TO 1-1-691.pdf

TO 1-1-691

TECHNICAL MANUAL

CLEANING AND CORROSION PREVENTION

AND CONTROL,

AEROSPACE AND NON-AEROSPACE EQUIPMENT

F42620-00-D-0038

FA8501-07-F-A080

This manual incorporates Interim Operational Supplement (IOS) TO 1-1-691S-1, dated 25 September 2014.

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

Published Under Authority of the Secretary of the Air Force

2 NOVEMBER 2009 CHANGE 10 - 14 JANUARY 2015

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

Dates of issue for original and changed pages are:

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

Change . . . . . . . . 6 . . . . 17 February 2014 Change . . . . . . . . 7 . . . . . . . 29 May 2014 Change . . . . . . . . 8 . . . . . . . 11 July 2014 Change . . . . . . . . 9 . . . . 4 December 2014 Change . . . . . . . 10. . . . .14 January 2015

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3-29 3-30 - 3-36 3-37 3-38 - 3-39 3-40 3-41 3-42 - 3-43 3-44 - 3-46 3-47 3-48 3-48.1 - 3-48.2 Added 3-49 3-50 3-51 3-52 - 3-53 3-54 - 3-55 3-56 - 3-57 3-58 - 3-59 3-60 - 3-63 3-64 4-1 4-2 4-3 - 4-4 4-4.1 Added 4-4.2 Blank 4-5 - 4-14 4-15 4-16 - 4-18 5-1 - 5-11 5-12 5-13 - 5-15 5-16 5-17 - 5-26 5-27 5-28 5-29 5-30 5-31 - 5-41 5-42 - 5-44 5-45 - 5-46 5-46.1 Added

5-46.2 Blank 5-47 - 5-50 5-51 - 5-52 Added 6-1 6-2 6-3 - 6-5 6-6 - 6-31 6-32 6-33 - 6-36 7-1 - 7-2 7-3 7-4 - 7-6 7-7 7-8 - 7-10 7-11 - 7-13 7-14 7-15 - 7-19 7-20 Blank 8-1 - 8-2 8-2.1 Added 8-2.2 Blank 8-3 - 8-5 8-6 8-7 8-8 8-9 8-10 - 8-11 8-12 - 8-13 8-14 8-14.1 Added 8-14.2 Blank 8-15 8-16 8-16.1 Added 8-16.2 Blank 8-17 8-18 Blank 9-1 - 9-3 9-4 Blank 10-1 Added 10-2

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

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10-3 Added 10-4 Blank A-1 - A-9 A-10 A-11 - A-12 A-13 A-14 A-15 A-16 - A-19 A-20 - A-21 A-22 - A-54 A-55 - A-57 A-58 Blank B-1 - B-18 B-19 - B-20 B-20.1 Added B-20.2 Blank B-21 - B-27 B-28 - B-30 B-30.1 - B-30.3 Added B-30.4 Blank B-31 - B-41 B-42 B-43 - B-45 B-46 Blank Glossary 1 - Glossary 4 Index 1 - Index 3 Index 4 Index 4.1 Added Index 4.2 Blank Index 5 Index 6 - Index 8 Index 8.1 - Index 8.2 Deleted Index 9 - Index 14 Deleted

