PROCESS AND MATERIAL SPECIFICATION

PROCESS SPECIFICATION

01-01-02

Surface preparation prior to external paint

a p p lication

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PROCESS AND MATERIAL SPECIFICATION

LIST OF EFFECTIVE PAGES

SUBJECT

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DATE

RECORD OF REVISION

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AIPS09-04-001
LEP 01-01-02
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PROCESS AND MATERIAL SPECIFICATION

AIPS
Airbus Process Specification
Surface preparation prior to external paint application

Published and distributed by :

AIRBUS S.A.S.
ENGINEERING DIRECTORATE
31707 BLAGNAC Cedex
FRANCE

Copyright reserved
Ref. no. AIPS09-04-001
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Contents

Scope

Normative references

Definition, applicability and limitations

Requirements

Process qualification

Appendix

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1 Scope
This Airbus Process Specification defines the requirement for "Surface preparation prior to external paint
application".
The purpose of this specification is to give design and quality requirements to manufacturers. Although the
essential requirements of a process are defined, the specification does not give complete in house process
instructions, these shall be given in the manufacturers detailed process instruction and supporting work
instructions.
This specification shall not be used as an inspection document unless parts or assemblies have been
manufactured according to this specification.
It shall be applied when mentioned in the relevant standard, material specification or drawing.

2 Normative references
This Airbus specification incorporates by dated or undated reference provisions from other publications. All
normative references cited at the appropriate places in the text are listed hereafter. For dated references,
subsequent amendments to or revisions of any of these publications apply to this Airbus specification only when
incorporated in it by amendment of revision. For undated references, the latest issue of the publication referred to
shall be applied.
National standards should be applied if Airbus standards are not available.
ABS 5044

AIPS 03-03-001
AIPS 05-02-003
AITM 2.0040

Clad sheets and strips - Aluminium alloy 2024 standard surface quality - thickness
0.2mm to 0.6mm
Material specification - Corrosion inhibiting primer
Material specification - Non corrosion inhibiting primer
Material specification - External paint system: primer + top coat
Material specification - Wing coating system
Material specification - Chromate free external paint system: primer + top coat applied
on basic primer
Material specification - Chromate free external paint system: primer + intermediate
coat + top coat applied on basic primer
Material specification - External paint system: chromate free primer + wing coating
Material specification - Sealants - General purpose
Technical specification - Carbon fibre reinforced epoxy prepreg
Technical specification - Preimpregnated metallic mesh for electromagnetic shielding
and lightning strike protection
Material specification - Liquid non-aqueous cleaning agents
Process specification - Chromic Acid Anodising (CAA)
Process specification - Tartaric Sulphuric Anodising (TSA) of aluminium alloys for
corrosion protection and paint pre-treatment
Process specification - Rework of damage in aluminium and aluminium alloy surfaces
Process specification - Application of external paint systems
Airbus Test Method - Paint adhesion on fastener heads.

ISO 2409
ISO 2808
ISO 2812

Paints and varnishes - Cross-cut test.

Paints and varnishes - Determination of film thickness.
Paints and varnishes - Determination of resistance to liquids.

AIMS 04-04-001
AIMS 04-04-002
AIMS 04-04-013
AIMS 04-04-026
AIMS 04-04-031
AIMS 04-04-032
AIMS 04-04-034
AIMS 04-05-001
AIMS 05-01-000
AIMS 05-12-000
AIMS 09-03-000
AIPS 02-01-001
AIPS 02-01-003

3 Definition, applicability and limitations

3.1 Definition
For definitions relating to this AIPS as paint shop, developer, and user...refer to "Application of external paint
systems" AIPS 05-02-003.
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3.2 Applicability
This Airbus specification is applicable when invoked by the drawing directly or through another document for the
purpose given in the scope. When processing to AIPS09-04-001 is required, it shall be invoked on the drawing by
the words "Surface preparation prior to external paint application" of AIPS09-04-001. Process instructions shall not
be called on drawing.
The process described in this document is applicable for all aircraft programs and all types of aircraft external
surfaces: primed and/or anodised metallic substrates, composite substrates coated with basic primer or antistatic
paint, surfaces with anti-erosion paint with or without top coat, etc...
The surface preparation shall not have to remove and damage protections and substrates like: surface coating,
anodization, composite substrates and fastener, basic primer, anti-lightning grid, and sealant.
This surface preparation process is valid for all the external paint application to parts where external surfaces have
been painted in a full paint scheme at an earlier detail or assembly stage.
3.3 Limitations of the process
For surfaces already painted with top coat paint or surfaces to which paint is not to be applied, a masking operation
shall be provided so that these parts are not submitted to this preparation and to avoid damage to them or soiling.
The required surface preparation procedures shall be implemented for all external paint systems qualified or
unqualified by Airbus but requested by the customer.
Caution: some solvents (such as Methyl Ethyl Kethone) are strictly forbidden for use on composite materials
because of translaminar cracking risks.

