B-M101.pdf

CAGE 77751

B-M101

Revision D 05 August 2015 ii

TABLE OF REVISIONS

Revision Changes Reason for Change Approved

Original issue Original issue. - -

Revision A

Incorporated amendments and added second procurement sources.

To comply with requirements of contract. Added Note 3 to Table 2.

H. Kleindienst

Revision B 02/05/88

This revision incorporated the following:

(a) Amendments A1, A2, and A3 with modification and A4.

(b) Established grade classification;

added Grade 25.

(c) Reformatted in accordance with RA900Y1200 Appendix B.

(d) Revised Qualified Products List

NOTE: Revision B supersedes the Fairchild Republic Company issues.

Required updating. G. Leavy

Revision C 03/07/97

Reviewed specification for ozone depleting substances (ODSs) and hazardous air pollutants (HAPs).

To comply with requirements of the contract.

G. Leavy

Reformatted all tables. To improve clarity.

Added Foreword. To describe the review of this specification for toxins, pollutants and other hazardous materials, and establish user responsibility for following all laws and regulations involving their use.

Added Note 3 to Table 2. To require vapor degreasing to be accomplished in accordance with all applicable Federal, state and local environmental regulation, and using required emission controls.

iii

Revised Table 3, Qualified Products List, as follows:

Deleted Thermoform 3050 from QPL as it is no longer manufactured due to asbestos in product. Deleted FM41 due to asbestos in product. Manufacturer of FM410 adhesives was American Cyanamid; is now Cytec Engineered Materials; added address. Under AF 3024 adhesive, added Scotch-Weld designation to part number, noted proper division of 3M and added their corporate headquarters address.

To delete obsolete materials, delete materials containing asbestos, a known carcinogen, update corporate identities and add their full addresses for ease of contact.

Revision D 08/05/15

Revised Table IV referenced in Section1.0.

To agree with updated table. S. Miro

Revised Type II operating temperature description in Section 1.1.1.

To agree with supplier operating temperature data.

Updated specification callouts and titles in Section 2.1.

To agree with the latest government specs.

Updated Northrop Grumman specification titles in Section 2.2.

To clarify process description.

Clarified storage life in Section 3.5. To clarify when storage life begins.

Added Section 3.5.2. To include requirements for retest of material exceeding its storage life.

Defined Table II values as average. To clarify values in Table II.

Added purchaser receiving inspection tests per Table III.

In concurrence with Air Force comments.

Added Section 4.4 description of purchaser receiving inspection tests.

To clarify purchaser receiving inspection test requirements.

Revised wording of Section 4.5.4.2. In concurrence with Air Force comments to include an alternate cleaning process for tube shear testing.

Revised Qualified Products List as Table IV and revised supplier addresses.

In concurrence with supplier comments.

iv

Added Henkel MA-562 to the Qualified Products List for Grade 50.

Per Air Force Engineering Order

EO04C0163.

Air Force Engineering Order EO11A1372-H superseding Northrop Grumman specification B- M101 with Boeing material specification BMS-5-90V was purposely not incorporated.

The Air Force continues to purchase expandable adhesive to Northrop Grumman material specification, B-M101, for A-10 parts.

v

TABLE OF CONTENTS

TABLE OF REVISIONS ........................................................................................................ ii

LIST OF TABLES ................................................................................................................ vi

LIST OF FIGURES ............................................................................................................. vii

FOREWORD ..................................................................................................................... viii

