Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.

htm

Sealants and Sealing

INTRODUCTION

GENERAL

Sealing is a vital process in the manufacture of today’s commercial aircraft. Sealants are used to contai
maintain cabin pressure, reduce fire hazards, exclude moisture, prevent corrosion, and fill gaps an
discontinuities on the aircraft exterior. All of these sealing functions are important and affect the performance
of the aircraft. For example, fuel tank sealing is critical because fuel leakage is a safety item that can result in
grounding the aircraft until the problem is corrected. Sealing for corrosion prevention must be done properly
or in-service problems requiring extensive maintenance may occur.

These considerations indicate how important proper sealing is. It directly affects the quality and reliabil
aircraft.

DEFINITION OF SEALING

Sealing is a process that confines liquids and gases within a given area or prevents them from entering are
from which they must be excluded. Sealing is accomplished by closing all structural passages that these
fluids can penetrate. The material used to seal these passages is applied as a wet, flowable paste. After a
period of time, the sealant “cures” to form a rubbery solid that adheres firmly to the surfaces it contacts.

LEVELS OF SEALING

The level of sealing required for a given area is defined by the applicable construction and assembly
drawings and is dictated by engineering considerations. The four levels of sealing are absolute, ex
intermediate, and limited. The absolute level of sealing represents the most demanding requirements, an
limited level, the least. Precise definition of which types of structure must be sealed for each level of sealing
are found in A/C manufactures general sealing process specifications. (See Boeing BAC 5000, Canadian
MPS 142-4 and DeHavilland PPS 21.21 etc.)

FUNCTIONS OF SEALS

Fuel Areas

In integral fuel tanks, seals must contain fuel for the life of the airplane under various conditions o
temperature, pressure, and structural loading.

Pressurised Areas

Seals maintain pressure at a predetermined minimum level under all flight conditions.

Environmental Areas

1 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

Seals on exterior surfaces prevent water and other fluids from entering and also function as aerodyn
smoothers.

Corrosion Areas

Seals protect the structure by preventing entry of corrosive fluids.

Electrical Areas

Seals provide protection for electrical components.

Firewall Areas

Seals prevent spread of flames beyond the firewall until fire can be extinguished.

Acid Areas

Seals protect structure from attack by battery acids.

ENVIRONMENTS

Sealants must maintain adhesion to the structure and have sufficient flexibility to function effectively un
variety of environmental and stress conditions:

·
Differential pressures may vary from small negative values to positive values of approximately 1
lb/in2.
·
The operating temperature range is approximately -65°F to 160°F (400°F in some loca
high-temperature areas).
·
Structural loads during flight and ground operations cause deflections, which the sealant must be able
to withstand at all operating temperatures.

TYPES OF SEALS

Fillet Seals

Fillet seals are applied at the edges of structural joints. They consist of beads of sealant that must adhere
firmly to the structure on both sides of the seam being sealed and must conform to the dimensiona
requirements of the process specification. Fillet seals are used where maximum protection from fluid leakage
is required, such as in fuel and pressure areas.

Injection Seals

2 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

Injection seals are applied to fill channels and holes that occur as a result of the structural design. Quite often
injections are required to continue or to back up a fillet seal.

Faying Surface Seals

Faying surface seals consist of a layer of sealant sandwiched between two fastened mating surfaces. These
seals are used primarily to prevent corrosion of aircraft structure and to facilitate leak tracing in the fuel tank.

Prepack Seals

Prepack seals are installed prior to assembly to fill structural cavities that are enclosed after assembly an
cannot be properly injected.

Brush Coat Seals

Brush-coat seals, as the name implies, are formed by brushing the sealant into place. The sealant i
low-viscosity material that is easily applied in this manner. The method is principally used in applying a
sealant precoat prior to fillet sealing the integral fuel tank. Brush coating is also commonly used to sea
exposed ends of fasteners against corrosion.

THE SEAL PLANE

The seal plane is the structural boundary on which the continuity of seal is established. For example, in
integral fuel tanks (conventional aircraft structures sealed for the containment of fuel), the seal plane consists
of the barrier beyond which fuel may not pass. This barrier consists of structure, fasteners, and sealant.

