35-1-3reg.pdf

TO 35-1-3

TECHNICAL MANUAL

CORROSION PREVENTION AND CONTROL,

CLEANING, PAINTING, AND MARKING

OF USAF SUPPORT EQUIPMENT (SE)

DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. PA Case Number 05-07173. Submit recommended changes or problems with this Technical Order to 406 SCMS/GULAC, Robins AFB, GA 31098. Questions concerning technical content shall be referred to

AFRL/RXSSR.

Published Under Authority of the Secretary of the Air Force

1 SEPTEMBER 2006 CHANGE 8 - 1 JUNE 2012

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

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.

INSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

LIST OF EFFECTIVE PAGES

Page No.

Dates of issue for original and changed pages are:

Original. . . . . . . . . .0 . . . 1 September 2006 Change . . . . . . . . . . 5 . . . .1 September 2010

A Cha Change . . . . . . . . . .1 . . . . . . . . 5 June 2007 Change . . . . . . . . . .2 . . . . . 21 August 2007 Change . . . . . . . . . .3 . . . . 26 February 2008 Change . . . . . . . . . .4 . . . . . . 6 August 2009

Change . . . . . . . . . . 6 . . . . 24 February 2011 Change . . . . . . . . . . 7 . . . . . . . . 15 July 2011 Change . . . . . . . . . . 8 . . . . . . . . 1 June 2012 *Change No.

Page *Change No. No.

Page *Change No. No.

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 198, CONSISTING OF THE FOLLOWING:

Title A i ii iii iv v vi Blank vii viii ix x 1-1 - 1-4 1-5 1-6 1-7 1-8 - 1-14 2-1 2-2 2-3 2-4 2-5 2-6 2-7 Blank 2-8 2-9 2-10 - 2-13 2-14 2-15 2-16 2-17 - 2-18 2-19 Added 2-20 Blank 3-1 3-2 3-2.1 3-2.2 Blank 3-3 - 3-4

3-4.1 3-4.2 Blank 3-5 3-6 3-7 - 3-8 3-9 3-10 3-11 - 3-13 3-14 3-15 3-16 - 3-18 3-19 3-20 Blank 4-1 4-2 4-3 4-4 4-5 4-6 - 4-17 4-18 4-19 - 4-31 4-32 - 4-33 4-34 4-35 4-36 - 4-45 4-46 - 4-47 Deleted 4-48 4-49 - 4-71 4-72 4-73 4-74 - 4-76 4-77 - 4-81 4-82 4-83 - 4-85 4-86 - 4-87 4-88 4-89 4-90

4-91 4-92 4-93 - 4-97 4-98 4-99 - 4-104 4-105 - 4-107 4-108 4-109 - 4-110 5-1 5-2 5-3 - 5-4 6-1 - 6-2 6-3 6-4 Blank 7-1 - 7-3 Added 7-4 Blank A-1 - A-2 A-3 - A-4 A-5 A-6 - A-8 *Zero in this column indicates an original page.

USAFnge 8

TABLE OF CONTENTS

Chapter Page Chapter Page LIST OF ILLUSTRATIONS........................................iv