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TABLE OF CONTENTS

Chapter Page

LIST OF ILLUSTRATIONS . . . . . . . . . . . . . x

LIST OF TABLES . . . . . . . . . . . . . . . . . . . . xi

FOREWORD . . . . . . . . . . . . . . . . . . . . . . . xiii

SAFETY SUMMARY . . . . . . . . . . . . . . . . . xvii

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

1.1 CORROSION CONTROL

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

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

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

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

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

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

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

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

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

2.1 INTRODUCTION TO CORRO-

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

2.2 DEFINITION OF

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

2.3 CHEMICAL DEFINITIONS . . . . . 2-1

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

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

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

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

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

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

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

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

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

2.4.4.1 Elimination of Anode, Cathode, Electrolyte, or Electrical Contact. . . . . . . . . . . . . . . . . . 2-1

2.5 DEVELOPMENT OF

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

2.5.1 Corrosion Under Painted

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

2.6 FACTORS INFLUENCE

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

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

2.6.2 Dissimilar Metal Coupling (Galvanic

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

2.6.3 Anode and Cathode Surface

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

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

2.6.5 Heat Treatment and Grain

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

Chapter Page

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

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

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

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

2.7.6.1 Metal Ion Concentration Cells . . . . 2-7

2.7.6.2 Oxygen Concentration Cells. . . . . . 2-7

2.7.6.3 Active/Passive Cells . . . . . . . . . . . 2-8

2.7.6.4 Stress Corrosion Cracking . . . . . . . 2-8

2.7.6.5 Associated Hazards. . . . . . . . . . . . 2-8

2.7.6.6 Causes . . . . . . . . . . . . . . . . . . . . 2-8

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

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

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

2.7.10 High Temperature Oxidation (Hot

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

2.8 METALS AFFECTED BY

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

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

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

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

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

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

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

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

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

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

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

2.8.11 Graphite/Carbon Fiber

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

2.9 CORROSIVE

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

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

2.9.1.1 Condensed Moisture . . . . . . . . . . . 2-17

2.9.1.2 Effect of Moisture . . . . . . . . . . . . 2-17

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

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

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

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

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

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

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

2.9.8.1 Desert . . . . . . . . . . . . . . . . . . . . 2-18

2.9.8.2 Temperate Zones . . . . . . . . . . . . . 2-18

Change 4 i

2.9.8.3 Tropics . . . . . . . . . . . . . . . . . . . . 2-18

2.9.9 Factors of Influence in Tropical

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

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

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

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

2.9.13 Industrial and Ship Emitted Air

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

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

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

2.9.15.1 Bacteria . . . . . . . . . . . . . . . . . . . 2-19

2.9.15.2 Microbial Growth

Requirements. . . . . . . . . . . . . . 2-19

2.9.15.3 Microbial Nutrients. . . . . . . . . . . . 2-19

2.10 DEGRADATION OF

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

2.11 PREVENTIVE

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

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

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

3.1 PREVENTIVE MAINTENANCE

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

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

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

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

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

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

3.2.2.1 Cleaning Frequency . . . . . . . . . . . 3-7

3.2.3 Aircraft Clear Water Rinse (CWR)

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

3.2.3.1 Aircraft Stationed Within 1.25 Miles

of Salt Water . . . . . . . . . . . . . . 3-7

3.2.3.2 Low Level (Below 3,000 Feet) Salt

Water Runway Approach . . . . . . 3-8

3.2.3.3 Search, Rescue, and Recovery Mis-

sions and Low-Level Flight Op-erations Under 3,000 Feet . . . . . 3-8

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

3.2.5 Deployed Aircraft Wash

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

3.3 CLEANING COMPOUNDS . . . . . 3-9

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

3.3.1.1 MIL-PRF-87937, Type I and MIL-

PRF-85570, Type I . . . . . . . . . . 3-9

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

PRF-85570, Type II . . . . . . . . . 3-9

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

PRF-85570, Type V . . . . . . . . . 3-9

3.3.1.4 MIL-PRF-87937, Type IV . . . . . . . 3-9

3.3.1.5 MIL-PRF-85570, Type IV . . . . . . . 3-9

Chapter Page

3.3.1.6 MIL-PRF-85570, Type III . . . . . . . 3-10

3.3.2 Solvent Emulsion and Aqueous

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

3.3.2.1 MIL-PRF-85704, Type I . . . . . . . . 3-10

3.3.2.2 A-A-59921, (Formerly MIL-C-

43616), Class 1A . . . . . . . . . . . 3-10

3.3.3 Aqueous Parts Washer Cleaning

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

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

3.3.4.1 MIL-PRF-680 Degreasing Solvent

and A-A-59601 Dry Cleaning and Degreasing Solvent, P-D-680 . . . . . . . . . . . . . . . . . 3-11

