SAIRBUS IHDUSTRIE

PROCESS AND MATERIAL SPECIFICATION

PROCESS SPECIFICATION

01-01-22

ACCEPTANCE AND REPAIR OF

SURFACE DEFECTS ON METAL
PARTS TO BE PAINTED

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 ©AIRBUS IHDUSTRIE
PROCESS AND MATERIAL SPECIFICATION

RECORD OF REVISIONS

REV . ISSUE INSERTED REV . ISSUE INSERTED

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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE

RECORD OF REVISION 1 Feb 01/87

LIST OF EFFECTIVE PAGES 1 Aug 01/95

TABLE OF CONTENTS 1 Aug 01/95

01-01-22 1 Aug 01/95

01-01-22 2 Aug 01/95
01-01-22 3 Aug 01/95
01-01-22 4 Aug 01/95
01-01-22 5 Aug 01/95
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PROCESS AND MATERIAL SPECIFICATION

TABLE OF CONTENTS

SUBJ ECT PAGE

1. GENERAL 1

1 .1 Subject 1
1 .2 Limitations of use 1
1 .3 Health and safety statement 1

2. DEFINITIONS OF DEFECTS 2

2 .1 Scratches 2
2 .2 Bulges and dents 2
2 .3 Impacts 2

3. EVALUATION OF DEFECTS 2

3 .1 Measurement of depth 2
3 .2 Measurements of the surface dimensions of defects 3

4. DEFECTS ACCEPTABLE WITHOUT CONCESSION BUT WHICH MUST BE REWORKED 3

4 .1 Scratches 3
4 .2 Bulges and dents 3
4 .3 Impacts 3

5. REPAIR OF DEFECTS 4

5 .1 Scratches 4
5 .2 Bulges and dents 5
5 .3 Impacts 5

6. REFERENCED DOCUMENTS 6

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PROCESS AND MATERIAL SPECIFICATION-

1. GENERAL

1 .1 Subject

This Document shall not be used as a basis for manufacture and supply of
original and replacement parts to AIRBUS INDUSTRIE unless specifically
required in a contract or purchase agreement .

This specification defines the conditions for the acceptance or refusal

of accidental surface damage which can occur on the various metal parts
of an aircraft either during manufacture or after delivery to customer .

The process is applicable to :

Painted surfaces .

Surfaces which are not yet painted but will be painted .

1 .2 Limitations of use

This process is not applicable to defects on :

Pipes .

Bores (see tolerances on drawings) .

- Raw materials in the as-delivered condition .

This specifications deals with minor defects . For this reason, repair
procedures are described in a practical way .

Any defect larger than those described in this specification must be

treated on a case-by-case basis, taking account of :

The component affected .

The extent of the damage .

Its position on the component affected .

1 .3 Health and safety statement

This specification does not necessarily detail the precautions necessary

to meet the requirements of health and safety .

It is the responsibility of the user of this specification to consult

and establish appropriate health and safety precautions and the method
should be operated only by trained personnel .

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PROCESS AND MATERIAL SPECIFICATION

2. DEFINITIONS OF DEFECTS

2 .1 Scratches

These are narrow marks which penetrate into the material and which
affect the surface finish .

They are caused by rubbing against an object with sharp edges .

2 .2 Bulges and dents

These are Localized defects caused by bumping against blunt instruments .

They affect the form of the surface but do not penetrate the material .

2 .3 Impacts

These are localized defects caused by bumping against sharp-edged

objects .

This type of defect includes both a dent and penetration into the
material .

3. EVALUATION OF DEFECTS

The defects described in this specification are evaluated, measured for

depth and superficial dimension .

In some cases it could be necessary to carry out a Liquid penetrant test .

3 .1 Measurement of depth

The following equipment and materials can be used to measure the depth :

An optical micrometer .

Setting resin to take prints .

The print taken is magnified (for example x 50) and measured on the
screen of a profile projector .

A dial gage fitted with a needle probe .

Then needle probe must have an extremely sharp point to accurately

measure the form of the defect .

The Load applied to the point must be kept to a minimum to avoid the
point penetrating into the material .

Specimens of scratches .

Equipment for indirect measurement of the depth of scratches (e .g .

measuring the thickness of material below the bottom of each
scratch) .