LIST OF TABLES.........................................................v

FOREWORD.............................................................. vii

SAFETY SUMMARY..................................................ix

1 CORROSION THEORY, IDENTIFICATION,

CAUSES AND EFFECTS ................................. 1-1

1.1 Purpose.................................................... 1-1

1.2 Definition of Corrosion........................... 1-1

1.3 Chemical Definitions .............................. 1-1

1.3.1 Atom........................................................ 1-1

1.3.2 Electron ................................................... 1-1

1.3.3 Ions.......................................................... 1-1

1.3.4 Electrolyte ............................................... 1-1

1.4 Theory of Corrosion................................ 1-1

1.4.1 Anode ...................................................... 1-1

1.4.2 Cathode ................................................... 1-1

1.4.3 Electrolyte ............................................... 1-1

1.4.4 Electrical Path ......................................... 1-1

1.5 Development of Corrosion...................... 1-1

1.5.1 Corrosion Origination Locations ............ 1-1

1.5.2 Corrosion Under Painted Surfaces .......... 1-2

1.6 Factors Influencing Corrosion ................ 1-2

1.6.1 Type of Metal.......................................... 1-2

1.6.2 Dissimilar Metal Coupling (Galvanic

Corrosion) ........................................... 1-2

1.6.3 Anode and Cathode Surface Area ........... 1-4

1.6.4 Climate .................................................... 1-4

1.6.4.1 Desert ...................................................... 1-4

1.6.4.2 Temperate Zones..................................... 1-4

1.6.4.3 Tropics .................................................... 1-4

1.6.4.3.1 Factors of Influence in Tropical

Environments ...................................... 1-4

1.6.5 Heat Treatment and Grain Direction....... 1-4

1.6.6 Electrolytes.............................................. 1-4

1.6.7 Microbial Induced/Influenced

Corrosion............................................. 1-6

1.6.8 Mechanical Stress ................................... 1-7

1.6.9 Time ........................................................ 1-7

1.6.10 Manufacturing......................................... 1-7

1.6.11 Storage .................................................... 1-7

1.6.12 Degradation of Non-metals..................... 1-7

1.6.13 Preventive Maintenance (PM) ................ 1-7

1.7 Types of Corrosion.................................. 1-8

1.7.1 Uniform Etch Corrosion.......................... 1-8

1.7.2 Galvanic Corrosion ................................. 1-8

1.7.3 Pitting Corrosion ..................................... 1-9

1.7.4 Intergranular Corrosion........................... 1-9

1.7.5 Exfoliation Corrosion.............................. 1-9

1.7.6 Concentration/Crevice Corrosion ........... 1-9

1.7.7 Stress Corrosion Cracking .................... 1-11

1.7.8 Hydrogen Embrittlement....................... 1-11

1.7.9 Corrosion Fatigue.................................. 1-11

1.7.10 Filiform Corrosion ................................ 1-11

1.7.11 Fretting Corrosion ................................. 1-12

1.8 Metals Affected By Corrosion .............. 1-13

1.8.1 Magnesium............................................ 1-13

1.8.2 Steel....................................................... 1-13

1.8.3 Aluminum ............................................. 1-13

1.8.4 Copper and Copper Alloys.................... 1-13

1.8.5 Stainless Steel ....................................... 1-13

1.8.6 Nickel and Chromium........................... 1-14

2 CLEANING............................................................... 2-1

2.1 General .................................................... 2-1

2.1.1 Introduction............................................. 2-1

2.1.2 SE Wash Cycles ...................................... 2-1

2.1.3 Definition of Cleaning ............................ 2-1

2.1.4 Types of Cleaners.................................... 2-1

2.1.5 Methods of Cleaning............................... 2-1

2.1.6 Cleaning Materials .................................. 2-8

2.1.7 General Cleaning Material and

Processes ........................................... 2-13

2.1.7.1 Cleaning Solutions ................................ 2-13

2.1.7.2 Cleaning Compounds............................ 2-14

2.1.7.3 Water Temperature ............................... 2-14

2.1.7.4 Deployed/Remote Sites......................... 2-14

2.1.7.4.1 Water Assessment ................................. 2-14

2.1.7.4.2 Engines and Engine Components ......... 2-14

i

TABLE OF CONTENTS - CONTINUED

Section Page Section Page

2.1.8 Cleaning of Non-metal Parts Prior to

Painting . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.1.8.1 Composites . . . . . . . . . . . . . . . . . . . . . . 2-14

2.1.8.2 Plastics . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2.1.9 Cleaning of Electrical Parts . . . . . . . . . 2-14

2.1.10 Preparation of SE for Cleaning . . . . . . . 2-15

2.1.11 Cleaning of Engine Components and

Enclosures . . . . . . . . . . . . . . . . . . . . 2-15

2.2 MECHANICAL CLEANING . . . . . . . 2-16

2.2.1 General Information . . . . . . . . . . . . . . . 2-16

2.2.2 Coating Removal on Composite

Surfaces. . . . . . . . . . . . . . . . . . . . . . . 2-16

2.2.3 Coating Removal on Metallic

Surfaces. . . . . . . . . . . . . . . . . . . . . . . 2-17

2.2.4 Grinding . . . . . . . . . . . . . . . . . . . . . . . . 2-17

2.2.5 Wire Brushing. . . . . . . . . . . . . . . . . . . . 2-17

2.2.6 High-Pressure Water (HPW)

Paint Removal Method . . . . . . . . . . . 2-17

2.2.6.1 Authorized HPW Equipment . . . . . . . . 2-18

2.2.6.2 Training Requirements . . . . . . . . . . . . . 2-19

2.2.6.3 Personnel and Equipment Preparation

Prior to HPW . . . . . . . . . . . . . . . . . . 2-19

2.2.6.4 HPW Paint Removal Operation . . . . . . 2-19

2.2.6.5 Post HPW Paint Removal Cleaning . . . 2-19

3 PAINTING, SEALING, CORROSION

PREVENTIVE COMPOUND

APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 Definition of Exposure . . . . . . . . . . . . . . 3-1

3.3 Requirements For Painting - Field

Level . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.3.1 Complete Repainting Criteria . . . . . . . . . 3-1

3.3.2 Abrasive Blasting . . . . . . . . . . . . . . . . . . 3-1

3.3.3 Temporary Coating Repairs . . . . . . . . . . 3-2

3.3.4 Touch-up Primer . . . . . . . . . . . . . . . . . .3-2.1

3.4 Requirements For Painting - Depot

Level and Contractor Support. . . . . .3-2.1

3.4.1 Corrosion Rework Determination. . . . .3-2.1

3.4.2 Contractor Compliance . . . . . . . . . . . . 3-2.1

3.5 Authorized Colors, SEMPENS, and

Materials . . . . . . . . . . . . . . . . . . . . . 3-2.1

3.5.1 SE Standardized Colors . . . . . . . . . . . .3-2.1

3.5.2 SE Standard Topcoat. . . . . . . . . . . . . . . . 3-3

3.5.3 Authorized Colors for Liquid Oxygen, Nitrogen Storage Carts and Tanks. . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3.5.4 Passenger or Loading Ramps . . . . . . . .3-4.1

3.5.5 Presidential Support Equipment and

USAF Demo Team . . . . . . . . . . . . . .3-4.1

3.6 CORROSION TREATMENT FOR

STEELCABLES . . . . . . . . . . . . . . . .3-4.1

3.7 PIANO TYPE HINGES . . . . . . . . . . . .3-4.1

3.8 MATING SURFACES

PROTECTION

REQUIREMENTS . . . . . . . . . . . . . .3-4.1

3.8.1 Mating Surfaces - Bare Steel . . . . . . . .3-4.1

3.8.2 Mating Surfaces - All Other Metals . . .3-4.1

3.8.3 Sealers and Sealant Usage . . . . . . . . . .3-4.1

3.9 ACOUSTICAL MATERIAL

PRECAUTIONS. . . . . . . . . . . . . . . . . 3-6

3.9.1 Coustifoam PUI and AF . . . . . . . . . . . . . 3-6

3.9.2 Nonmetallic Fastener . . . . . . . . . . . . . . . 3-6

3.10 DRAINAGE . . . . . . . . . . . . . . . . . . . . . . 3-6

3.10.1 Fluid Collection Points . . . . . . . . . . . . . . 3-6

3.10.2 Modifying Fluid Collection Points . . . . . 3-6

3.11 MAINTENANCE STAND RAILS AND

RAIL HOLDERS . . . . . . . . . . . . . . . . 3-7

3.11.1 Drain Holes . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.11.2 Drain Hole Corrosion Prevention and

Treatment . . . . . . . . . . . . . . . . . . . . . . 3-7

3.12 HOLLOW STRUCTURAL

MEMBERS. . . . . . . . . . . . . . . . . . . . . 3-7

3.12.1 Drainage for Closed Hollow Members, When Open Drain Holes are Possible . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3.12.2 Drainage for Closed Hollow Members, When Open Drain Holes are Not Possible . . . . . . . . . . . . . . . . . . . . 3-7

