . 5-16 5-10 A Water-Break Free Surface Compared with One with Breaks . . . . . . . . . . 5-41 5-11 Peening Intensity Conversion Graph (Isp to Irp) . . . . . . . . . . . . . . . . . . . . . 5-48 5-12 Saturation Coverage Curves for

MIL-W-81840, Type I Wheels . . . . . 5-49 5-13 Saturation Coverage Curves for

MIL-W-81840, Type II Wheels (Flaps) . . . . . . . . . . . . . . . . . . . . . 5-50

5-14 Flap De ection Ranges . . . . . . . . . . . 5-51 6-1 Pneumatic Sealant Gun . . . . . . . . . . . 6-12 6-2 Sealant Application Nozzles . . . . . . . . 6-13 6-3 Countersink Application Nozzles . . . . . 6-14 vi Change 1

6-4 Rivet Application Nozzles . . . . . . . . . 6-15 6-5 Sealant and Adhesive Smoothing Tools . 6-16 6-6 Sealant Injection Guns . . . . . . . . . . . . 6-17 6-7 Injection Style Semkit® . . . . . . . . . . . 6-18.1 6-8 Non-metallic Spatula . . . . . . . . . . . . . 6-24 6-9 Faying Surface Sealing . . . . . . . . . . . 6-26 6-10 Typical Fillet Seal . . . . . . . . . . . . . . . 6-27 6-11 Typical Injection Seal . . . . . . . . . . . . 6-28 6-12 Typical Methods of Sealing Fasteners . . 6-28 6-13 Typical Lap Skin Sealing . . . . . . . . . . 6-30 6-14 Sealing Procedures for Typical Aircraft

Fitting . . . . . . . . . . . . . . . . . . . . . 6-31 6-15 Typical Spar Cap Sealing . . . . . . . . . . 6-32 6-16 Sealing of Access Doors . . . . . . . . . . 6-33 7-1 Beryllium-Copper Spiral Contact With

Environmental Fluorosilicone Seal . . 7-15

7-2 Dorsal Longeron EMI Seal . . . . . . . . . 7-16 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 . . . . . . 9-1 9-2 Global Dust Producing Regions . . . . . . 9-2 9-3 Open Circuit Board . . . . . . . . . . . . . . 9-3 B-1 Back Mounted Full Facepiece

Respirator . . . . . . . . . . . . . . . . . . B-40 B-2 Front Mounted Full Facepiece

Respirator . . . . . . . . . . . . . . . . . . B-41 B-3 Hooded Air Respirator System . . . . . . B-42

LIST OF TABLES

Table Title Page Table Title Page

2-1 Corrosion of Metals - Type of Attack and Appearance of Corrosion Products . . . 2-16

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

Components . . . . . . . . . . . . . . . . . . 3-12 3-3 Recommended Dilution of Low

Temperature Cleaner . . . . . . . . . . . . . 3-46 3-4 Common Military Greases the Their

Uses . . . . . . . . . . . . . . . . . . . . . . . . 3-52 3-5 Time Limitations for CPC’s . . . . . . . . . . 3-54 3-6 Corrosion Preventive Compounds . . . . . . 3-54 3-7 Preservation of Specific Areas and

Components . . . . . . . . . . . . . . . . . . 3-57 4-1 NDI Inspection Tools for Various Types of

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

Corrosion Removal . . . . . . . . . . . . . . 5-11 5-4 Recommended Non-Powered Abrasives for

Corrosion Removal . . . . . . . . . . . . . . 5-12 5-5 Typical Chemical Corrosion Removal

Procedures For Aluminum Alloy Parts and Assemblies . . . . . . . . . . . . . . . . 5-20

5-6 Typical Chemical Corrosion Removal Procedures for Magnesium Alloys . . . . 5-23

5-7 Typical Chemical Corrosion Removal Procedures for Ferrous Metals Other Than Stainless Steel (CRES) . . . . . . . 5-27

5-8 Typical Chemical Corrosion Removal Procedures for Stainless Steel (CRES) and Nickel Based Alloys . . . . . . . . . . 5-29