3.3.4.2 TT-I-735 Isopropyl Alcohol . . . . . . 3-11

3.3.4.3 ASTM D 740 Methyl Ethyl Ketone

(MEK) . . . . . . . . . . . . . . . . . . 3-11

3.3.4.4 Aliphatic Naphtha . . . . . . . . . . . . 3-11

3.3.4.5 MIL-T-81772, Type I (Polyurethane)

and Type II (Epoxy) Thinner. . . . . . . . . . . . . . . . . . 3-11

3.3.5 Miscellaneous Cleaning Agents . . . 3-11

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

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

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

3.4.1 High Pressure/Hot Water Wash

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

3.4.2 Portable, 15 Gallon, Foam Generat-

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

3.4.3 Portable, 45 Gallon, Foam Generat-

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

3.4.4 Turbine Engine Compressor Clean-

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

3.4.5 Miscellaneous Large Cleaning

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

3.4.6 Spray Cleaning Guns for

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

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

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

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

3.4.9.1 Effectiveness of Cleaning in Aque-

ous Parts Washers. . . . . . . . . . . 3-34

3.4.9.2 Determination of Capacity of the

Aqueous Parts Washer. . . . . . . . 3-35

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

3.5 CLEANING PROCEDURES . . . . . 3-36

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

3.5.1.1 Electrical . . . . . . . . . . . . . . . . . . 3-36

3.5.1.2 Personal Protection . . . . . . . . . . . . 3-37

3.5.1.3 Use of Solvents . . . . . . . . . . . . . . 3-37

3.5.1.4 Use of Cleaners . . . . . . . . . . . . . . 3-37

3.5.1.5 Water Intrusion . . . . . . . . . . . . . . 3-38

3.5.1.6 Oxygen Systems . . . . . . . . . . . . . 3-38

3.5.1.7 Special Precautions. . . . . . . . . . . . 3-38

TO 1-1-691

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ii Change 5

3.5.1.8 Preparation for Cleaning . . . . . . . . 3-38

3.5.1.9 Pre-Wash Lubrication Point

Protection . . . . . . . . . . . . . . . . 3-38

3.5.1.10 Water/Cleaning Compound

Intrusion . . . . . . . . . . . . . . . . . 3-38

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

3.5.2.1 Alkaline Detergent and/or Solvent

Emulsion Cleaning, Painted and Unpainted Surfaces; Fresh Water Readily Available . . . . . . . . . . . 3-39