3.13 CORROSION PREVENTIVE

COMPOUNDS (CPC) . . . . . . . . . . . . 3-8

3.13.1 MIL-PRF-81309 . . . . . . . . . . . . . . . . . . . 3-8

3.13.2 MIL-DTL-85054. . . . . . . . . . . . . . . . . . . 3-9

3.13.3 MIL-PRF-16173 CPC Solvent Cutback, Cold Application. . . . . . . . . . . . . . . . . 3-9

3.13.4 MIL-PRF-63460 Lubricant, Cleaner, and

Preservative for Weapons and Weapon Systems . . . . . . . . . . . . . 3-9

3.13.5 MIL-L-87177 Lubricants, Water

Displacing . . . . . . . . . . . . . . . . . . . . . . 3-9

3.13.6 CPC Methods of Application . . . . . . . . . 3-9

3.14 CPC Application on Ferrous Alloys . . . . 3-9

3.15 CPC APPLICATION ON OTHER

ALLOYS. . . . . . . . . . . . . . . . . . . . . . . 3-9

3.16 COATING APPLICATIONS . . . . . . . . 3-10

3.16.1 Material Selection . . . . . . . . . . . . . . . . . 3-10 ii Change 5

Chapter Page Chapter Page

3.16.2 SE Surface Preparation Categories ....... 3-12

3.16.3 Organic Zinc-Rich Primer..................... 3-12

3.16.4 MIL-PRF-85285 Polyurethane, Type I ................................................ 3-13

3.16.5 Thermal Spray Coating Systems........... 3-13

3.17 Field Level Maintenance

Painting Requirements ...................... 3-15

3.17.1 Touch-Up Painting................................ 3-15

3.18 Maintenance Painting............................ 3-15

3.18.1 Maintenance Painting Restrictions........ 3-15

3.18.2 Prepackaged Coating Touch-Up Kits ... 3-16

3.18.3 Radiators Coatings ................................ 3-16

3.19 Liquid Oxygen and Liquid Nitrogen

Servicing Carts and Storage Tanks ... 3-16

3.19.1 Authorized Materials for Liquid

Oxygen and Nitrogen Tanks ............. 3-16

3.20 Walkways and Stepping Surface

Coatings ............................................ 3-16

3.21 Colors for Waste Containers ................. 3-16

3.22 SE Undercoating ................................... 3-16

3.22.1 SE Undercoating Considerations .......... 3-17

3.23 Storage Compartments.......................... 3-17

3.24 Split Wheel Assemblies ........................ 3-17

3.24.1 Split Wheel Coating Requirements....... 3-17

3.25 Mufflers................................................. 3-17

3.26 Miscellaneous Cleaning, Sealing, and

CPC Requirements............................ 3-18

3.26.1 Sealing of Addressograph or

Dash-A Plates.................................... 3-18

3.26.2 Electrical Hardware and Terminals....... 3-18

3.26.3 Light Assemblies................................... 3-18

3.26.4 Internal Electrical Components:

Circuit Breakers, Relays, etc............. 3-18

3.26.5 Electrical Connectors ............................ 3-18

3.26.6 Switches ................................................ 3-19

3.26.7 Wire Harness and Cables ...................... 3-19

3.26.8 Heli-Coil Insert Replacement................ 3-19

4 MARKING OF SUPPORT EQUIPMENT ............... 4-1

4.1 General .................................................... 4-1

4.2 Safety and Servicing Markings ............... 4-1

4.2.1 National Star Symbol .............................. 4-1

4.2.2 Marking Requirements............................ 4-1

4.2.3 Product Identification.............................. 4-1

4.2.4 SE Reflectorization ................................. 4-2

4.3 Agency Identification Markings ............. 4-2

4.3.1 Air Force Owned - Contractor

Operated Equipment ........................... 4-2

4.3.2 Mobilized Equipment.............................. 4-2

4.4 Informational Markings (Optional)......... 4-3

4.5 Color, Style and Size of Markings .......... 4-3

4.5.1 Use of Reflective Tape, Decals, and Vinyl Lettering ............................. 4-3

4.5.2 Field Numbers......................................... 4-4

4.5.3 USAF Legends........................................ 4-4

4.5.4 Color Numbers........................................ 4-4

4.5.5 Markings Size ......................................... 4-5

4.5.6 Tire Pressure/Tow Speed ........................ 4-5

4.6 Maintenance of Markings ....................... 4-5

4.6.1 Markings Removal .................................. 4-5

4.6.2 National Guard Decalcomania ................ 4-5

4.7 Caution/Warning Markings..................... 4-5

4.7.1 Pintle Hook Caution Marking ................. 4-5

4.7.2 Spring Loaded Warning Marking ........... 4-5

4.7.3 Aircraft Towbar Caution Marking .......... 4-5

4.7.4 Tire Pressure/Tow Speed Markings........ 4-5

4.7.5 Personnel Static Discharge Marking....... 4-5

4.8 Fuel Cell Repair SE Identification .......... 4-5

5 CORROSION PREVENTION AND CONTROL OF

HUSH HOUSES................................................. 5-1

5.1 Materials.................................................. 5-1

5.1.1 Fastener Replacement ............................. 5-1

5.2 Repair ...................................................... 5-1

5.2.1 Galvanized Steel ..................................... 5-1

5.2.2 Carbon Steel ............................................ 5-1

5.2.3 Stainless Steel ......................................... 5-1

5.2.3.1 Type 321 Stainless Steel ......................... 5-2

5.2.3.4 AISI 409 Stainless Steel.......................... 5-2

5.2.3.7 Sealing..................................................... 5-2

5.3 Pretreatment Compounds........................ 5-2

5.3.1 Rust Remover 81287 (Naval Jelly) ......... 5-2

5.4 Primers .................................................... 5-3

5.4.1 Organic Zinc-Rich Primers ..................... 5-3

5.4.2 Inorganic Zinc-Rich Primers................... 5-3

5.5 Painting ................................................... 5-3 Change 8 iii

Chapter Page Chapter Page

5.5.1 Structural Corrosion Protection .................. 5-3

5.5.2 Camouflage Requirements.......................... 5-3

5.6 Inorganic Zinc Primed Surfaces.................. 5-3

5.6.1 Primer Requirements on the Door

Frame Beams, Support Beams, and Exhaust Tube.................................... 5-3