5-9 Control of Corrosion Removal/ Pickling Action of Nitric-Hydrofluoric Acid Solutions . . . . . . . . . . . . . . . . . . . . 5-31

5-10 Typical Chemical Corrosion Removal Procedures for Copper and Copper Alloys . . . . . . . . . . . . . . . . . . . . . . 5-33

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

5-12 Typical Chemical Corrosion Removal Procedures for Plated and Phosphated Surfaces . . . . . . . . . . . . . . . . . . . . . 5-37

5-13 Prepaint Treatments for Metal Surfaces . . 5-42 5-14 Tool Operation Speed Requirements . . . . 5-46 5-15 Standard Peening Intensity (Isp) for

Complete Coverage Arc-Height in Inches . . . . . . . . . . . . . . . . . . . . . . 5-46

6-1 Sealing Compounds . . . . . . . . . . . . . . . 6-3 6-2 Time Requirements for Sealants When

Used At 75 Degree F (24 Degree C) and 50 Precent RH . . . . . . . . . . . . . . 6-19

8-1 Priority Guide for Emergency Treatment of Aircraft, Missiles, & Equipment . . . 8-2

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

A-1 Units 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 ILLUSTRATIONS - CONTINUED

Figure Title Page Figure Title Page

Change 2 vii/(viii 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.

1.1 Usage. 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 aircraft, missile, or equipment manual, the system specific manual shall take precedence over this manual. Paragraph 5 lists related tech-nical publications used by personnel involved in cleaning and corrosion control.

2 SCOPE.

The material in this manual provides basic cleaning, corro-sion prevention and control, and corrective maintenance information to be used at organizational, intermediate, and depot levels. This manual is divided into a foreword, safety summary, eight chapters, two appendices, a glossary, and an alphabetical index.

2.1 Foreword. This Foreword explains the purpose, responsibility for changing this manual, and presents the scope and outlay of the manual.

2.2 Safety Summary. This Safety Summary provides

general safety precautions personnel shall use during all phases of operations and maintenance.

2.3 Chapter 1, Introduction. This chapter explains the

appropriate usage of this manual.

2.4 Chapter 2, Corrosion Theory. This chapter ex-

plains what corrosion is, why it occurs, the various forms it can take, and how to recognize it.

2.5 Chapter 3, Preventive Maintenance. This chapter

outlines accepted 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 related equipment.

2.6 Chapter 4, Inspection and Corrosion Prone Ar-

eas. This chapter describes inspection techniques for detecting corrosion in Section I and discusses corrosion prone areas in Section II.

2.7 Chapter 5, Corrosion Removal and Surface Treat-

ment. This chapter outlines the approved methods for the removal of corrosion damage in Section I and the application of surface treatments in Section II.

2.8 Chapter 6, Sealants. This chapter covers recom-

mended materials and procedures for the application of sealing compounds to aircraft, missile, and related equipment structures.

2.9 Chapter 7, Treatment of Specific Areas. This

chapter describes the recommended procedures for treating and protecting against corrosion in specific areas.

2.10 Chapter 8, Emergency Procedures. This chapter

outlines emergency procedures to be followed after exposure of aircraft to salt water, fire extinguishing chemicals, etc.

2.11 Appendix A, Consumable Materials. This appen-

dix lists the recommended materials for cleaning, corrosion prevention, surface treatment, and preservation of aircraft, missiles, and related equipment.

2.12 Appendix B, Equipment for Cleaning and Corro-

sion Prevention and Control. This appendix lists equip-ment used for cleaning, corrosion removal, conversion coat-ing, and sealing of aircraft, as well as associated safety equipment including personal protective equipment (PPE) for these operations.

2.13 Glossary. The glossary defines terms commonly

used by personnel performing aircraft, missile, and equip-ment cleaning and corrosion prevention and control.

2.14 Alphabetical Index. This index locates specific

subjects in the manual.