3.5.2.2 Waterless Wipe Down. . . . . . . . . . 3-42

3.5.2.3 Alkaline Detergent Cleaning with

Only Limited Fresh Water Available . . . . . . . . . . . . . . . . 3-42

3.5.2.4 Solvent Cleaning . . . . . . . . . . . . . 3-42

3.5.2.5 Interior Cleaning (Vacuum) . . . . . . 3-43

3.5.2.6 Low Temperature Cleaning . . . . . . 3-45

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

3.5.3.1 Requirements. . . . . . . . . . . . . . . . 3-46

3.5.3.2 Taxi-Through Rinsing . . . . . . . . . . 3-46

3.5.3.3 Manual Application . . . . . . . . . . . 3-46

3.5.3.4 Rinsing Procedures . . . . . . . . . . . . 3-46

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

3.5.4.1 Post Cleaning Task Sequence . . . . . 3-46

3.5.5 Treatment and Disposal of Wash

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

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

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

3.5.7.1 Materials. . . . . . . . . . . . . . . . . . . 3-49

3.5.7.2 Application . . . . . . . . . . . . . . . . . 3-49

3.5.7.3 Removal . . . . . . . . . . . . . . . . . . . 3-49

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

3.5.8.1 Bird Strike Cleanup . . . . . . . . . . . 3-50

3.5.8.2 Internal/Enclosed (Water Sensitive)

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

3.5.9 Bodily Fluids Contamination

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

3.5.9.1 Bodily Fluid Containment During

Flight . . . . . . . . . . . . . . . . . . . 3-51

3.5.9.2 Bodily Fluid Cleanup . . . . . . . . . . 3-51

3.5.9.3 Disinfection of Contaminated

Areas . . . . . . . . . . . . . . . . . . . 3-52

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

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

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

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

3.6.2.1 Surface Preparation for Solid Film

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

3.6.2.2 SAE AS5272

(MIL-PRF-46010) . . . . . . . . . . 3-54

3.6.2.3 MIL-PRF-46147 and/or

MIL-L-23398 . . . . . . . . . . . . . 3-54

Chapter Page

3.6.3 Application of Conventional

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

3.6.3.1 Grease Gun Application . . . . . . . . 3-55

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

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

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

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

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

3.7.3.1 Water Displacing Compounds. . . . . 3-56

3.7.3.2 Non-Water Displacing

Compounds . . . . . . . . . . . . . . . 3-56

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

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

3.7.5.1 MIL-PRF-81309, Corrosion Preven-

tive Compound, Water Displac-ing, Ultra Thin Film and MIL-L- 87177, Lubricants, Corrosion Preventive, Water Displacing, Synthetic. . . . . . . . . . . . . . . . . 3-59