5.7 Galvanized Surfaces.................................... 5-4

5.7.1 Roof............................................................. 5-4

5.7.2 Walls and Doors.......................................... 5-4

6 CORROSION PREVENTION AND CONTROL

OF NOISE SUPPRESSOR SYSTEMS (NSS) ...... 6-1

6.1 General ........................................................ 6-1

6.2 Materials ..................................................... 6-1

6.3 Fastener Replacement ................................. 6-1

6.4 Structural Repair ......................................... 6-1

6.4.1 Structural Repair Carbon Steel ................... 6-1

6.4.2 Galvanized Steel ......................................... 6-1

6.4.3 AISI 409 Stainless Steel.............................. 6-1

6.5 Sealing......................................................... 6-2

6.6 Primers ........................................................ 6-2

6.6.1 Organic Zinc-Rich Primers ......................... 6-2

6.6.2 MIL-PRF-23236, Type I, Class 3 ............... 6-2

6.6.3 Heat Resistant Primer Briner 2905 ............. 6-2

6.6.4 Heat Resistant Silicone Coating -

Briner 2986 ............................................. 6-2

6.6.5 High Temperature Resistant Silicone

Coating - Briner 4765 ............................. 6-3

6.6.6 High Temperature Resistant Silicone

Coating Thurmalox 270-18..................... 6-3

7 SOUTHWEST ASIA OPERATIONS

AND ENVIRONMENTS....................................... 7-1

7.1 General........................................................ 7-1

7.1.1 Environmental Effects ................................ 7-1

7.1.1.1 Soils and Humidity ..................................... 7-1

7.2 SE SWA AOR Deployment........................ 7-2

7.2.1 Pre-deployment ........................................... 7-2

7.2.2 Deployment Location ................................. 7-2

7.2.2.1 SE Units Requiring Additional Cleaning.... 7-2

7.2.3 Maintenance Touch-Up Painting ................ 7-3

7.2.3.1 Temporary Coating Repair ......................... 7-3

7.2.3.2 Permanent Authorized Touch-Ups ............. 7-3

7.2.4 Equipment Storage...................................... 7-3

A EQUIPMENT AND CONSUMABLE

MATERIALS USED FOR CORROSION

CONTROL ............................................................ A-1

A.1 Equipment and Consumable Materials ...... A-1

LIST OF ILLUSTRATIONS

Number Title Page Number Title Page

1-1 Diagram of a Simplified Corrosion Cell and an Example of Raised Corrosion Product............ 1-2

1-2 Corrosion Accelerated by Condensed Moisture............................................................... 1-5

1-3 Open Cell Foam and Resulting Corrosion ............... 1-6 1-4 View of the Results of Microbial Induced

Corrosion ............................................................. 1-6 1-5 Example of Uniform Etch ........................................ 1-8 1-6 Example of Galvanic Corrosion - Steel Hinge

Bolted to an Aluminum Door .............................. 1-9 1-7 Example of Pitting Corrosion................................... 1-9 1-8 Illustration of an Intergranular Corrosion Cell....... 1-10 1-9 Example of Exfoliation Corrosion ......................... 1-10 1-10 Examples of Concentration/Crevice Corrosion...... 1-10 1-11 Illustration of a Typical Concentration

Corrosion Cell.................................................... 1-11 1-12 Example of Filiform Corrosion .............................. 1-12 1-13 Illustration of a Fretting Corrosion Cell ................. 1-12 3-1 Example of Standing Water Due to

Inadequate Drainage Provisions .......................... 3-6

3-2 Hollow Member Drain Hole Configuration ............. 3-7 3-3 Hollow Member Weld-Nut Configuration ............... 3-8 3-4 Corrosion Under Data Plate ................................... 3-18 4-1 NATO Liquid Oxygen Servicing Markings............. 4-1 4-2 NATO Liquid Nitrogen Servicing Markings ........... 4-1 4-3 Sample Mobility Placard .......................................... 4-4 4-4 1,500 LB Utility Crane............................................. 4-7 4-5 ACE Air Conditioner MC1A, Diesel ....................... 4-9 4-6 AF/M27M-1 Pumping Unit, Hydraulic, Diesel Driven..................................................... 4-11 4-7 AF/M32T-1 Cabin Leakage Tester ........................ 4-13 4-8 Aircraft Oxygen Servicing Cart ............................. 4-15 4-9 A/M24T-8 Load Bank............................................ 4-17 4-10 A/M32A-60A Gas Turbine Generator ................... 4-19 4-11 A/M32A-86 Generator, Diesel ............................... 4-21 4-12 A/M32A-95 Compressor, Gas Turbine, Trailer Mounted................................................. 4-23 4-13 A/M32C-10C/10D Air Conditioner Set ................. 4-25 4-14 A/M32C-5 Air Conditioner Set.............................. 4-27 4-15 Auxiliary Ground Power Unit (AGPU) ................. 4-29 iv Change 4

LIST OF ILLUSTRATIONS - CONTINUED

Number Title Page Number Title Page 4-16 B-1/B-2 Air Conditioner, Trailer Mounted ............4-31 4-17 B-4 Maintenance Stand ..........................................4-33 4-18 B-5 Maintenance Stand ..........................................4-35 4-19 B-2 Maintenance Stand ..........................................4-37 4-20 B-7/B-1 Maintenance Stand ...................................4-39 4-21 B809A Generator Set .............................................4-41 4-22 C-1 Maintenance Stand ..........................................4-43 4-23 Spraying Unit, Corrosion Control Wash Cart ........4-45 4-24 Deleted 4-25 EPU-6 Aircraft Power Supply ................................4-49 4-26 FDECU-3 Environmental Control Unit..................4-51 4-27 Fuel Bowser 400 Gallon.........................................4-53 4-28 H-1 Heater ..............................................................4-55 4-29 HDU-13M Heater ...................................................4-57 4-30 Hydraulic Cart ........................................................4-59 4-31 Jack, Hydraulic 10 - 30 Ton ...................................4-61 4-32 Jack, 35 Ton, Axle..................................................4-63 4-33 Liquid Cooling Service (LCS) Cart........................4-65 4-34 Liquid Oxygen Cart ................................................4-67 4-35 LN2 Liquid Nitrogen Cart ......................................4-69 4-36 MC-1A High Pack Air Compressor .......................4-71 4-37 MA-3D Air Conditioner .........................................4-73 4-38 MC-2A Air Compressor .........................................4-75