Change 1 ix

3 ABBREVIATIONS AND ACRONYMS.

This manual contains standard and non-standard abbrevia-tions. The standard abbreviations are in accordance with

ASME Y14.38.

AFCPCO Air Force Corrosion Prevention and Control Office

AFFF Aqueous Film Forming Foam AISI American Iron and Steel Institute BOD Biological Oxygen Demand CaCO3 Calcium Carbonate CBR Chemical, Biological, Radiological CFM Cubic Feet per Minute CPC Corrosion Preventive Compounds CRES Corrosion Resistant Steels CWR Clear Water Rinse °C Degrees Celsius °F Degrees Fahrenheit 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 IAW In Accordance With ID Inside Diameter in Inch KSI Kilograms per Square Inch LG Landing Gear LOX Liquid Oxygen MEK Methyl Ethyl Ketone 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 % Percent pH Potential of Hydrogen

PMF Pre-Mixed and Frozen PPE Personal Protective Equipment ppm Parts Per Million QPL Qualified Products List RH Relative Humidity RTU Ready To Use SE Support Equipment SPD System Program Director SPM System Program Manager TDS Total Dissolved Solids TNP Touch-N-PrepTM

TPH Total Petroleum Hydrocarbon TSS Total Suspended Solids

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/MLS-OLR, 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@ robin-s.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.in-dustrialbackhop@ robins.af.mil.

4.1 Recommended Changes, Corrections, or Dele-

tions. All activities using this manual are invited to submit recommended modifications, additions, or deletions. Use the current reporting system in TO 00-5-1 to submit these changes to WR-ALC/LESGI.

5 RELATED PUBLICATIONS.

List of Related Publications

Number Title DOD 6050.5LR Hazardous Material Control and Management

(HMC&M)

AFI 32-1067 Water Systems AFI 32-7080 Pollution Prevention Pro-gram AFI 40-201 Managing Radioactive Ma-terials in the U.S. Air Force

AFM 23-110, Vol.7,Pt.3 Inspection and Control of USAF Shelf Life Equip-ment x

List of Related Publications - Continued

Number Title AFM 88-11 Sanitary and Industrial

Waste Water Collection AFM 91-11 Solid Waste Management AFOSH STD 91-501 Air Force Consolidated

Occupational Safety Standard

AFP 85-14 Commanders Facility Im-provement Guide

MIL-HDBK-729 Corrosion and Corrosion Prevention-Metals

TO 00-5-1 AF Technical Order System TO 00-20-1 Aerospace Equipment

Maintenance Inspection, Documentation, Policy and Procedures

TO 00-20-2 Maintenance Data Docu-mentation

TO 00-25-107 Maintenance Assistance TO 00-25-172 Ground Servicing of Air-craft and Static Ground-ing/Bonding

TO 00-25-234 General Shop Practice Re-quirements for the Re-pair, Maintenance, and Test of Electronic Equip-ment

TO 00-25-235 Safety Procedures and Equipment For Confined Space Entry (Including Missile Propellant Tanks)

TO 00-35D-54 USAF Material Deficiency Reporting and Investigat-ing System

TO 00-85-3 Corrosion Control for Pack-aging

TO 00-85A-03-1 Preservation, Packaging and Packing - External Air-craft 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, Aerospace and Non- Aerospace Equipment

List of Related Publications - Continued

Number Title TO 1-1-17 Storage of Aircraft and

Missiles Systems TO 1-1-24 Maintenance Repair and

Electrical Requirements for Fiberglass Airborne Radomes

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

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

1-1-689-5 Cleaning and Corrosion Control, Volume IV, 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 Repair

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 Transpar-ent Plastic

TO 1-1A-14 Installation Practices for Aircraft Electric and Electronic Wiring

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

TO 2-1-11 Corrosion Control of En-gine Parts During Over-haul and Field Level Maintenance, Reciprocat-ing, Turbojet, and Gas Turbine Aircraft Engines

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

Change 2 xi

List of Related Publications - Continued

Number Title 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 Aircraft 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 2R-1-11 Corrosion Control - Recip-rocating Aircraft Engines

TO 2R-1-84 Cleaning of Reciprocating Engines and Parts

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

TO 4S-1-182 General O/H & Mainte-nance Instr. All FSC 1620 Landing 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, Inspec-tion and Testing Aircraft Safety Belts, Shoulder Harness, and Miscella-neous Personnel Restraint Equipment.

