DPS4-50-201_88277_NULL_E_0001_E_NULL_0001_29_K_N_Y_N_N_Y_D.pdf

Revised 1 August 2017

PROCESS SPECIFICATION

DPS4.50-201

The Boeing Company REVISION: E

Title Page

RESTRICTIONS

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COATING TOUCH-UP REQUIREMENTS

BOEING PROCESS SPECIFICATION

THE BOEING COMPANY

DPS4.50-201

Revision E 12 February 2014

COATING TOUCH-UP REQUIREMENTS

WARNING -- EXPORT CONTROLLED: CONTACT THE OFFICE OF INTERNAL GOVERNANCE FOR GUIDANCE

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TABLE OF CONTENTS

Section Title Page

1 SCOPE

2 APPLICABLE DOCUMENTS

3 MATERIALS & SPECIAL EQUIPMENT

4 REQUIREMENTS

4.1 General

4.2 Substitutions

4.3 Overspray

4.4 Surface Rework

4.6 Torque Stripes

4.7 Sealant

4.7.1 Fuel Tank

4.7.2 Interior

4.7.3 Exterior

4.7.4 Intermittently Visible Surfaces

5 INSTRUCTIONS/PROCEDURES

5.1 Supplier Procedures

5.2 Safety/Fire - Internal Boeing Operations

5.3 Surface Preparation

5.4 General Touch-Up

5.4.6 Spares & Part Storage

5.5 Fasteners with Hi-Kote 1 Coating

5.6 Fasteners not coated with Hi-Kote 1

5.7 Cargo/Ramp Floor

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See Cover Page

Copyright © Boeing. All rights reserved. See Cover Page.

Section Title Page

5.8 Jam Nuts & Connector Rods

5.9 Bearings & Bushings

5.10 Nutplates and Gang Channels

5.11 Hydraulic Clamps & Electrical Clamps

5.11.1 Paint Touch-up

5.11.2 Bilge

5.12 Aluminum Pipes, Tubing, and Fittings Touch-Up

6 QUALITY CONFORMANCE/CONTROL PROVISIONS

6.1 Process Control

6.2 Quality Control

6.3 Nonconformances

REVISION INFO

1. SCOPE

1.1 This Process Standard specifies the requirements and instructions for coating touch-up after assembly or installation. It shall be used when specified by a Finish Specification, Engineering drawing, or other Engineering authority. Where there is a conflict between this Process Standard and an Engineering drawing or other Engineering authority, the Engineering drawing or authority shall take precedence.

1.2 This Process Standard shall be used when notecode 9AAU, "Touch up with required organic coating after assembly or installation", is indicated on a C-17 Engineering drawing.

2. APPLICABLE DOCUMENTS

DPS1.37 - Electrical Bonding Connections - Military DPS3.14-17 - Repair of Surface Defects - Aluminum Alloys DPS3.80-17 - Installation of External Swage and Deutschlite Fitting

Connections, C-17 Aircraft.

DPS3.307-17 - Corrosion Inhibiting Compounds – Military Aircraft DPS3.314-16 - Assembly & Aircraft Storage Protection - Military DPS3.317 - Preservation and Protection of Machined Parts DPS4.50-36-17 - Epoxy (FR) Coating System DPS4.50-62 - Impact Resistant Coating System DPS4.50-66 - Paint Adhesion Tests DPS4.50-127 - Fuel Tank Coating DPS4.50-138 - Epoxy Primer, DMS2104 DPS4.50-165-17 - Aliphatic Polyurethane Coating DMS2115 DPS4.50-168 - Heat Resistant Urethane Coating DPS9.45 - Conversion Coatings for Aluminum 17P9M2001 - C-17 Finish Specification

3. MATERIALS & SPECIAL EQUIPMENT - N/A

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4. REQUIREMENTS

4.1 General

4.1.1 Parts shall be touched-up per the requirements of Table I.

4.1.2 Organic coating touch-up shall occur at the latest assembly or installation sequence where the fasteners or parts are still accessible. For parts or assemblies transported to another department or facility, organic coating touch-up shall be performed except where subsequent paint operations are specified.