4-39 MC-7 Air Compressor............................................ 4-77 4-40 MD-1 Towbar ......................................................... 4-79 4-41 MEP Generators ..................................................... 4-81 4-42 MHU-83C/E Bomblift Truck .................................4-83 4-43 MJ-1B Bomblift Truck ........................................... 4-85 4-44 Hydraulic Test Stand .............................................. 4-87 4-45 Light Cart, FL-1D................................................... 4-89 4-46 NF-2D Light Cart, Diesel .......................................4-91 4-47 Oil Cart ...................................................................4-93 4-48 Purging Unit GSU-62M LOX Storage ................... 4-95 4-49 Radome Dolly......................................................... 4-97 4-50 Self-Generating Nitrogen Cart ............................... 4-99 4-51 Service Cart .......................................................... 4-101 4-52 Trielectron Generator ........................................... 4-103 4-53 Universal Maintenance Stand............................... 4-107 4-54 New Generation Heater ........................................ 4-109 5-1 Angle Iron Sealant Application ................................ 5-2

7-1 SWA AOR................................................................ 7-1

7-2 Sand/Dust Intrusion .................................................. 7-1 7-3 Residue from Salts Caused by Condensation........... 7-1 7-4 Locally Manufactured Permeable Covers ................ 7-2 7-5 Wire Bundle Sand/Dust

Accumulation....................................................... 7-2

LIST OF TABLES

Number Title Page Number Title Page

1-1 Galvanic Series of Metals and Alloys ...................... 1-3 1-2 Corrosion of Metals - Type of Attack and

Appearance of Corrosion Products....................1-14 2-1 Wash Interval Based on Corrosion Severity

Zones....................................................................2-2 2-2 Authorized Cleaning Materials...............................2-10 2-3 Authorized HPW Equipment..................................2-18

3-1 Authorized Coating System...................................... 3-3 3-2 Pretreatment Instructions........................................ 3-10 3-3 Metalization Material Sources of Supply ............... 3-14 4-1 Mobility Placard Construction Information ............. 4-3 4-2 Mobility Placard Stencil Requirements.................... 4-3 5-1 Hush House Coating Chart ....................................... 5-3 A-1 Equipment and Consumable Materials List ............ A-1 Change 8 v/(vi blank)

FOREWORD

1. PURPOSE.

The purpose of this manual is to provide information necessary to prevent or minimize the impact of corrosion on Support Equipment (SE). This manual is designed to provide basic cor-rosion principal, theory, identification, prevention and control information to enable SE technicians to differentiate between the different types of corrosion in order to identify the appro-priate temporary repair materials and processes. This technical order is specific to SE; however, for areas not covered in this manual, or expanded information on a particular material or process, technicians or contractors should refer to TO 1-1-691, “Aircraft Weapon Systems Cleaning and Corrosion Control”.

For additional guidance, refer to TO 1-1-8, “Application and Removal of Organic Coatings, Aerospace and Non-Aerospace Equipment”, and TO 1-1-689, “Avionic Cleaning, and Corro-sion Prevention/Control”.

2. SCOPE.

This manual is designed to provide basic information to be used by Organizational/Unit, Intermediate, and Depot levels of maintenance. This manual shall also be used to provide guid-ance for corrosion prevention and control activities of con-tracted maintenance inspection, repair, and overhaul of SE. If conflicting instructions occur that pertain to the marking and painting of USAF SE, the end item manual takes precedence over this manual. Conflicts in resolving any conflicting materi-als and processes application requirements shall be referred to the Air Force Corrosion Prevention and Control Office, AFRL/RXSSR, Robins AFB, GA. Conflicts regarding all other criteria in this manual shall be referred to WR-ALC, Robins AFB, GA for resolution.

2.1 Chapter 1 Description. This chapter provides the basic

information needed by SE technicians to accurately identify the causes, types of corrosion and how to minimize the factors that cause and accelerate corrosion. This chapter also provides procedures for the SE technicians to be able to treat corrosion in the early stages.

2.2 Chapter 2 Description. This chapter establishes the rec-

ommended SE wash cycles based on location; provides a list-ing and description of authorized cleaning compounds; and lists specific cleaning processes for SE.

2.3 Chapter 3 Description. This chapter provides the SE

technician with the coating requirements authorized coating systems, sealing requirements, and corrosion preventive com-pound applications. It also provides the only authorized colors for USAF SE.

2.4 Chapter 4 Description. This chapter displays authorized

markings and their locations on SE.

2.5 Chapter 5 Description. This chapter covers the materi-

als and processes for construction and maintenance of Hush Houses.

2.6 Chapter 6 Description. This chapter covers the materi-

als and processes for NSS.

2.6A Chapter 7 Description. This chapter covers opera-tions unique to the Southwest Asia Region.

2.7 Appendix A Description. This appendix provides a list

of consumable material authorized for use on SE.

3. ABBREVIATIONS AND ACRONYMS.

Abbreviations and acronyms used in this manual are in the accordance with ASME Y14.38.