3.7.5.2 MIL-DTL-85054, Corrosion Preven-

tive Compound, Clear . . . . . . . . 3-59

3.7.5.3 MIL-PRF-16173, Corrosion Preven-

tive Compound, Solvent Cutback, Cold Application . . . . . . . . . . . 3-60

3.7.5.4 MIL-PRF-63460, Lubricant, Cleaner, and Preservative for Weapons and Weapon Systems . . . . . . . . . . . 3-63

3.7.5.5 MIL-PRF-32033, Lubricating Oil, General Purpose, Preservative, Water Displacing . . . . . . . . . . . 3-63

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

3.7.7 Preservation Application

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

3.7.7.1 Brushing . . . . . . . . . . . . . . . . . . . 3-64

3.7.7.2 Dipping . . . . . . . . . . . . . . . . . . . 3-64

3.7.7.3 Spraying . . . . . . . . . . . . . . . . . . . 3-64

3.8 APPLICATION OF POLISH AND

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

4 INSPECTION AND CORROSION PRONE

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

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

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

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

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

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

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

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

TO 1-1-691

Change 2 iii

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

4.2.1.1 Evidence of Corrosion . . . . . . . . . 4-2

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

4.2.2.1 Use of Depth Gauges . . . . . . . . . . 4-2

4.2.3 Visual Inspection with a

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

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

4.2.4.1 Analog Mechanical Read-Out

Type. . . . . . . . . . . . . . . . . . . . 4-4

4.2.4.2 Digital Read-Out Type . . . . . . . . . 4-4.1

4.2.5 Fluorescent Penetrant

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

4.2.5.1 Limitations of Penetrant

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

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

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

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

4.3 EVALUATION OF CORROSION

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

4.4 DEGREES OF CORROSION . . . . 4-6

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

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

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

SECTION II CORROSION PRONE AREAS . 4-9

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

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

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

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

4.5.4 Engine Exhaust and Gun Gas Im-

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

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

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

4.5.7 Engine Frontal Areas and Air Inlet

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

4.5.8 Wing/Fin-Fold Joints and Wing and

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

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

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

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

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

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

4.5.14 Battery Compartments and Battery

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

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

4.5.16 Electrical Connectors and Other

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

5 CORROSION REMOVAL AND SURFACE

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

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

Chapter Page

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

5.5.1.1 Mechanical Compatibility . . . . . . . 5-2

5.5.1.2 Material Compatibility . . . . . . . . . 5-2

5.5.2 Non-Powered Tools and

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

5.5.2.1 Abrasive Mats . . . . . . . . . . . . . . . 5-2

5.5.2.2 Abrasive Cloth. . . . . . . . . . . . . . . 5-2

5.5.2.3 Abrasive Paper . . . . . . . . . . . . . . 5-2

5.5.2.4 Metallic Wools. . . . . . . . . . . . . . . 5-2

5.5.2.5 Wire Brushes. . . . . . . . . . . . . . . . 5-3

5.5.2.6 Pumice Powder . . . . . . . . . . . . . . 5-3

5.5.2.7 Scrapers . . . . . . . . . . . . . . . . . . . 5-3

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

5.5.3.1 Pneumatic Drill Motors . . . . . . . . . 5-5