1.0 SCOPE

1.1 Classification

2.0 APPLICABLE DOCUMENTS

2.1 Industry Specifications

2.2 A-10 Program Specifications

3.0 REQUIREMENTS

3.1 Materials

3.2 Cure Cycle for Determining Product Characteristics

3.3 Properties

3.4 Service Temperature

3.5 Storage Life

3.6 Toxicity and Safety

3.7 Marking of Exterior Package

3.8 Workmanship

3.9 Qualification

4.0 QUALITY ASSURANCE PROVISIONS

4.1 Responsibility for Inspection

4.2 Qualification Testing

4.3 Acceptance (Supplier Conformance) Tests

4.4 Purchaser Receiving Inspection Tests

4.5 Test Methods

5.0 PREPARATION FOR DELIVERY

5.1 Sheet Adhesive

5.2 Packaging

5.3 Exterior Packaging

6.0 DEFINITIONS

6.1 Batch

6.2 Lot

vi

LIST OF TABLES

Table I: Physical Properties, Grades 25 and 50

Table II: Mechanical Properties, Types I and II

Table III: Purchaser Receiving Inspection Tests

Table IV: Qualified Products List vii

LIST OF FIGURES

Figure 1: Peak Exotherm and Sagging Test Specimen

Figure 2: Tube Shear Curing and Test Fixtures viii

FOREWORD

This specification has been reviewed for EPA 17 toxic chemicals, SARA 313-listed pollutants, as well as ozone depleting substances. No ozone depleting substances were found.

Hazardous air pollutants and toxic materials have been eliminated or minimized to comply with the Air Force Pollution Prevention Program, AFI 32-7080. A reasonable effort has been made to eliminate rather than minimize pollutants and to use environmentally acceptable substitutes. Certain substitutions, however, have not been made due to their potential unknown deleterious effects on the A-10 weapon system.

It must be understood that the materials, methods, applications and processes can contain toxic and hazardous materials. It is the responsibility of the user to ensure safe and proper use in accordance with all applicable OSHA, EPA, Federal, state and local regulations.

1.0 SCOPE

This specification establishes the requirements for expandable adhesive systems for use in splicing honeycomb core materials, for core-to-edge member bonding, or for local densification of honeycomb core and bonding of inserts. Only materials listed in the Qualified Products List, Table IV, shall be purchased in accordance with this specification.

1.1 Classification

The expandable adhesive shall be of the following types and grades.

1.1.1 Types

Type I For use from –65°F to 180°F

Type II For use from –65°F to 300°F

1.1.2 Grades

The grade indicates the nominal unexpanded and uncured thickness of the adhesive film.

Grade 25 0.025”

Grade 50 0.050”

2.0 APPLICABLE DOCUMENTS

The following documents form a part of this specification to the extent specified herein. The revision level of these documents at the time of contract will apply, unless otherwise specified. In the event of conflict between the documents referenced herein and the contents of this specification, the contents of this specification shall be considered a superseding requirement.

2.1 Industry Specifications

2.1.1 ASTM Specifications

ASTM-D4126 Vapor Degreasing Grade and General Solvent Grade 1,1,1- Trichloroethane

2.1.2 SAE AMS Specifications

SAE-AMS-QQ-A-250/4 Aluminum Alloy 2024, Plate and Sheet

SAE-AMS-WW-T-700/4 Tube, Aluminum Alloy, Drawn, Seamless, 5052

2.2 A-10 Program Specifications

S-F501 Bonding (250°F), Structural Adhesive-Sandwich/Laminates, Aluminum Alloy

A-F501 Bonding (350°F), Structural Adhesive-Sandwich/Laminates, Aluminum Alloy

3.0 REQUIREMENTS

3.1 Materials

3.1.1 If a grade is not specified on the applicable Engineering drawing, Grade 50 shall be used.

3.1.2 The adhesive supplied to this specification shall be suitable for splicing non-metallic and metallic core without damage to core node bonds adjacent to the splice.

3.1.2.1 The adhesive shall be supplied as unsupported sheets, with suitable non-adhering separator film on both surfaces.

3.1.3 The expandable adhesive shall be formulated using epoxy-type resin containing foaming and curing agents, fillers, pigments and reinforcements as necessary to meet the requirements of this specification.

3.2 Cure Cycle for Determining Product Characteristics

The adhesive shall be capable of meeting the requirements noted herein with a heat-up rate schedule of 2°F to 5°F per minute. Type I adhesives shall be cured for 60 ± 10 minutes at 250°F ± 10°F. Type II adhesives shall be cured for 60 ± 10 minutes at 350°F ± 10°F. The circulating-air oven shall not be over 90°F at the start of the cure cycle.

3.3 Properties

3.3.1 Physical properties shall conform to the requirements of Table I after exposure to 90°F for a period of 240 hours.

3.3.2 Mechanical properties shall conform to the requirements of Table II after exposure to 90°F for a period of 240 hours.