Abbreviation Definition

AISI American Iron and Steel Institute AFOSH Air Force Office of Safety and Health AFRL/RXSSR Air Force Corrosion Prevention and Control Office AOR Area of Responsibility BBE Base Bioenvironmental Engineer BOD Biochemical Oxygen Demand CPC Corrosion Preventive Compound CRES Corrosion Resistant Steel DO Dissolved Oxygen ESD Electrostatic Discharge HPW High-Pressure Water ID Inside Diameter MIG Gas Metal-Arc MSDS Material Safety Data Sheet MWAS Metallization Process Metal Wire

Arc Spray NACE National Association of Corrosion

Engineers NSN National Stock Number OD Outside Diameter OSHA Occupational Safety and Health

Administration pH Potential of Hydrogen PSI Pounds Per Square Inch PSIG Pounds Per Square Inch Gauge PM Preventive Maintenance PPE Personal Protective Equipment QPL/QPD Qualified Products List/Database RH Relative Humidity RTV Room Temperature Vulcanizing Change 8 vii

Abbreviation Definition SCC Stress corrosion cracking SE Support Equipment SSDC Steel Structure Painting Council SWA Southwest Asia TIG Gas Tungsten Arc TDS Total Dissolved Solids VOC Volatile Organic Compound

4. LIST OF RELATED PUBLICATIONS.

Below is a list of publications referenced in this manual.

Number Title TO 00-25-234 General Shop Practice Requirement for the Repair, Maintenance and Test of Electrical Equipment

TO 00-35D-54 USAF Materiel Deficiency Reporting and Investigating System

TO 00-5-1 Air Force Technical Order Systems

Number Title

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

TO 1-1-691 Aircraft Weapons Systems - Cleaning and Corrosion Control

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

TO 35C2-3-1- Periodic Inspection Work Cards - 426WC-4-20-1 Diesel Engine Driven Generator Sets

A/M32A-86 Series

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

TO 42B-1-23 Management of Recoverable and Waste Liquid Petroleum Products

5. RECOMMENDATIONS FOR CHANGES.

Recommendations for changes shall be submitted on AFTO Form 22 in accordance with TO 00-5-1.

viii Change 4

SAFETY SUMMARY

1. GENERAL SAFETY INSTRUCTIONS.

The safety precautions in AFOSH Standard 91-66, AFOSH Standard 91-100 and OSHA Standard 1910.107 are applicable to the operation of paint shops and spray-painting equipment and shall be followed during cleaning and repainting of SE.

2. WARNING AND CAUTION STATEMENTS.

These statements have been strategically placed throughout this text prior to operating or maintenance procedures, prac-tices or conditions considered essential to the protection of per-sonnel (WARNING) or equipment and property (CAUTION).

A WARNING and CAUTION will apply each time the related step is repeated. Prior to starting any task, the WARNINGS or CAUTIONS included in the text for the task will be reviewed and understood.

3. DEFINITIONS.

The following definitions apply to WARNINGS and CAU- TIONS found throughout this publication.

Highlights an operation or maintenance procedure, practice, statement, etc., which, if not strictly ob-served, could result in injury, long term health hazard or death to personnel.

Highlights an operation or maintenance procedure, practice, statement, etc., which, if not strictly ob-served, could result in damage or destruction to equipment or loss of mission effectiveness.

NOTE

Highlights an essential operating or maintenance pro-cedure, condition or statement.

4. MATERIALS HANDLING.

4.1 Personnel Hazards. Many of the materials and proce-

dures outlined in this technical order are potentially hazardous to personnel, if used improperly. When using chemicals such as paint strippers, cleaning compounds, conversion coatings, and solvents, follow the correct procedures and wear appropri-ate protective gear to prevent injury to personnel. Read the appropriate Material Safety Data Sheet (MSDS), manufac-turer's instructions and be familiar with related warnings and cautions in this technical order prior to using any material.

Misuse of certain materials can also damage parts or cause cor-rosion. Refer to DOD 6050.5-LR, Hazardous Material Infor-mation System, FED STD 313, Material Safety Data, Transportation Data, and Disposal Data for Hazardous Mate-rial Furnished to Government Activities, or the appropriate systems command documents for the handling, storage, and disposal of hazardous materials. When in doubt, contact the local safety office, base bioenvironmental office, or regional medical center for guidance.

4.2 Environmental Hazards. Many of the materials and

procedures outlined in this technical order are also potentially hazardous to the environment. Wherever possible, methods for preventing pollution, minimizing waste, and using less toxic materials are given. Consult the base bioenvironmental office for information about the handling, storage, and disposal of hazardous waste.

5. GENERAL PRECAUTIONS.

The following general safety precautions are not related to any specific procedure and therefore do not appear elsewhere in this technical manual. These are general safety precautions and instructions people must understand and apply during many phases of operation and maintenance to ensure personal safety and health and the protection of Air Force property.

5.1 Live Circuits. Operating personnel must observe all

safety requirements at all times. Do not replace components or make adjustments inside equipment with the electrical supply turned on. Under certain conditions, danger may exist even when the power control is in the off position due to charges retained by capacitors. To avoid injuries, always remove power, discharge, and ground a circuit before touching it.

Adhere to all lock out/tag out requirements.

5.2 Resuscitation. Personnel working with or near danger-

ous voltage shall be trained in modern methods of resuscita-tion. Information and training sources may be obtained from the Director of Base Medical Services.

5.3 Finger Rings/Jewelry. Finger rings have caused many

serious injuries. Remove rings, watches and other metallic objects that may cause shock or burn hazards. Unless specifi-cally allowed by shop safety procedures, remove finger rings during all maintenance activity.

5.4 Compressed Air. Use of compressed air can create an

environment of propelled particles. Do not direct air streams ix towards yourself or other personnel. Air pressure shall be reduced to less than 30 PSIG and used with effective chip guarding and personal protective equipment.

5.5 DANGEROUS PRESSURES. Care must be taken

during testing to ensure that all test connections are proper and tight. All system components must be compatible with applied pressure. Personnel must be protected by a safety shield or located at a distance sufficient to prevent injury.

6. PERSONAL PROTECTIVE EQUIPMENT (PPE).

If unique local conditions make compliance with the protec-tive clothing or other occupational health requirements speci-fied in this manual unnecessary or impractical, obtain an evaluation of the operation from the Bioenvironmental Engi-neer. The Bioenvironmental Engineer or Base Safety Office will determine the required precautions and approved PPE.