4.1.3 Organic coating touch-up of electrically bonded areas shall not occur until all bonding is complete.

4.1.4 Unless otherwise stated, parts which require organic coating touch-up shall receive the same organic coatings as the finish requirement of the immediately adjacent surfaces.

Refer to the C-17 Finish Specification (17P9M2001) or Table II for general information on coatings used on the C-17. If the proper coating cannot be determined, contact C-17 Materials & Processes Engineering.

4.1.5 Coatings shall cure per applicable DPS prior to application of corrosion inhibiting compound.

4.1.6 Coating touch-up shall not affect form, fit or function of the base part or substrate.

Coating touch-up shall not freeze nutplates or inhibit electrical bonding.

4.1.7 Where Corrosion Inhibiting Compound (CIC) is called out, DPM 6577 CIC shall be applied per DPS3.307-17.

4.1.8 Paint touch-up of areas which do not require coating per this DPS is acceptable provided all other requirements of this specification are met.

4.1.9 Fasteners shall be inspected per applicable acceptance standard prior to coating touch-up.

4.2 Substitutions

4.2.1 DPS4.50-168 “Heat Resistant Urethane Coating” may be used in lieu of DPS4.50-36-17 “Epoxy (FR) Coating System” for touch-up within pylon and high temperature areas.

4.2.2 DPS4.50-138 "Epoxy Primer, DMS2104" may be used in lieu of DPS4.50-62 "Impact Resistant Coating System" for touch-up on exterior moldline surfaces of assemblies and installations. No substitution shall be made for detail parts.

4.2.3 MC coating applied per DPS9.45 may be used in lieu of CC coating for touch-up of fasteners and assemblies where electrical bonding is not required.

4.3 Overspray

4.3.1 Parts or surfaces adjacent to the touch-up area that have a different finish requirement shall be protected to prevent overspray.

4.3.2 Holes and threaded areas which will be used for further installations shall not be touched-up.

4.3.3 Overspray onto other areas shall be minimized.

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4.4 Surface Rework - Rework of damaged aluminum surfaces shall be performed per DPS3.14-17. For damage to other surfaces, contact the appropriate Engineering Authority prior to performing rework or touch-up operations.

4.5 Coating touch-up shall be uniform, smooth and free of defects or scratches which expose the substrate.

4.6 Torque Stripes - Fasteners which require both a torque stripe and coating touch-up shall first be torque striped then touched-up per this DPS. The torque stripe shall remain visible after touch-up.

4.7 Sealant

4.7.1 Fuel Tank - Coating touch-up of fuel tank sealant shall be performed as necessary to prevent chip contamination during manufacture. General sealant overcoating is acceptable provided the surface preparation procedures of this DPS are followed.

4.7.2 Interior - Coating touch-up of sealant on interior areas such as the bilge, cargo floor, or skin panel interiors is not required but is acceptable provided the surface preparation procedures of this DPS are followed.

4.7.3 Exterior - Sealant on the exterior moldline shall be painted per the requirements of this specification.

4.7.4 Intermittently Visible Surfaces - Sealant on intermittently visible surfaces, as defined in 17P9M2001, shall be painted per the requirements of this specification. Touch-up of sealant on the landing gear is not required but is acceptable provided the surface preparation procedures of this DPS are followed.

TABLE I - TOUCH-UP REQUIREMENTS

Part/Location Requirement Procedure Paragraph Any portion of a part, assembly or installation which will be painted during a subsequent manufacturing stage.

No touch-up required provided that the part will be stored indoors for six months or less or stored outdoors for no more than 24 hours prior to painting. (1)

N/A

Parts and assemblies made for spares.

Touch-up all areas per this DPS.

Protect bare fastener holes per paragraph 5.4.6

5.4

Coating damage (nicks, scratches, etc) occurring after final coating application.

Rework substrate if damage is identified. Touch-up area to match adjacent coating.

5.4

Fasteners equipped with grease fittings.

No touch-up required for fastener head, washers or nuts.

N/A

Fuel vapor or fuel wetted fastener ends installed in locations greater than six inches above the lower wing skin or bottom of the fuel tank

No touch-up required above 6".

Touch up areas 6" and below per paragraph 5.4.