3.4 Service Temperature

Products qualified to this specification shall be capable of functioning in the normal aircraft environment and over the temperature range of –65°F to 180°F for Type I, and –65°F to 300°F for Type II.

3.5 Storage Life

Products qualified to this specification shall be capable of meeting all the requirements noted herein after storage of 6 months at 0°F or below from date of receipt.

Table I: Physical Properties, Grades 25 and 50

Property Grade 25 Grade 50

Thickness, inches, nominal 0.025 ± 0.005 0.050 ± 0.005

Weight–Uncured Sheet, lbs./sq. ft., maximum 0.190 0.380

Slump/Sagging, inches, maximum 0.25 0.25

Expansion Ratio 1.5–3.5 1.5–3.5

Density–Cured, lbs./cu. ft., maximum 45 45

Exotherm, °F, maximum 550 550

Volatiles, Percent, maximum 1 1

Table II: Mechanical Properties, Types I and II

Tube Shear, psi at °F 1/, 2/ Average Values

Type I Type II

–67 700 700

75 600 700

180 450 600

250 200 600

350 - 100

75 3/ 500 700

75 4/ 600 700

1/ Minimum of 5 specimens shall be tested for each condition.

2/ Minimum individual values shall not be less than 85% of average values.

3/ Three-day water boil then test at 75°F.

4/ Vapor degrease per ASTM D4126 for 30 minutes then dry at 250°F for

30 minutes and test at 75°F.

3.5.1 Work Life

Products qualified to this specification shall be capable of meeting all the requirements noted herein after exposure to 90°F for a period of 240 hours.

3.5.2 Retesting of Procured Material that has Exceeded its Initial Storage Life

After the initial 6-month storage life, the expandable adhesive may be revalidated for an additional 3-month storage life. The maximum shelf life at 0°F or below, which includes supplier shelf life, shall be 9 months from the date of manufacture. The adhesive shall meet the requirements of Table I for expansion ratio and cured density and Table II for tube shear when tested at room temperature. Test three (3) specimens per test method.

3.6 Toxicity and Safety

This material may cause minor skin irritation and should be handled only when wearing gloves.

3.7 Marking of Exterior Package

Each exterior shipping container shall be legibly marked with the following information in such a manner that the markings shall not smear or be obliterated during normal handling or use:

ADHESIVE, EXPANDABLE, HONEYCOMB CORE SPLICE, TYPE AND GRADE

A-10 SPEC. NO., REVISION AND AMENDMENT

PURCHASE ORDER

MANUFACTURER'S MATERIAL DESIGNATION

DATE OF MANUFACTURE

LOT NUMBER

QUANTITY

PERISHABLE – STORE BELOW 0°F

3.8 Workmanship

The product shall be uniform in quality and condition, smooth, homogeneous, and free from foreign materials and imperfections detrimental to fabrication, appearance or performance of parts, and shall meet all the Quality Assurance requirements of this specification.

3.9 Qualification

3.9.1 The foaming adhesive furnished under this specification shall be a product that has been tested and has met all the requirements specified herein (see Table III), and has been listed on the Qualified Products List.

3.9.2 Sample material shall be approved by the purchaser before material for production is supplied, unless such approval is waived. Results of tests on production material shall be equivalent to those on the approved sample.

3.9.3 The supplier shall use ingredients, manufacturing procedures, processes, and methods of inspection on production material that are the same as those used on the approved sample material. If any change is necessary in ingredients, in type of equipment for processing, or in manufacturing procedures that could affect quality or properties of the material, the supplier shall submit samples for reapproval unless the purchaser grants written approval after review of a detailed statement of materials and processing used on the approved sample and those proposed. No production material made by the revised procedure shall be shipped prior to receipt of approval of such procedure.

3.10 Differentiating Requirements

3.10.1 Grade 25 is different from Grade 50 in the supplied thickness only (see Table I).

3.10.2 Type I is different from Type II as defined in Table II.

4.0 QUALITY ASSURANCE PROVISIONS

4.1 Responsibility for Inspection

The supplier of the product shall supply all samples and shall be responsible for performing all required tests. Results of such tests shall be reported to the purchaser. The purchaser reserves the right to perform such confirmatory testing as deemed necessary to ensure that the product conforms to the requirements of this specification.