3 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

Typical Integral Fuel tank Structure

WHEN USING PRC

· Read the appropriate MSDS sheet

· Use correct type of protective gloves
· Mix by weight (get used to colour of a proper mix)
Ø Balance scale with mixing plate and mix stick first
Ø Use separate clean sticks to take catalyst and base compounds out of their containers
§ Do not get catalyst (part B) in can (part A) or vice versa
Ø Leave catalyst (part B) and can (part A) clean
· Use paper under mixing palate and mixing tools when you lay them on the bench
· Put masking paper under your project when applying the sealant
· Spread sealant evenly using spatula, brush or small roller
· Secure parts using clecos
· When riveting, wipe excess sealant from rivet tails with small cloth or paper before bucking
· Clean up clecos in acetone
· When finished, wrap used mixing palate and mixing sticks in paper and place in garbage
· Cleanup
· Leave area clean

EQUIPMENT AND MATERIALS

CLEANING EQUIPMENT AND MATERIALS

Vacuum Cleaner

The vacuum cleaner removes aluminum shavings, chips and other debris from areas to be sealed.

Brushes

4 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

Brushes are used for removing loose materials and for preliminary solvent cleaning to remove heavy soi
Stencil brushes or trimmed paintbrushes with short stiff bristles are best.

Cheesecloth (or other approved wiping materials)

Wipers are used for preliminary and final solvent cleaning of areas to be sealed.

Pipe Cleaners

Pipe cleaners are used for solvent cleaning channels and other inaccessible structural areas prior to seali
Cotton swabs are also useful for this purpose.

Solvents

Solvents are used for cleaning structure prior to sealing. Solvents used for cleaning must be approved
applicable sealing process specification. Methyl ethyl ketone (MEK) is commonly used. Approved metal
safety cans are to be used for solvent storage.

Plastic Squeeze Bottles

Plastic squeeze bottle are used for dispensing solvent onto wiping materials when cleaning surfaces prio
sealing. Transfer solvent from safety can to squeeze bottle for cleaning operations. Note: all bottles of solvent
or any other substance must be labelled and used in accordance with WHMIS regulations.

5 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

APPLICATION EQUIPMENT

Sealant Gun

Initial application of sealants is generally made with a standard air-operated sealant gun. A sealant-fill
cartridge is inserted into the barrel of the gun. A plunger at the upper end of the cartridge and a
reduced-diameter lower end contain the sealant. After removal of the cap, a nozzle of the desired
configuration is attached to the lower threaded end of the cartridge. Sealant is extruded when the trigg
depressed to open an air valve, allowing pressure to be applied against the plunger.

Nozzles

Nozzles are available in assorted sizes and shapes for various sealing requirements and are made of the sam
type of plastic material as the cartridge. Some types of nozzles may be cut at the tip to provide a mo
convenient angle or diameter for application of sealant. Multiple orifice nozzles are available for more
spreading of sealant over relatively large areas for faying surface sealing.

6 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

Rollers

Both metal and rubber rollers are available to spread sealants for faying surface sealing. Rubber r
approximately 50 Shore “A” durometer hardness are superior and recommended for use. Another met
achieving a roller with satisfactory hardness is to build up several layers of sealant on a miniature paint roll
and periodically remove some of the cured sealant with a belt sander. These rollers do a better job of
spreading the sealant and are effective in keeping it out of previously drilled fastener holes.

Scrapers

Plastic scrapers are also used to spread sealant over a surface. These are recommended for situations whe
using a roller would be awkward because of access or other considerations.

Fairing Tools

Fairing tools are used to work applied sealant to the required fillet configuration. Specially designed spatulas,
nozzles, tongue depressors, brushes, or any suitable tool may be used.

Mirrors

Occasionally, cleaning and sealing operations must be accomplished in areas that are out of the sealer’s direct
line of sight. In such situations, a swivel-handled mirror provides the visibility needed to perform t
successfully.

7 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

Miscellaneous

Some sealants of very thin consistency may be applied by spraying. In this case, standard paint spray
equipment is used. These sealants may also be applied by a special Boeing-developed roller system. Th
consists of a 3-in-wide section of paint roller with a perforated shell. A formed section of stainless steel
tubing attaches the roller to a standard sealant gun and sealant-filled cartridge. Sealant is fed to the interior of
the roller and can be extruded through the perforations as required for application.