7. CLEANERS/CHEMICALS/PAINTS/PRIMERS.

Some cleaners, chemicals, paints, and primers have adverse effects on skin, eyes, and the respiratory tract. Observe manu-facturer's warning labels, Material Safety Data Sheet (MSDS) and other instructions for proper handling, storage, and dis-posal; and current safety directives. Use only in authorized areas.

8. ELECTROSTATIC DISCHARGE (ESD).

Certain circuit card assemblies and their components will be damaged by seemingly undetectable electrostatic discharge.

Care must be exercised during handling/repair of those items.

Use Electrostatic Discharge (ESD) precautionary procedures outlined in TO 00-25-234, General Shop Practice Require-ments for Repair, Maintenance and Test of Electrical Equip-ment, and MIL-HDBK-263, Electrostatic Discharge Control Handbook for Protection of Electrical and Electronic Parts, Assemblies and Equipment.

x Change 4

CHAPTER 1

CORROSION THEORY, IDENTIFICATION, CAUSES AND EFFECTS

1.1 PURPOSE.

The purpose of this chapter is to provide SE maintenance per-sonnel with the basic knowledge necessary to understand the causes of corrosion, identify the different types of corrosion that will in-turn help minimize corrosion damage through pre-vention and early detection and treatment. To help prevent corrosion, SE technicians must first need to understand corro-sion causes and effects and be able to recognize there are several types of corrosion with different preventive measures.

This chapter is an introduction to corrosion theory, the causes of corrosion and the factors that influence its development.

The various forms of corrosion and the effect of corrosive environments normally on SE are also described in this chap-ter.

1.2 DEFINITION OF CORROSION.

Corrosion is the electrochemical deterioration of a metal because of its chemical reaction with the surrounding environ-ment. This reaction occurs because of the tendency of metals to return to their naturally occurring states, usually oxide or sulfide ores. For example, iron in the presence of moisture and air will return to its natural state, iron oxide or rust. Aluminum and magnesium form corrosion products that are white oxides or hydroxides. When corrosion occurs, water is usually present in some form (e.g., humidity, moisture, condensation, rain, salt spray, etc.), acting as an electrolyte and reacting chemically with metal surfaces.

1.3 CHEMICAL DEFINITIONS.

1.3.1 Atom. The smallest unit of an element. There are more

than 100 elements, including metals (such as aluminum, mag-nesium, iron, nickel, titanium, cadmium, chromium, copper, and carbon) and non-metals (such as hydrogen, oxygen, sulfur, and chlorine).

1.3.2 Electron. A negatively charged particle much smaller

than an atom. An electrical current occurs when electrons are forced to move through metal conductors. Electrons also flow through water solutions, but only in the presence of ions.

1.3.3 Ions. Atoms or groups of atoms bound together that is

either positively or negatively charged. An electrical current occurs when ions are forced to move through water solutions.

Ions cannot move through metal conductors.

1.3.4 Electrolyte. A liquid solution (usually water) contain-ing ions. Salt water is an electrolyte, an aqueous (i.e., water) solution of sodium ions and chloride ions.

1.4 THEORY OF CORROSION.

A corrosion cell is much like a battery. When a metal cor-rodes, the metal atoms lose electrons and become metal ions in an electrolyte solution. The positively charged metal ions can combine with negatively charged ions to form corrosion prod-ucts, such as metallic chlorides, oxides, hydroxides, and sul-fides. Four conditions must exist before this type of corrosion can occur.

1.4.1 Anode. A metal must be present that has a tendency to

corrode. The corroding metal is known as the anode.

1.4.2 Cathode. A dissimilar conductive material (the cath-

ode) that has less of a tendency to corrode than the anode must be present. Examples include a different metal, a protected part of the same metal, or conductive plastics/composite.

1.4.3 Electrolyte. A conductive liquid (electrolyte) must

connect the anode and cathode so that ions can carry electrical current between them.

1.4.4 Electrical Path. Electrical contact between the anode

and cathode (usually in the form of metal-to-metal contact) must exist so that electrons can move from the anode, where they are released, to the cathode. Eliminating any one of these four conditions, illustrated in Figure 1-1, will stop corrosion.

For example, a paint film on a metal surface will prevent the conducting liquid (electrolyte) from connecting the anode and cathode, thereby stopping the electric current. Another exam-ple is when two connected dissimilar metal parts placed in pure water corrode very slowly because of the lack of ions to conduct the electric current. In seawater, the corrosion reaction is accelerated by a factor of 1,000 or more.

1.5 DEVELOPMENT OF CORROSION.

1.5.1 Corrosion Origination Locations. All corrosive

attacks begin on the surface of metals whether it is the inside of a bolt hole, border of a metal crystal, hand rail interior or bottom of a frame. If allowed to progress, corrosion can pene-trate into and through the metal. When corrosion products form, they often precipitate onto the corroding surface as a powdery or scaled deposit. Other evidence of corrosion is the bulging/blistering of the metal surfaces. Thin film corrosion forms on electrical contact points and pins may appear as a tarnish, or powdery deposit on the metal surface.

1-1

Figure 1-1. Diagram of a Simplified Corrosion Cell and an Example of Raised Corrosion Product

1.5.2 Corrosion Under Painted Surfaces. Paint coatings

can mask the initial stages of corrosion. Because corrosion products occupy more volume than the original metal, fre-quently inspect paint surfaces for irregularities such as blisters, flakes, chips, and lumps.

1.6 FACTORS INFLUENCING CORROSION.

Both natural and man-made environments cause corrosion of SE. Natural conditions that affect the corrosion process are moisture, temperature, salt atmospheres, ozone, sand, dust, solar radiation, insects and birds, and microorganisms. Man-made conditions that affect the corrosion process are industrial pollution, manufacturing operations, storage conditions, and shipment. By understanding these conditions, maintenance personnel will be better able to prevent SE damage. Factors that influence metal corrosion and the rate at which it occurs are outlined in Table 1-1.