4 Requirements
4.1 Technical requirements
4.1.1 Surface appearance
4.1.1.1

Surface appearance before surface preparation

The surfaces shall be homogenous, without defect (pores in composites, scratches in

metal, etc.). Some appearance defect such as relief, shocks, dents cannot be leveled by
surface preparation
4.1.1.2

Surface appearance after surface preparation

On completion of various phases of this process, the surfaces treated for painting shall be:
without temporary protection,
clean, that is free from contamination by solids, chemical pollution and in particular:
- cutting oil,
- trace of hydraulic fluids (skydrol, Hyjet IV),
- fuel (Kerosene),
- sealant scrapings,
- atmospheric pollution (combustion shoots, etc.),
- products containing silicones (sealants, greases, adhesives),
- traces of markers, inks, graphite,
- traces or residues of glues,
- release agents,
- water repellent products,
the polluted surface layer of paint or oxide shall be removed,
levelled, that is free from:
- basic primer runs or inclusions,
- orange peel,
- scratches repaired according to the relevant specifications.
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4.1.1.3

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Surface appearance after paint system application

After drying, the applied paint system shall be regular and uniform without surface defects according to AIPS05-02003.
4.1.2 Non-degradation of substrates and fasteners
The non-degradation of metallic and composite substrates and fasteners protections shall be checked visually at all
stages where the external paint scheme is applied:
metallic substrates and fasteners: non-degradation of
- fasteners: no damage but after surface preparation, the surface treatment of the fastener must not
be totally removed
- basic primer: the coat shall be uniform.
Note: If the removal of basic primer and surface pre-treatment occurs after sanding, it is necessary to reapply
basic protection of substrate according to AIPS 03-03-001 "Rework of damage aluminium and aluminium alloy
surfaces".

composite substrates: non-degradation of

- mesh: the mesh shall not be damaged,
- fibers: fibers shall not be visible on surface,
- resin: a slightly dull aspect is acceptable,
- basic primer: the coat shall be uniform.

edges and sealant: check appearance, and ensure that the fillet is not damaged.

Only qualified cleaning solvent in accordance with AIMS 09-03-000 Cat.VI shall be used.
4.2 Engineering requirements
4.2.1 Basic primer residual thickness
The thickness of basic primer shall be measured before the surface preparation at initial condition and after the
surface preparation according to ISO 2808.
Ensure that the basic primer is remaining after surface preparation: the thickness of the primer shall be
15 urn minimum.
4.2.2 Paint adhesion on metal sheets
After application of the final paint scheme (AIPS 05-02-003), the adhesion test shall be performed on flat metal
sheets in accordance with 5.2.1.1. The requirements are grade 0 at initial stage and grade 1 maximum after
water immersion.
4.2.3 Paint adhesion on fastener heads coatings
After application of the final paint scheme (AIPS 05-02-003), the adhesion test shall be performed on fasteners
heads in accordance with 5.2.1.2. The requirements are grade 0 at initial stage and grade 3 maximum after water
immersion.
4.3 Quality requirements
4.3.1 General requirements
When processing according to this AIPS all process parameters within the paintshop shall be continuously
maintained within the limits defined in the Process Instruction.
All paintshops shall comply with the general and cleanliness requirements as defined in the Process Instruction.
This shall be ensured by permanent control of:
the facilities (installation and equipment) and the products used,
compliance of the application process conditions to the requirements of this document and the Process Instruction.
All records of test/ inspection results shall be stored under the control of the quality assurance of the paint
shop or other skilled departments.
All operators of the process shall be given appropriate training to provide the level of proficiency required to
ensure that the technical and quality requirements of this specification are met.
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The following minimum properties and corresponding quality requirements are considered necessary to verify
the above specified design requirements.
4.3.2 Test Frequency
The frequency for permanent and regular control checks shall be defined by the quality assurance of the paint shop
with agreement of Airbus Quality Department.
After specific events, appropriate performance of the process shall be ensured by additional quality tests.
4.3.3 Visual checks
All series production checks are reported in the following table 1.