SEALING COMPOUNDS

DESCRIPTION

Sealing compounds are synthetic rubber materials that are applied in a flowable consistency and cure
chemical reaction to a solid with elastomeric properties. Most of the sealants you will use in your job are
known chemically as polysulfides. Some silicone sealants are used where their special properties are
required. All polysulfides are two-part materials and cure is initiated when the rubber polymer base i
combined with an accelerator. Some silicones cure in the same manner, and others are one-part materials th
cure by reaction with atmospheric moisture.

Most two-part sealants are purchased in kit form and must be mixed and used, or quick-frozen and stored
under refrigeration. Some two-part materials, however, are purchased premixed and frozen.

Logistical considerations, such as maintenance of sealing inventories in the shops, usually make it impractical

8 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

to use a sealant immediately after mixing. Therefore, quick-freezing and frozen storage are used to pre
initiation of the curing reaction. When thawed for use on the airplane, the sealant is then essentially in the
same condition as when it was first mixed.

SPECIFICATION CLASSIFICATIONS

The classification system for sealants in Boeing material specifications (BMS’s) is as follows:

· Class A-Brushcoat Sealant. Thinned with solvent to provide viscosity suitable for brushing.
· Class B-Filleting Sealant. Relatively heavy consistency with good thixotropic (low-slump) properties.
· Class C-Faying Surface Sealant. Medium consistency for good spreadability.
· Class D-Hole-Filling Sealant. Similar to Class B with very low slump.
· Class E and F-Sprayable Sealants.

PROPERTIES

Each individual sealant is compounded to provide the specific combination of properties desired. Pro
significant to you as a sealer are as follows.

Application Time

Application time is the time in hours after thawing during which the sealant can be readily extruded from
sealant gun and applied tot he structure. The application time is included in the universal classification
system as a dash number following the classification letter (except for Class C). For example, Class B
indicates a fillet sealing material with a minimum application time of 2 hours. Application time is no
applicable to one-part sealants.

Squeeze-Out Life

Squeeze-out life is the time in hours after thawing during which a faying surface sealant can be squeezed out
of a joint when fasteners are installed. The squeeze-out life is included in the universal classification system
as a dash number following the Class C designation. For example, Class C-20 indicates a faying surface
sealant with a minimum squeeze-out life of 20 hours.

Tack-Free Time

Tack-free time is the time in hours after thawing (after application for one-part silicones) that is required for
the sealant to cure sufficiently so that it will not transfer to the finger or to a plastic film.

Cure Time

For manufacturing purposes, cure time is the time in hours after thawing (after application for one-pa
silicones) that is required for the sealant to cure firmly enough to be handled without damage or deformat
After cure time has elapsed, manufacturing operations such as drilling and fastening can be performed
without damage to the sealant. Maximum allowable cure times are specified in the applicable BMS, and
typical cure times for most sealants are given in process specification.(See Boeing BAC 5000, Canadian MPS
142-4 and DeHavilland PPS 21.21 etc.)

Environmental Effects

9 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

All the properties listed are related to each other and are a function of the cure rate. The cure rate is s
influenced by temperature and humidity, and is directly proportional to both; i.e., lower than norma
temperature and humidity retard the cure rate and higher than normal temperature and humidity increase th
cure rate.

SPECIAL PRECAUTIONS FOR SILICONES

·
Uncured silicones readily absorb carbon dioxide (CO2). This will cause severe bubbling or foaming
of the sealant. Therefore, all uncured silicone sealants, even those in plastic cartridges, must b
protected from contact with CO2 sources, especially dry ice. Under no circumstances shall mix
two-part silicones be stored in C02-type freezers. Mechanical freezers only shall be used.

· Silicones must be stored separately from other sealants to prevent cross contamination.

·
When applying silicone sealants, do not contaminate adjacent areas. Silicones act as a release film and
will prevent adhesion of any subsequently applied finishes.

·
Tools used for silicone sealant shall be used for these sealants only. Do not use for any other
materials.

WARNING: COMPONENTS OF SOME SEALANTS ARE TOXIC AND CAN BE

ABSORBED THROUGH THE SKIN. SKIN CONTACT SHOULD BE AVOIDED. U
GLOVES AS REQUIRED. WHEN SKIN CONTACT OCCURS, REMOVE THE SEALA
AND WASH THE AFFECTED AREA. NEVER USE YOUR FINGERS T
FILLETS—ALWAYS USE A FAIRING TOOL.