5.5.3.2 Pneumatic Sanders . . . . . . . . . . . . 5-5

5.5.3.3 3M Co. Scotch-BriteTM Finishing

Flap Brushes . . . . . . . . . . . . . . 5-6

5.5.3.4 Abrasive Flap Wheels . . . . . . . . . . 5-6

5.5.3.5 Abrasive Cloth and Paper . . . . . . . 5-6

5.5.3.6 Powered Wire Brushes . . . . . . . . . 5-6

5.5.3.7 Rotary Files. . . . . . . . . . . . . . . . . 5-7

5.5.3.8 3M Co. RolocTM Disc and Radial

Disc Abrasives. . . . . . . . . . . . . 5-7

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

5.5.4.1 Conventional Equipment . . . . . . . . 5-8

5.5.4.2 Portable Vacuum Abrasive Blast

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

5.5.4.3 Wet Abrasive Blasting

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

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

5.7 PITTING ON CRITICAL

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

5.8 CORROSION REMOVAL

PROCEDURES-MECHANICAL 5-11

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

5.8.1.1 Personal Protection . . . . . . . . . . . . 5-12

5.8.1.2 Mechanical Damage . . . . . . . . . . . 5-14

5.8.2 Non-Powered Mechanical Corrosion

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

5.8.3 Powered Mechanical Corrosion

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

5.8.4 Abrasive Blasting Corrosion

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

5.8.4.1 Abrasive Blasting Procedures . . . . . 5-15

5.9 CORROSION

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

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

5.9.1.1 Preparation . . . . . . . . . . . . . . . . . 5-17

TO 1-1-691

iv Change 7

5.9.1.2 Chemical Corrosion Removal Mate-

rials for Aluminum Alloys . . . . . 5-17

5.9.1.3 Application of Organic

Coatings . . . . . . . . . . . . . . . . . 5-20

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

5.9.2.1 Preparation . . . . . . . . . . . . . . . . . 5-20

5.9.2.2 Chemical Corrosion Removal Mate-

rials for Magnesium Alloys . . . . 5-20

5.9.2.3 Application of Organic

Coatings . . . . . . . . . . . . . . . . . 5-21

5.9.3 Ferrous Metal (Steel) Alloys Other

Than Stainless Steels

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

5.9.3.1 Preparation . . . . . . . . . . . . . . . . . 5-21

5.9.3.2 Chemical Corrosion Removing Ma-

terials for Ferrous Metal Alloys Other Than Stainless Steels

(CRES). . . . . . . . . . . . . . . . . . 5-22

5.9.3.3 Application of Organic

Coatings . . . . . . . . . . . . . . . . . 5-26

5.9.4 Stainless Steel (CRES) and Nickel

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

5.9.4.1 Preparation . . . . . . . . . . . . . . . . . 5-26

5.9.4.2 Chemical Corrosion Removing Ma-

terials for Stainless Steel (CRES) and Nickel Based Alloys . . . . . . 5-27

5.9.4.3 Passivation of Stainless Steel

(CRES) Alloy Parts . . . . . . . . . 5-30

5.9.4.4 Application of Organic

Coatings . . . . . . . . . . . . . . . . . 5-30

5.9.5 Copper and Copper Based

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

5.9.5.1 Preparation . . . . . . . . . . . . . . . . . 5-30

5.9.5.2 Chemical Corrosion Removing Ma-

terials for Copper and Copper Based Alloys . . . . . . . . . . . . . . 5-30

5.9.5.3 Application of Organic

Coatings . . . . . . . . . . . . . . . . . 5-32

5.9.6 Titanium and Titanium Based

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

5.9.6.1 Preparation . . . . . . . . . . . . . . . . . 5-32

5.9.6.2 Chemical Corrosion Removal Mate-

rials for Titanium and Titanium Based Alloys . . . . . . . . . . . . . . 5-32

5.9.6.3 Application of Organic

Coatings . . . . . . . . . . . . . . . . . 5-33

5.9.7 Plated and Phosphated Surfaces . . . 5-33

5.9.7.1 Preparation . . . . . . . . . . . . . . . . . 5-34

5.9.7.2 Treatment of Corroded Areas on

Cadmium or Zinc Plated Surfaces . . . . . . . . . . . . . . . . . 5-34

5.9.7.3 Treatment of Corroded Areas on

Plated Surfaces Except Cadmium or Zinc Plating. . . . . . . . . . . . . 5-35

Chapter Page

5.9.7.4 Treatment of Corroded Areas on

Phosphated Surfaces . . . . . . . . . 5-35

5.9.7.5 Application of Organic

Coatings . . . . . . . . . . . . . . . . . 5-35

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

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

5.10.1 Chemical Prepaint Treatments . . . . 5-36

5.10.1.1 MIL-DTL-81706 Chemical Conver-

sion Materials for Coating Alumi-num and Aluminum Alloys . . . . 5-36

5.10.1.2 SAE AMS-M-3171 (MIL-M-3171),

Type VI Magnesium Alloy, Pro-cesses for Pretreatment and Pre-vention of Corrosion on; Chromic Acid Brush-On Treatment . . . . . 5-37