4.3.4 Basic primer residual thickness

The thickness of basic primer shall be measured before the surface preparation at initial condition and after the
surface preparation according to ISO 2808.
Ensure that the basic primer is remaining after surface preparation: the thickness of the primer shall be
15 urn minimum.
4.3.5 Paint adhesion on metal sheets
After application of the final paint scheme (AIPS 05-02-003), the adhesion test shall be performed on flat metal
sheets in accordance with 5.2.1.1. The requirements are grade 0 at initial stage and grade 1 after water
immersion.

5 Process qualification
5.1 Basic qualification requirement
The general process qualification, the qualification of industrial facilities and Airbus quality assurance are described
in prevailing procedure documents.
The Surface preparation process shall be stable and reproducible before launching the technical qualification, so
that the selected set of process steps and parameters is taken for the qualification.
The production shop shall use its facilities under serial production conditions for the performance of the qualification
tests.
Process parameters, environmental conditions etc. applied for qualification shall ensure process performance
within the entire process window applied at the relevant shop.
Qualification of the Surface preparation process shall consider all paint schemes that are subsequently applied at
the specific shop.
Qualification test programme (QTP)
The means for showing compliance with the requirements for achieving technical qualification of the Surface
preparation process shall be defined by the qualification test programme.
This includes the standard qualification test defined by this AIPS hereinafter (chapter 5.2) as well as any
amendment or deviation.
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5.2 Standard qualification test programme

This chapter provides the details of the standard test programme, which shall be taken into account for the
definition of the specific qualification test programme (QTP) for the technical qualification of a shop.
In addition to the acceptance criteria, specific test requirements are defined as amendment and/or deviation from
the specified test method.
5.2.1
5.2.1.1

Demonstration of the required performance and quality level

Paint adhesion on metal sheets

The adhesion test shall be performed after the final drying time, by cross cut then by tearing with adhesive
tape in accordance with ISO 2409.
Before the beginning of tests, a final drying time of 168h at (232)C and (555)%RH shall be respected.
Half of test specimens shall be tested at initial stage at (232)C and the remainder shall be tested after
immersion in demineralised water for 14 days at (232)C in accordance with ISO 2812.
The requirements are grade 0 at initial stage and grade 1 after water immersion.
5.2.1.2

Paint adhesion on fastener heads coatings

The adhesion test shall be performed after the final drying time, by cross cut then by tearing with adhesive tape on
fastener heads coatings in accordance with AITM 2.0040.
Before the beginning of tests, a final drying time of 168h at (232)C and (555)%RH shall be respected.
Half of test specimens shall be tested at initial stage at (232)C and the remainder shall be tested after immersion
in demineralised water for 14 days at (232)C in accordance with ISO 2812.
The requirements are grade 0 at initial stage and grade 3 after water immersion.
5.2.2
5.2.2.1

Standard qualification test program

Test specimen definitions

The test specimen designs (substrate, protection and dimensions) are specified in appendixes A and B.
The materials shall be supplied according to the relevant AIMS.
5.2.2.2

Tests to be performed on specimens

The user shall carry out the tests on test specimens using facilities, devices, qualified solvents and paint systems in
industrial conditions.
The test to be performed on specimens are given in table 2:

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5.2.3 Qualification Test Report (QTR)

The qualification test report shall document the qualification tests performed and its results.
It has to be written in English language.
The test report shall make reference to this AIPS and include at least all the following information:.
- Name / address of the developer/ address of the involved plant,
- Process Specification / issue date,
- Equipment,
- Paint system,
- Application parameters and workshop conditions (viscosity, relative hygrometry, temperature, recoating
time between coats),
- Material batches, supplier references,
- Manufacturing of specimens,
- Parameters/equipment used to manufacture specimens,
- Storage conditions/time for the individual packages of specimens,
- All inspections results/pictures,
- All test results: all tested values shall be given for every test (detailed value and average value),
- Adjustments to the process specification to be incorporated because of the tool or devices results,
- Any incident which might have influenced the results,
- Selection of appropriate test specimens to demonstrate the performances.

6 Appendix

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Appendix A
Definition of metallic test specimens

Figure A.1 - Metallic test specimen

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Appendix B
Definition of composite test specimens

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RECORD OF REVISIONS

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