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PROCESS AND MATERIAL SPECIFICATION

3 .2 Measurements of the surface dimensions,of defects

These dimensions can be measured with a normal graduated ruler .

4. DEFECTS ACCEPTABLE WITHOUT CONCESSION BUT WHICH MUST BE REWORKED

This category includes the following defects :

4 .1 Scratches

For scratches to be repairable under this specification, they must meet

the acceptance standards below :

a) The depth of a scratch is not to exceed 5% of the thickness of the

material except that if the scratch crosses the head or other part
of a fastener, the depth of the scratch in the fastener is not to
exceed 0 .1 mm .

b) The maximum acceptable extent is as follow :

- Single scratch : no limit .

- Multiple scratch : localized within an area not exceeding 20 cm' .

4 .2 Bulges and dents

The surface area of any bulge or dent is not to exceed 2500 mm 2 .

The maximum height or depth is not to exceed 2% of the shortest

dimension of the defect, measured along the surface .

4 .3 Impacts

The surface area of any impact is not to exceed 2500 mm2 .

The maximum height or depth is not to exceed 2% of the shortest

dimension of the defect, measured along the surface .

The penetration into the metal must be not greater than 0 .1 mm .

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PROCESS AND MATERIAL SPECIFICATION

5. REPAIR OF DEFECTS

5 .1 Scratches

All operations described in this para . must mandatorily be carried out

by hand .

Scratches are blended-out as follows :

a) Burrs must be physically removed but not turned back into the
scratch .

Turning the material back into the scratch is acceptable only on

clad sheets and provided that the scratch has not perforated the
cladding .

If the cladding has been perforated, make the following tests :

- Dab tests (clad light alloy sheets)

To check whether a score or impact has perforated the cladding, or

if the cladding has been broken during repair, carry out a dab
test using one of the following solutions :

Solution A

Etching : 10 ml of 40% hydrofluoric acid in 90 ml of distilled

water .

Neutralization : 15 grams of sodium carbonate in 1 liter of

distilled water .

Solution B

Etching : 20% caustic soda .

Neutralization : 5% chromic acid .

These solutions must be prepared by the Local Inspection

Laboratory .

Liquid penetrant test

A liquid penetrant crack test shall carried out in any doubtful

cases .

Subsequently touching up with a protective treatment by chromating by

brush according PMS 01-02-05 and paint (primer or primer and
topcoat) shall be carried out in accordance with written procedures
that have been approved by the Design Authority .

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PROCESS AND MATERIAL SPECIFICATION

b) The scratch can be blended out by rubbing with grade 400 adhesive
paper and finishing with an abrasive rubber, aluminum wool or by
polishing, depening on the finish required .

The width of the blended area shall not exceed approximatly 200 times
the measured depth of the scratch .

NOTE : Burnishing is formally forbidden (except on clad sheets, as

described in para . a) above) . The use of any machine which could
heat the metal is also forbidden .

Titanium must be blended with abrasive paper wetted with water or

white spirit .

5 .2 Bulges and dents

Painted surfaces (or surfaces to be painted) .

These defects should be repaired only if they jeopardize the external

appearance of the part .

The following repair methods may be used :

a) The metal may be smoothed or rubbed back into shape .

b) The metal may be restored to the correct shape using soft faced
mallets which do not mark the surface .

c) Dents may be filled with an approved filler and the paint finish
restored in accordance with approved written procedures .

5 .3 Impacts

Before any repair, carry out a crack test in accordance with an approved
written procedure on both faces of the component involved, at the point
where the object has penetrated into the metal .

No cracks are acceptable .

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PROCESS AND MATERIAL SPECIFICATION

5 .3 .1 Penetration in metal

The defect may be blended out using the processes described for blending
out of scratches .

Bulges and dents associated with penetration of the metal may be

repaired only after the penetration has been repaired as described above .
The repairs are to be made in accordance with the requirements, above,
for repair of simple bulges and dents, or touching up of a protective
treatment in accordance with written procedures that have been previously
approved by the Design Authority .

After repairing a bulge or dent in an unpainted surface that has also

suffered penetration of the surface, both sides of the metal in the
repair area are to be subjected to dye penetrant examination .

6. REFERENCED DOCUMENTS

PMS 01-02-05 Chromating of aluminum and aluminum alloys

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