4.1.1 The purchaser shall maintain an out-time log that tracks the exposure of the adhesive when not in low-temperature storage.

4.2 Qualification Testing

Qualification testing shall include those tests needed to demonstrate that the product meets or exceeds the properties listed in Tables I and II.

4.3 Acceptance (Supplier Conformance) Tests

Acceptance testing on each batch of adhesive shall be performed by the manufacturer.

Acceptance tests shall be expansion ratio and tube shear at 75°F on un-aged material.

4.4 Purchaser Receiving Inspection Tests

The purchaser shall perform testing per Table III prior to acceptance of supplier certified material.

4.5 Test Methods

4.5.1 Sagging

The sagging characteristics of the adhesive shall be determined by fabricating a specimen (per Figure 1) with no face bonding adhesive between the upper facing and the core and using a 0.020-in. thick upper facing. Remove the upper facing, observe the degree of fill of the splice material, and measure the sag of the splice adhesive from the upper face of the core. Evidence of adherence of foam adhesive on the upper facing over the entire splice area will also constitute acceptability of the sagging test.

4.5.2 Expansion Ratio for Adhesive

4.5.2.1 Cut three 2-in. x 2-in. pieces of foam adhesive sheet material and measure the thickness of each at each corner and at the center to the nearest 0.01 in.

4.5.2.2 Place the specimens separately on a caul plate (12 in. x 12 in. min.) that has been covered with a suitable parting agent to prevent adhesion of the test pieces to the plate.

Table III: Purchaser Receiving Inspection Tests

Property 1/ Grade 25 Grade 50

Thickness, inches, nominal 0.025 ± 0.005 0.050 ± 0.005

Weight–Uncured Sheet, lbs./sq. ft., maximum 0.190 0.380

Expansion Ratio 1.5–3.5 1.5–3.5

Density–Cured, lbs./cu. ft., maximum 45 45

Property 1/ 2/ Type I Type II

Tube Shear, psi at 75°F, average value 600 700

1/ Minimum of 3 specimens shall be tested for each condition.

2/ Minimum individual tube shear values shall not be less than 85% of average values.

Figure 1: Peak Exotherm and Sagging Test Specimen

4.5.2.3 Place the caul plate with the adhesive specimens in a circulating-air oven and cure per Section 3.2.

4.5.2.4 Measure the thickness of each adhesive specimen at each corner and in the middle to the nearest 0.01 in. and calculate the expansion ratio as follows:

Expansion ratio = Average thickness of each specimen after cure

Average original thickness of the specimen

4.5.3 Density of Cured Adhesive

4.5.3.1 Measure the width and length of the cured specimens used in the expansion ratio determinations to the nearest 0.01 in. (0.3 mm).

4.5.3.2 Weigh each specimen to the nearest mg.

4.5.3.3 Using the average thickness of each specimen obtained during the expansion ratio determination, calculate the density of the cured adhesive as follows:

Density = Weight, g

Volume, cu. in.

x 3.81

4.5.4 Tube Shear Testing

4.5.4.1 Use drawn aluminum tubes, 5052, SAE-AMS-WW-T-700/4, or alloy of comparable compressive strength. The outer tube shall be of one inch O.D. and the inner tube of one-half inch O.D. Both tubes shall be 9 inches long and have wall thickness of 0.049 inch.

4.5.4.2 Pretreat the tubes using FPL etch or phosphoric acid anodize procedures per A-10 specifications S-F501 or A-F501, or an equivalent cleaning process with the understanding that the tube shear failure mode cannot be interfacial between the adhesive and the aluminum.

4.5.4.3 The quantity of adhesive required to fill the tube shear assembly annular volume (approximately 4 cubic inches) must be determined experimentally for each adhesive. This quantity normally falls in the range of 43 to 47 grams. Use the same quantity ± 1 gram for all tube shear tests with the same adhesive.