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

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

5.10.4 Application of Surface

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

5.10.4.1 Conversion Coating Using TNP

Pens . . . . . . . . . . . . . . . . . . . . 5-39

5.10.5 Notes on Conversion Coating/Sur-

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

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

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

SECTION III SHOT

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

5.11 PEENING OF METAL

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

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

5.11.1.1 Shot Peening and Glass or Ceramic

Bead Peening . . . . . . . . . . . . . 5-43

5.11.1.2 Roto-Peening (Rotary Flap

Peening) . . . . . . . . . . . . . . . . . 5-43

5.11.2 Roto-Peening (Rotary Flap Peening)

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

5.11.2.1 Equipment. . . . . . . . . . . . . . . . . . 5-44

5.11.2.2 Surface Preparation Procedure . . . . 5-44

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

5.11.3.1 Arc Height Conversion . . . . . . . . . 5-45

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

5.11.4.1 Rotary Tool Speed . . . . . . . . . . . . 5-45

5.11.4.2 Flap Operation. . . . . . . . . . . . . . . 5-45

5.11.4.3 Coverage . . . . . . . . . . . . . . . . . . 5-45

5.11.4.4 Part Peening Time . . . . . . . . . . . . 5-46

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

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

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

TO 1-1-691

Change 5 v

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

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

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

6.3.1.1 Two-Part Kit (KT) . . . . . . . . . . . . 6-1

6.3.1.2 Cartridge (CA). . . . . . . . . . . . . . . 6-1

6.3.1.3 Pre-Mixed and Frozen (PMF). . . . . 6-1

6.3.2 Polysulfide, Polyurethane, and Poly-

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

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

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

6.3.5 SAE AMS 3255 Oil and Water Re-

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

6.3.6 Av-Dec® Polyurethane Sealant

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

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

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

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

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

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

6.4.5 Sealant Removal and Application

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

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

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

6.5.1.1 Enhancement of Sealant Curing . . . 6-4

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

6.5.3 Mixing MIL-PRF-81733, Type III

Sprayable Sealant Coating . . . . . 6-5

6.6 SEALANT APPLICATION

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

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

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

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

6.6.4 Brush Spatula or Caulking Gun

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

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

6.6.6 Peel and Stick Application; SAE

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

6.7 SEALING OF SPECIFIC

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

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

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

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

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

6.7.5 Integral Fuel Cells/Tanks and Re-

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

6.7.6 Form-In-Place (FIP) Gasket Sealant

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

Chapter Page

6.7.7 SAE AMS 3255 EPTFE (Skyflex®)

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

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

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

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

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

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

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

6.8 STORAGE/SHELF LIFE CON-

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

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

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

7.2 BATTERY COMPARTMENTS,

BOXES, AND ADJACENT

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

7.2.1 Preparation of Solutions for Clean-

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

7.2.1.1 Litmus Indicating Solution. . . . . . . 7-1

7.2.1.2 Bromothymol Blue Indicating

Solution . . . . . . . . . . . . . . . . . 7-2

7.2.1.3 Sodium Bicarbonate Neutralizing

Solution . . . . . . . . . . . . . . . . . 7-2

7.2.1.4 Boric Acid and/or Monobasic So-

dium Phosphate Neutralizing Solutions. . . . . . . . . . . . . . . . . 7-2

7.2.2 Cleaning and Neutralizing

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

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

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

7.4 CORROSION TREATMENT FOR

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

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

7.6 INTEGRAL AND EXTERNAL

FUEL TANKS AND DROP

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

7.6.1 Corrosion Removal and Rework of

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

7.6.2 Removal of Corrosion and Rework

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

7.6.2.1 Tank Exterior Surfaces . . . . . . . . . 7-4

7.6.2.2 Tank Interior Surfaces . . . . . . . . . . 7-5

7.7 FAYING SURFACES AND AT-

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

7.7.1 Faying Surfaces, Joints, and

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

TO 1-1-691

vi Change 2

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

7.7.3 Severely Corroded (Rusted)

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

7.8 NATURAL AND SYNTHETIC

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

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

7.10 SURFACES AND COMPONENTS

EXPOSED TO EXHAUST

GASES, GUN GASES, AND

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

7.11 ELECTRICAL AND ELECTRONIC

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

7.11.1 Grounding and Bonding

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

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

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

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

7.11.5 Moisture and Fungus Proofing of

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

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

7.12 STRUCTURAL TUBING MEM-

BERS AND ASSEMBLIES . . . . 7-8

7.12.1 Structural Aluminum Alloy

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

7.12.2 Structural Magnesium Alloy

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

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

7.12.4.1 Exterior . . . . . . . . . . . . . . . . . . . 7-8

7.12.4.2 Interior . . . . . . . . . . . . . . . . . . . . 7-8

7.12.4.3 Sealing . . . . . . . . . . . . . . . . . . . . 7-8

7.13 NON-STRUCTURAL TUBING

MEMBERS AND

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

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

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

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

7.13.4 Special Instructions for Tubing Fit-

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

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

7.14 CORROSION REMOVAL FROM

THIN METAL (0.0625 INCH

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

7.15 AIR INTAKE DUCTS FOR JET

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

7.16 CLOSELY COILED SPRINGS . . . 7-11

Chapter Page

7.17 CORROSION PREVENTION ON

ASSEMBLIES AND PARTS RE-

MOVED FROM AIRCRAFT

DURING MAINTENANCE, 30

DAY SHORT TERM STORAGE,

AND OVER 30 DAY LONG

TERM STORAGE

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

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

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

7.18 DEPLETED URANIUM

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

7.18.1 Corrosion and Finish Damage Treat-

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

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

7.20 BERYLLIUM-COPPER ALLOYS,

BERYLLIUM-ALUMINUM AL-

LOYS, AND BERYLLIUM

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

7.20.1 Corrosion Removal and

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

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

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

7.21.1 Treatment of EMI Seals and

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

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

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

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

8.3 EMERGENCY

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

8.3.1 Priority Removal List of Equipment