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

List of Related Publications - Continued

Number Title 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, Painting, and Marking of USAF Support Equip-ment (SE)

TO 35-1-4 Processing and Inspection of Support Equipment for Storage and Shipment

TO 35-1-12 Compounds and Procedures for Cleaning Aerospace Ground Equipment

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

TO 42A1-1-1 Evaluation and Service Testing of Materials - Cleaning, Painting, Seal-ing, Protective Treating, Anti-Corrosion, Inspec-tion Materials, and Re-lated Items

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

TO 42B-1-6 Corrosion Preventive Lubri-cants and Anti-Seize Compounds

TO 42C-1-2 Anti-Icing, Deicing, and Defrosting of Parked Air-craft

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

TO 42C2-1-7 Electro deposition of Met-als and Metal Surface Treatments to meet Air Force Maintenance Requirements.

xii Change 1

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 operating 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 injury to, or death of, personnel or long term health hazards.

Highlights an essential operating or maintenance procedure, practice, condition, statement, etc., which if not strictly observed, could result in damage to, or destruction of, equipment or loss of mission effectiveness.

NOTE

Highlights an essential operating or maintenance procedure, condition or statement.

3 SAFETY PRECAUTIONS.

The following safety precautions shall be observed while performing procedures in this manual.

• Some cleaning materials specified herein are flam-mable and/or toxic. Keep away from open flame or other ignition sources. Do not use synthetic wiping cloths with flammable solvents. Open all circuit breakers associated with battery power prior to ap-plication of any flammable solvent. Provide adequate ventilation and avoid skin/eye contact. Wear Personal Protective Equipment (PPE). Consult the Material Safety Data Sheets (MSDS) for specific information on hazards, effects and protective equipment require-ments.

• Some cleaning processes described herein use mate-rials and generate effluent that may be hazardous to personnel and the environment. Contact the local bioenvironmental engineer and safety office for guid-ance on PPE and other health and safety precautions, and waste disposal.

• Some cleaning operations described herein utilize power tool operations and abrasive blasting opera-tions which often generate toxic/hazardous airborne particles. Always wear proper PPE.

• Ensure that all electrical power is disconnected and all systems in aircraft, missiles, or equipment are deactivated before starting cleaning operations on avionics, electronics, or electrical equipment to pre-vent electrical shock.

• Remove jewelry and remove/cover loose fitting clothing before operating power equipment to pre-vent entanglement and injury.

• Cleaning with compressed air can create airborne particles that may enter eyes or penetrate skin.

Pressure shall not exceed 30 PSIG. Wear goggles. Do not direct compressed air against skin.

• Depleted uranium is extremely toxic and shall be worked only under a license from the Nuclear Regu-latory Agency (NRA). Machining or other work, such as surface sanding, may be done only by the licensee. No drilling, sanding, abrasive blasting, or other mechanical work is permitted on depleted uranium by any field level (organizational or inter-mediate) maintenance activity. If the protective finish (plating) which covers the depleted uranium is chipped, peeled, or otherwise removed so the dark gray or black uranium oxide is visible, the part must be returned to the licensee for rework or disposal.

Packaging and shipping procedures shall conform to AFI 40-201 and any other related current regulations for handling radioactive materials.

xiii/(xiv blank)

CHAPTER 1

INTRODUCTION

1.1 CORROSION CONTROL PROGRAM.

All activities responsible for maintenance of aircraft, mis-siles, and related equipment shall establish corrosion preven-tion and control programs as required by AFI 21-105. The type of program depends upon the environment to which the aircraft, missile, or equipment may be exposed. Aircraft, missiles, and equipment may be exposed to industrial gases, salts, rain, mud, and mists containing sea salts if located near salt water.