SEALING PROCESSES

MIXING

General

Two-part sealants must be completely mixed. If sealant is completely mixed, colour will be uniform
throughout. A streaked appearance is evidence of incomplete mixing.

CAUTION: INCOMPLETE MIXING MAY AFFECT CURE AND PERFORMANCE PROPERTIES OF

THE SEALANT.

Machine Mixing

Most of the sealant you use will be mixed by specialized machines in their labelled plastic cartridges.
Machine mixing provides the most reliable, consistent material and is the only way that high-volum
requirements can be met. Machine mixing is described in the Avcorp/BCIT Module 7 “Mixing of Sealants”.

Hand Mixing

10 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

It may be necessary to hand mix a quantity of sealant. Kits of the material needed are available.

To hand mix sealant kits proceed as follows:

·
Check label to verify that you have the correct material and that the expiration date has not be
exceeded.
·
Stir accelerator thoroughly until all solids are dispersed and a smooth, uniform material is o
(Accelerator may be either a liquid or a paste.)
· Add the entire
accelerator to the base container and mix thoroughly, using a spatula or other suitable tool until
uniform blend with no evidence of streaking is obtained. Verify that there is no unmixed base
accelerator in the container.
In cases where less than the entire volume of the container is needed, proceed as follows:

·
Check label to verify that you have the correct material and that the expiration date has not be
exceeded. Also note the ratio of base to accelerator required.
·
Mix accelerator thoroughly until all solids are dispersed and a smooth, uniform material is
(Accelerator may be either a liquid or a paste.)
· Place a mixing plate (a piece of scrap aluminum) and mixing stick on a scale and zero the scale.
·
Use the mixing stick to place the required amount of base compound on the mixing plate. Note th
weight of the base compound.
·
Using a clean stick, add the required weight of accelerator to the mixing plate. (Be certain n
contaminate either the base with the accelerator or vice-versa.)
· Mix the base and the accelerator together completely to achieve a smooth, streak free consistency.

THAWING

Obtain cartridges of the frozen sealant needed from the freezer. Verify that you have the correct material an
that the expiration date has not been exceeded.

Thaw Sealant to Room Temperature.

Allow sealant to thaw to room temperature before using. Five to 10 minutes in warm water or approximately
30 minutes at room temperature is usually sufficient.

11 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

CAUTION: MAKE SURE THAT SEALANT IS COMPELTELY THAWED, AS COLD SEALANT WI

NOT ADHERE TO THE STRUCTURE. PROPERLY THAWED SEALANT WILL FLO
EASILY FROM THE GUN AND WILL READILY “WET” THE SURFACE.

Do Not Refreeze

Never refreeze thawed sealant.

CLEANING

General

The importance of cleaning cannot be overemphasized. Sealant will not adhere to any surface that
contaminated. A thorough cleaning job is one of your most important responsibilities.

Preliminary Cleaning

Remove all chips, shavings, and other loose materials with a vacuum cleaner. Remove all heavy s
contaminants, using a stiff-bristled brush and solvent. Cheesecloth and other approved wipers may be us
desired instead of a brush. If there is no debris or sever contamination in the area to be sealed, prelimin
cleaning may be omitted.

Final Cleaning

Perform final cleaning immediately prior to sealing. Dampen clean wiping material with solvent and wipe the
area to be sealed. Before the solvent evaporates, wipe the area again with clean, dry wiping material. Repe
these steps until there is no visible contamination on the wipers. Traces of primer that may be present on
wiping materials do not constitute contamination.

·
If the total area to be cleaned is large, do not try to clean it in one operation. This will allow the
solvent to evaporate and wipers to become contaminated. Clean smaller areas progressively until th
total area has been cleaned.
· Always clean an area wider than the area to which sealant will be applied.

CAUTION: FOR ALL CLEANING OPERATIONS, USE ONLY THOSE WIPING MATERIAL
SOLVENTS THAT ARE APPROVED BY THE APPLICABLE PROCESS
SPECIFICATION.

WARNING: SOLVENTS ARE EITHER (1) FLAMMABLE AND TOXIC, OR (2) TOXIC. CONSU
WHMIS MSDS SHEETS FOR INFORMATION ON THE SAFE USE OF SOLVENTS.