N/A

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TABLE I - TOUCH-UP REQUIREMENTS (Continued)

Part/Location Requirement Procedure Paragraph Fasteners coated with Hi-Kote 1or (DMS2447), fastener ends which will be encapsulated with sealant.

No touch-up required on fasteners with Hi-Kote 1 or areas which will be encapsulated. Any areas of the substrate that are exposed after fastener installation such as surface scratches or exposed countersink shall be touched-up per paragraph 5.4.

5.5

Fasteners not coated with Hi- Kote 1 or (DMS2447).

Touch-up all fasteners heads, tails, nuts, washers, collars, etc. to match surrounding area.(2)

5.6

Cargo/Ramp Floor – Titanium & CRES fasteners through painted areas.

Touch-up fastener ends on the upper surface of the cargo /ramp floor only unless specified otherwise.

5.7

Jam nuts Touch-up Jam nut after final rigging of rod/nut. Avoid overspray onto threaded area.

5.8

Connector Rods Touch-up rod end and Jam nuts per 5.8 after final rigging of rod/nut;

apply Corrosion Inhibiting Compound (CIC) to rod ends and threads. (3)

5.8

Bearings & bushings Touch-up to edge of bearing/ bushing.

5.9

Nutplates & gang channels No touch-up required for fay surface sealed CRES nutplates and wet installed CRES or Titanium rivetless nutplates installed on the underside of the cargo/ramp floor and the tail ends of removable CRES or Titanium fasteners that are wet installed in the noted nutplates. Nuts and nutplates on the painted structure on the topside of the cargo/ramp floors or nutplates found in other areas not listed above shall be touched up. Avoid overspray per 4.3.

5.10

Clamps Touch-up electrical bonding areas per DPS1.37. Perform touch-up of other bared areas per this DPS. Do not touch-up if CIC will be subsequently applied. (3)

5.11

Aluminum pipes and tubing Touch-up exposed Aluminum portions, apply CIC to any dissimilar metals couplings and aluminum-to-aluminum joints. (3)

5.12

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TABLE I - TOUCH-UP REQUIREMENTS (Continued)

Part/Location Requirement Procedure Paragraph FOOTNOTES: (1) If the part is stored for longer periods than prescribed, the bare metal shall be protected as indicated in DPS3.314-16.

(2) No touch-up required if the immediately adjacent structure or component surface is not coated with an organic coating per Engineering drawing requirements (i.e., upper surface of cargo/ramp floor, certain locking mechanisms, certain composites, etc.).

(3) Do not apply corrosion inhibiting compound to parts in fuel wetted areas, areas exposed to fuel vapors, or areas exposed to over 200°F.

TABLE II - GENERAL COATING GUIDE

Location Coating Visual Indicator Application Specification

- Hi-Kote 1/DMS2447 Light amber to gold appearance on fasteners pink/red (3D0332 rivet, 3D0344 collar)

N/A

Exterior Moldline DMS2104 or DMS2144 and DMS2115 Type 2, DN 9907, Fed Std 595 #36173

Yellow primer Dark green primer Flat gray topcoat

DPS4.50-138

DPS4.50-62

DPS4.50-165-17

Main Landing Gear DMS2144 and

DMS2143 DN3635

Dark green primer Gloss gray topcoat

DPS4.50-62

MLG Pods DMS2144 and

DMS2143 DN9374

Dark green primer Gloss white topcoat

DPS4.50-62

Pylons & High Temperature Areas

DPM 5893 Yellow-green coating DPS4.50-168

Fuel Tank DMS1850 Yellow coating DPS4.50-127

Bilge & Area Under Cargo Floor

DMS1786 and

DMS2433 DN7507

Yellow-green primer Gloss white topcoat

DPS4.50-36-17

Other Interior Structure DMS1786 Yellow-green primer DPS4.50-36-17

5. INSTRUCTIONS/PROCEDURES

5.1 Supplier Procedures - A supplier is not required to comply with the Instructions section of this DPS if the supplier has written instructions that result in compliance with the Requirements section. However, when there are specific instructions invoked in a specific requirements paragraph, figure, or table, the supplier is required to comply with the instructions referenced within that paragraph, figure or table.