1.6.1 Type of Metal. The metals most commonly used in

SE construction are aluminum, steel, and to some extent mag-nesium. Cadmium, nickel, chromium, and silver are some-times used as protective plating. Metals have a wide range of corrosion resistance. The most active metals (i.e., those that tend to lose electrons easily), such as magnesium and alumi-num, corrode easily and are listed at the top of Table 1-1. The most noble metals (i.e., those that do not lose electrons easily), such as gold and silver, do not corrode easily and are listed at the bottom of Table 1-1.

1.6.2 Dissimilar Metal Coupling (Galvanic Corrosion).

When two dissimilar metals make electrical contact in the presence of an electrolyte, the rate at which corrosion occurs depends on the difference in their location on the galvanic scale (see Table 1-1). The greater the distance between the metals, the faster corrosion occurs. For example, magnesium corrodes very quickly when coupled with gold in a humid atmosphere. However, pure aluminum corrodes very slowly, if at all, when in contact with cadmium. It is essential in the repair of SE that compatible metals and metal fasteners, wash-ers, etc., be selected for repair and refurbishment processes. If dissimilar metal coupling must occur due to the equipment design or configuration, contact the appropriate system equip-ment specialist for the appropriate processes and materials to insulate the incompatible metals.

1.6.2.1 Graphite or carbon fiber composites are materials

which consist of reinforcing fibers in a matrix made of organic resin, usually epoxy. They are an important class of SE con-struction materials because of their high strength-to-weight ratios and high stiffness. Although graphite or carbon/carbon composites appear as a plastic, the graphite material is consid-ered a metal. Care should be exercised when attaching fasten-ers through the fibers. Use the appropriate sealant to insulate the composite from the metal parts.

1.6.2.2 Since carbon is the least active metal in the galvanic series, it will accelerate the corrosion of any metal to which it is coupled. Insulation, with sealant or other nonconductive coatings, between graphite or carbon epoxy composites and other metals surfaces or fasteners is necessary to prevent dis-similar metal attack on the attached part.

1-2

Table 1-1. Galvanic Series of Metals and Alloys 1-3

1.6.3 Anode and Cathode Surface Area. The rate of gal-

vanic corrosion also depends on the size of the parts in con-tact. If the surface area of the corroding metal (the anode) is smaller than the surface area of the less active metal (the cath-ode), corrosion will be rapid and severe. However, if the cor-roding metal is larger than the less active metal, corrosion will be slow and superficial. For example, an aluminum fastener in contact with a relatively nonreactive Monel structure may cor-rode severely, while a Monel bracket secured to a large alumi-num member would result in a relatively superficial attack on the aluminum.

1.6.4 Climate. Warm, moist air, typically found in tropical

climates, tends to accelerate corrosion because of the higher concentration of water vapor in the air. Additionally, high tem-perature environments tend to produce more rapid corrosion because of accelerated chemical reactions. Conversely, cold dry air, typically found in colder regions of the world, tends to slow corrosion rates due to less water vapor in the air. Corro-sion does not occur in very dry conditions. For this reason, desiccants or dehumidification systems are placed in, or con-nected to shipping or storage containers to create very dry local environments. The equipment’s proposed operational environments and established corrosion prevention and control optimal design parameters should be considered in SE design and procurement.

1.6.4.1 Desert. Hot, wind-swept deserts create a severe

maintenance problem because powdery dust can penetrate even supposedly sealed components. Typically, desert condi-tions are thought to have low humidity and rainfall. However, there are areas of the world considered as desert with high daytime temperatures, moderate to low night time tempera-tures, high humidity (in areas such as the Persian Gulf), ultra-violet radiation, and fine dust. These conditions pose the most serious, destructive elements of the desert climate due to the wide range of conditions experienced daily.

1.6.4.2 Temperate Zones. The temperate or intermediate

climate zone encompasses most of the North American and European continents. These areas at various times of the year may approximate the extremes of polar, desert, or tropical temperatures and humidity. The temperate zone temperatures range from -25 °F to +59 °F (-32 °C to +15 °C) in the winter and from +59 °F to +125 °F (+15 °C to +52 °C) in the sum-mer. The relative humidity (RH) also fluctuates between five and 100%. The most critical areas are coastal locations, during the warm periods of the year in which the relative humidity approaches 100% RH at night and the air has high concentra-tions of salt. Moisture from this salt laden air can condense on equipment during early evening and morning hours, thereby causing serious corrosion. Because of its relatively mild tem-peratures, the temperate zone is also the most heavily popu-lated. Consequently the smoke, smog, ozone, and corrosive fumes associated with heavy industry are also found there.

1.6.4.3 Tropics. One of the greatest challenges to SE manu-

facturing industries is to the design equipment that is protected from corrosion and deterioration in the continual heat and humidity of tropical climates. Even though they encompass only a small portion of the earth's land area, the tropics demand the greatest amount of consideration from the stand-point of corrosion treatment and control. Relative humidity of up to 100% RH at ambient air temperatures of 85 °F (29 °C) and above create a formidable threat of corrosion. When high humidity and temperature conditions are combined with salt-laden air, the corrosive environment becomes extremely severe. The critical combination of high temperatures, conden-sation, high relative humidity, and contaminants such as salt and sand may cause premature structural failure of equipment due to corrosion. Deterioration of the materials used in elec-tronic equipment may also be accelerated. Thin film corrosion on electrical contact points and pins act as insulators to electri-cal current adversely affecting the operations of SE.

1.6.4.3.1 Factors of Influence in Tropical Environ-

ments. Tropical environments are noted for long periods of heavy rainfall, during which 100 inches or more of rain may fall. Extended periods of high heat and humidity contribute to rapid corrosion of metals, cracking and flaking of rubber and plastic materials, and deterioration of seals. Equipment, whether stored or in use, requires special protective contain-ers/measures and frequent preventive maintenance. Microor-ganisms multiply excessively in tropical environments and attack many non-metallic materials. Many items become cov-ered with fungi in a matter of hours. Electronic equipment requires special efforts for effective operation in the tropics.

Intensive preventive maintenance and the best possible protec-tive techniques are necessary for SE and their components in tropical environments.

1.6.5 Heat Treatment and Grain Direction. When heat-

treated, heavy sections of metals do not cool uniformly because the metallic grain/crystalline structures tend to vary in chemical…