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

8.3.2 Emergency Reclamation Team . . . . 8-2

8.3.2.1 Personal Protection . . . . . . . . . . . . 8-2

8.3.2.2 Personnel Decontamination . . . . . . 8-2

8.3.3 Emergency Reclamation

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

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

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

8.4.1 Removal of Contaminated Installed

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

8.4.2 Disassembly/Removal of

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

8.4.2.1 Aircraft Involved in Water

Crashes. . . . . . . . . . . . . . . . . . 8-8

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

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

TO 1-1-691

Change 10 vii

8.5 GENERAL CLEANING

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

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

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

8.5.2.1 Method One (Preferred) . . . . . . . . 8-9

8.5.2.2 Method Two (Alternate) . . . . . . . . 8-9

8.5.3 Removing Fire Extinguishing Pow-

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

8.5.4 Removing MIL-F-24385 Aqueous

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

8.5.5 Removal of Carbon Dioxide (CO2), HFC-125, or Halon Fire Extin-guishing Agents . . . . . . . . . . . . 8-11

8.5.6 Removal of Protein Type Foam and

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

8.5.7 Treatment After Landing on a

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

8.5.8 Treatment After Exposure to Volca-

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

8.6 SPECIFIC INTERNAL

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

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

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

8.6.3 Avionic, Electronic, and Electrical

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

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

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

8.6.5.1 Cleanup . . . . . . . . . . . . . . . . . . . 8-13

8.7 SPECIFIC EXTERNAL AREAS OF

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

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

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

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

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

8.7.5 Treatment for Engines Which Have

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

Chapter Page

8.7.6 Helicopter Transmission, Rotor

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

8.7.6.1 External Surface

Contamination . . . . . . . . . . . . . 8-16

8.7.6.2 Internal Surface Contamination. . . . 8-16

8.7.7 Helicopter Main and Tail Rotor

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

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

8.7.8.1 Safety Precautions . . . . . . . . . . . . 8-16.1

8.7.8.2 Cleaning Procedure. . . . . . . . . . . . 8-16.1

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

9 SOUTHWEST ASIA ENVIRONMENTS . . . . 9-1

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

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

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

9.1.3 Aircraft Clear Water Rinse

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

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

9.2 PRE-DEPLOYMENT

RECOMMENDATIONS . . . . . . 9-1

9.3 RECOMMENDED ACTIONS

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

9.3.1 High Efficiency Particulate Air

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

9.3.1.1 Pneumatic Wheeled Units . . . . . . . 9-2

9.3.1.2 Pneumatic Backpack. . . . . . . . . . . 9-2

9.3.2 Areas to be Checked and

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

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

9.5 CORROSION PREVENTIVE

COMPOUNDS (CPC’s) . . . . . . 9-3

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

10 REMOTELY PILOTED AIRCRAFT CORRO-

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

10.1 REMOTELY PILOTED AIRCRAFT

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

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

10.2 CORROSION CONTROL

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

10.3 CARBON FIBER COMPOSITES

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

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

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

10.4 CORROSIVE

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

10.5 APPROVED CLEANING

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

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

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

TO 1-1-691

viii Change 4

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

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

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

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

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

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

10.6.1.1 Assembled RPA . . . . . . . . . . . . . . 10-3

10.6.1.2 Disassembled and Container Stored

RPAs . . . . . . . . . . . . . . . . . . . 10-3

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

10.6.2.1 Wipe Down or Spot Cleaning

Method. . . . . . . . . . . . . . . . . . 10-3

APPENDIX A CONSUMABLE

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

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

A.1.1 Shelf Life . . . . . . . . . . . . . . . . . . A-1

Chapter Page

A.1.2 Consumable Materials Containers. . . . . . . . . . . . . . . . A-1

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

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

APPENDIX B EQUIPMENT FOR CLEAN-

ING AND CORROSION PREVENTION

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

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

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

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

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

TO 1-1-691

Change 9 ix

LIST OF ILLUSTRATIONS

Number PageTitle

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Number PageTitle

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

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

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

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

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

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

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

Stripholder Arc Height Conversion Graph . . . . . . . . . . . . . . . . . . . . . . . 5-47

5-13 “A” Test Strip Arc Height Magnetic to SAE J442 Stripholder Conversion Chart, 0.001 Inch . . . . . . . . . . . . . . . 5-48 x Change 7

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

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

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

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

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

Number PageTitle

6-13 Typical Lap Skin Sealing . . . . . . . . . . . . 6-33 6-14 Sealing Procedures for Typical Aircraft

Fitting. . . . . . . . . . . . . . . . . . . . . . . 6-34 6-15 Typical Spar Cap Sealing. . . . . . . . . . . . 6-35 6-16 Sealing of Access Doors . . . . . . . . . . . . 6-36 7-1 Beryllium-Copper Spiral Contact with En-vironmental Fluorosilicone Seal . . . . . 7-16 7-2 Dorsal Longeron EMI Seal . . . . . . . . . . 7-17 7-3 Stainless Steel (CRES) EMI Screen. . . . . 7-17 7-4 Bonding Cable from Airframe to Graphite/

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

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

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

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

LIST OF TABLES

Number PageTitle

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

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

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

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

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

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

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

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

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

Number PageTitle

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

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

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

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

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

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

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

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

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

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

TO 1-1-691

LIST OF ILLUSTRATIONS - CONTINUED

Change 5 xi

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

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

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

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

Number PageTitle

10-1 Air Force RPA Tiers . . . . . . . . . . . . . . . 10-1 A-1 Unit of Issue Codes . . . . . . . . . . . . . . .