5.2 Safety/Fire - Internal Boeing Operations - The Boeing Safety Procedures Manual for Government Programs (TA-062) outlines the general safety precautions to be observed in connection with the procedures of this DPS. For detailed instructions consult Environmental, Health, and Safety (EHS), or Fire Services for fire, health, and safety requirements.

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5.3 Surface Preparation - Clean any dirt, oil or debris from the touch-up surface. Lightly abrade or solvent wipe the surface per the applicable coating DPS.

5.4 General Touch-Up

5.4.1 Select the organic coatings for touch-up to match the immediately adjacent area. If the proper coating cannot be determined contact Materials & Processes Engineering.

5.4.2 Apply all organic coatings per the applicable DPS.

5.4.3 If a part has already been primed and is only missing topcoat, primer does not need to be reapplied during coating touch-up.

5.4.4 Allow touch-up area to cure per the applicable DPS before performing any operation which would contaminate the surface such as sanding, grinding, etc.

5.4.5 Verify that the area touched-up meets all visual, color match, gloss or other quality requirements of the applicable coating specification.

5.4.6 Spares & Part Storage - Touch up unpainted fastener holes on parts for Spares or parts which will be unprotected and stored indoors for longer than 6 months or stored outdoors for longer than 24 hours as follows:

5.4.6.1 Verify holes meet all acceptance criteria.

5.4.6.2 Aluminum parts:

5.4.6.2.1 Treat holes for electrical bonding with Low Electrical Resistance Coating per

DPS9.45.

5.4.6.2.2 Apply MC Coating per DPS9.45 to all other fastener holes.

5.4.6.3 Protect non-aluminum, metallic parts per DPS3.317. Preservation fluids need only be applied to unpainted areas.

5.5 Fasteners with Hi-Kote 1 Coating

5.5.1 Touch up gouges or scratches through the Hi-Kote 1 coating. Touch up any exposed countersink. . See Figure 1A.

5.5.2 Gouges or scratches through the Hi-Kote 1 coating shall be touched-up. Exposed countersink shall be touched up. See Figure 1B and Figure 1D.

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5.5.3 Touch up any fastener with Hi-Kote 1 disbonding, spalling or adhesion loss. Clean any loose coating prior to touching up per this DPS. A dry tape adhesion test per DPS4.50-66 may be used to determine if Hi-Kote adhesion is acceptable. See Figure 1C.

FIGURE 1 - TOUCH-UP OF FASTENERS WITH HI-KOTE

5.6 Fasteners not coated with Hi-Kote 1

5.6.1 Apply coatings to all unpainted washers, fasteners, spacers, nuts, collars, etc., per paragraph 5.4. No touch-up required for the end of the fastener on the unpainted surface. For example, if the head of a fastener is on a painted surface but the tail goes through an unpainted surface; then coating touch-up is only required for the head.

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5.6.2 Touch up NAS 1329 & NAS 1330 Rivnuts as shown in Figure 4. Do not apply coating to bonding surface or internal diameter/threads of rivnut.

Touch-Up Required

FIGURE 2 - TOUCH-UP OF FASTENERS NOT COATED WITH HI-KOTE 1

FIGURE 3 - UNPAINTED PARTS

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FIGURE 4 - NAS 1329/NAS1330 RIVNUT TOUCH-UP

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5.7 Cargo/Ramp Floor - Apply coating per paragraph 5.4 to bare titanium, CRES nutplates and CRES rivetless nutplates in painted areas of the cargo/ramp floor. Apply coating to the portion of the fastener above the cargo/ramp floor only. No touch-up required for fasteners in unpainted areas.

Touch-Up Fastener Heads

Touch-Up Fastener Heads

FIGURE 5 - CARGO/RAMP FLOOR TOUCH-UP

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5.8 Jam Nuts & Connector Rods - After rigging operations are complete apply coating to nut and locking washer only per paragraph 5.4. Apply Corrosion Inhibiting Compound to rod end and threads per DPS3.307-17 and paragraph 4.1.7

Touch-Up Jam Nut and Locking Washer

Apply Corrosion Inhibiting Compound to rod end and threads

FIGURE 6 - JAM NUT AND ROD END TOUCH-UP

5.9 Bearings & Bushings - Apply coating to the assembly up to the edge of the bushing per paragraph 5.4.

Touch-up to edge of bushing/bearing

FIGURE 7 - BEARINGS & BUSHINGS

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5.10 Nutplates and Gang Channels - Apply coating to all exposed surfaces of the fasteners, nutplates and gang channels per paragraph 5.4. Do not apply coating to threaded areas.