4.5.4.4 Cover each end with a suitable flow retardant cloth and assemble in a curing jig as shown in Figure 2. Tighten the bolts by hand.

NOTE: Other types of cure test fixtures may be used providing venting and tube alignment is maintained.

Figure 2: Tube Shear Curing and Test Fixtures

4.5.4.5 Cure per Section 3.2 with the tube in a horizontal position.

4.5.4.6 Cut test specimens 0.50 ± 0.02 inch long with flat faces normal to the tube axis.

Deburr specimens. Discard one specimen from each end.

4.5.4.7 Test by shearing the inner tube using the tube shear test fixture shown in Figure 2.

4.5.4.8 Apply load-to-failure at a head travel rate of 0.06 ± 0.02 inch per minute.

4.5.4.9 Maintain the specimen within ± 5°F of the required temperature for 10 minutes minimum before load is applied and 20 minutes maximum before test is complete.

Continuously verify test temperatures by a thermocouple attached to the inner tube of the specimen.

4.5.4.10 Calculate shear strength in lbs./sq. in. using the outer surface of the inner tube as the shear surface (1.571 times actual specimen length is bond area).

4.5.5 Peak Exotherm Temperature

4.5.5.1 The peak exotherm temperature shall be determined on a test panel consisting of two 0.020-in. x 12.0-in. x 12.0-in. aluminum alloy faces and a 2.00-in.-thick honeycomb core as shown in Figure 1. The core shall be spliced in the center of the panel. A suitable thermocouple shall be inserted in the approximate geometric center of the splice. The panel shall be cured as specified in Section 3.2.

4.5.5.2 Record the maximum temperature of the thermocouple during cure of the test panel.

4.5.6 Percent Volatiles Testing

4.5.6.1 Weigh approximately 2 grams of each sample to ± 1 percent. Heat for 2 hours at 217°F ± 5°F. Cool in desiccator and reweigh. Repeat until a constant weight is obtained.

4.5.6.2 Calculations:

Percent Volatiles = Weight loss

Sample Weight x 100

4.5.7 Reports

The supplier of the product shall furnish with each shipment three copies of a report showing the results of tests made on the product to determine conformance to the acceptance test requirements of this specification and a statement that the product conforms to all other technical requirements of this specification. This report shall include the purchase order number, material specification number, supplier’s material designation, lot number, date of manufacture, form and quantity.

5.0 PREPARATION FOR DELIVERY

5.1 Sheet Adhesive

Sheet adhesive shall be identified by marking on at least one of the protective separator films on each sheet. Use characters approximately 3/8 in. in height that will not be obliterated by normal handling. Each grade shall be marked using a color unique to that grade as selected by the manufacturer.

5.2 Packaging

5.2.1 Sheet Adhesive

Sheet adhesive shall be supplied flat with each sheet protected on both sides by non-adherent separator film. Sheets shall be packaged individually, or as specified, in sealed bags of suitable non-adherent material to prevent penetration of moisture or loss of volatiles.

As a guideline, sheet sizes shall be 12 x 24 inches nominally.

5.3 Exterior Packaging

5.3.1 Packing

The protected sheets shall be packed in an exterior container capable of protecting the materials adequately during transit and storage below the specified temperature and meeting carrier rules and regulations applicable to the mode of transportation.

6.0 DEFINITIONS

6.1 Batch

A batch is defined as all material produced in a single production run made from the same batch of raw materials under the same fixed conditions, or, all material subjected to the same unit chemical or physical process intended to make the final product homogeneous, and submitted for delivery at one time.

6.2 Lot

A lot is the quantity of a batch in a given shipment of material.

Table IV: Qualified Products List

Material Supplier Designation Supplier

Types I and II Grades 25 and 50

FM410

Cytec Industries, Inc.

Engineered Materials 1300 Revolution Street Havre de Grace, MD 21078

Types I and II Grades 25 and 50

Scotch-Weld AF 3024

3M Company Springfield Plant 3211 East Chestnut Exp.

Springfield, MO 65802

Types I and II Grade 50

MA-562

Henkel Corporation Aerospace Group 2850 Willow Pass Road PO Box 312 Bay Point, CA 94565-0031