Do not apply coating such that it would interfere with the movement of the nut.

5.10.1 Protect threaded areas from overspray during touch-up

5.10.2 Loosen free floating gang channels and nutplate elements from any movement restrictions after coating has dried to touch. Sufficient float may be demonstrated by utilizing finger pressure to move the nut element relative to the fastener hole location.

Touch-up Nutplates

FIGURE 8 - NUTPLATE TOUCH-UP: TOUCH-UP AREAS (ABOVE) CORRECT TOUCH-UP (BELOW)

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5.11 Hydraulic Clamps & Electrical Clamps

5.11.1 Paint Touch-up - Touch up connection after electrical bonding is complete. Touch up brackets and fastener ends per paragraphs 5.4 and 5.6. Parts which will receive corrosion inhibiting compound do not require paint touch up.

Touch-up Fasteners

FIGURE 9 - CLAMP FASTENER TOUCH-UP

5.11.2 Bilge - For clamps and clamp fasteners below the cargo floor, verify application of corrosion inhibiting compound to fasteners and clamp-to-bracket seams. Apply corrosion inhibiting compound to uncoated clamps and fasteners.

FIGURE 10 - BILGE CLAMP FASTENER TOUCH-UP

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5.12 Aluminum Pipes, Tubing, and Fittings Touch-Up

5.12.1 Apply coating to bare aluminum areas of pipes and tubing to match adjacent finish. Do not apply coating to areas specifically left bare by an Engineering Authority or Drawing.

Corrosion inhibiting compound may be substituted for paint in areas which will not get hotter than 200° F.

5.12.2 Touch up pipe fittings per the fitting installation DPS. If the fitting DPS does not contain touch-up instructions then touch up per 5.12.1.

Touch-up Bare Aluminum Area of Pipe

Touch-up Bare Aluminum Area of Pipe

FIGURE 11 - PIPING AND TUBING TOUCH-UP

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FIGURE 12 - FITTING TOUCH-UP

6. QUALITY CONFORMANCE/CONTROL PROVISIONS

6.1 Process Control - Provide surveillance as necessary to determine compliance with this DPS and other applicable Engineering requirements

6.2 Quality Control - Verification of compliance to the following may be performed by Quality Assurance or the organization performing the work:

6.2.1 Coating thickness meets the requirements of the applicable DPS where coating thickness measurements are possible.

6.2.2 The coating is uniform, smooth and free of defects or scratches which expose the substrate.

6.2.3 Nutplates and gang channels have sufficient float to permit fasteners to be properly installed.

6.3 Nonconformances - Process nonconformances in accordance with standard practice.

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REVISION INFO

DPS 4.50-201, Revision "E" is released. This Revision replaces and includes Revision "D", dated 2-26-2013.

HANDLING INSTRUCTIONS (HI):

2. Comply At Specified Effectivity.

3. Comply When Invoked By Drawing Or Other Authority.

4. Compliance Optional; No Engrg. Requirement.

5. NOTED.

HI No.

EFFECTIVITY

On or Before April 15, 2014

PRODUCT CONFIGURATION CONTROL

CLASS II

DISTRIBUTION

STANDARD

SPECIALTY MANUAL NUMBERS

N/A

M&P QCB NO.

16051

MODEL

MIL

EWO

N/A

CCN

RT9T06E3

Summary of Changes and Reasons

4.1.8 - Changed to replace "Table I" reference with "this DPS".

Reason: Table I does not contain all of the touch-up requirements; the DPS does.

4.7 and Subs - Added sealant touch-up requirements.

Reason: Clarification requested by Production.

APPROVALS

CREATED BY M. Beatty 2014-02-11 APPROVED

DAE/AR COML - M&P N/A

CUSTODIAN COML - M&P N/A

BACK-UP COML - M&P N/A

GOVERNMENT - M&P K. Yoshida 2014-02-11 APPROVED

GOVERNMENT - IPT A. Amin 2014-02-11 APPROVED

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