APPLICATION OF SEALANT

General

·
Apply sealants to clean surfaces only. Before applying any sealant, verify that cleaning has
accomplished in accordance with the requirements previously described.
·

12 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

Verify that you have the correct sealant for the job and that the sealant has not been stored bey
expiration date (see label for expiration date).
·
Verify that the sealant is completely thawed and that the temperature of the structure is 5OoF or
greater. Application of cold sealant or application to cold structure results in poor adhesion because of
condensation of moisture from the air.
· Insert the sealant cartridge in the gun and install a nozzle suitable for the sealing job.

Fillet Sealing

Place the nozzle tip in the corner of the seam to be sealed and extrude a continuous bead of sealant. Obtain
the general fillet size desired by regulating the sealant flow rate and the speed of gun travel. Always hold th
gun in a near-vertical position so that the tip of the nozzle is pushed forward along the joint in the direction of
travel.

Applying A Fillet Seal

Typical Fillet Configurations

A small bead of sealant should precede the nozzle tip. Dragging the nozzle during filet application can result
in air entrapment and undetected voids in the cured fillet with the possibility of subsequent leakage. It must
be done very carefully. After application, work out air bubbles and fair the fillet to the required fi
configuration by use of an appropriate fairing tool. Fillet dimensional requirements are contained in
applicable process specification.

Edges of fillets must make continuous contact with the surface. Reentrant fillets are a potential source of
failure and are in violation of specification requirements.

13 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

Injection Sealing

Place the nozzle tip at one of the open ends of the channel and extrude sealant until the channel is comple
filled, as indicated by appearance of sealant at the other end. Where multiple channels exist, block fille
channels to ensure a complete seal.

Remove excess sealant, retaining a small amount at each end. Fair this in smoothly with the contacting
structure to provide continuity with subsequently applied fillets.

Faying Surface Sealing

Apply sealant to one of the two surfaces to be joined. Where the parts to be joined differ significantly in
sealant is usually applied to the smaller part (e.g., to a spar stiffener instead of a web).

Either extrude sealant directly onto one of the surfaces to be joined or, for some joints, extrude a bead along a
strip of masking tape located adjacent and parallel to the lengthwise direction of the area of sealant
application.

Spread the sealant using a roller or plastic scraper so that the surface is uniformly and completely covere
Areas bare of sealant are unacceptable. Thickness of the sealant layer should not exceed 0.005 inches. To
much sealant results in fastening problems and extensive clean up requirements after the joint is assembled
Too little fails to provide a continuous bead of squeezed-out sealant after fastening, as required by
specifications.

After fastening of the joint within the squeezed-out life of the sealant, either remove the squeezed-out sealant,
or fair in to form a small fillet as required.

Prepack Sealing

Apply a small bead of sealant along each corner of the cavity and then pack the entire cavity with an excess
of sealant. After assembly, fair extruded sealant to a fillet configuration within the sealant application time.

Brush Coat Sealing

Using a stiff-bristled brush, apply sealant to locations specified. In the case of fasteners, apply sealant
liberally both to the exposed area of the fastener and the immediately adjacent area. In the fuel tank, app
sealant so that the area covered will extend beyond the width of subsequently applied fillets.

SPECIFICATION REQUIREMENTS AND SPECIAL PROCESSES

14 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

GENERAL SEALING

General sealing requirements are covered by specifications (See Boeing BAC 5000, Canadian MPS 142-4
and DeHavilland PPS 21.21 etc.)

These cover most sealing other than that done in the integral fuel tank.

Fastener Sealing

All fastener sealing is a variation of one of the basic sealing processes.

Wet Installation
·
Flush Head-Apply sealant either to the underside of the head or the countersink immediatel
prior to installation.
· Protruding Head-Apply sealant to the underside of the head immediately prior to installation.

Fillet Sealing
·
Fillet seal collar and threaded end of fastener to dimensions specified in specifications (S
Boeing BAC 5000, Canadian MPS 142-4 and DeHavilland PPS 21.21 etc.)

Brush Coating
·
Apply brush coat as specified. Use a stiff-bristled brush to apply the specified brushable
sealant to the exterior or interior end of the fastener as specified. Cover the entire exposed area
of the fastener and extend the application to the adjacent structure for a width of 0.1 to 0.
inches.

Electrical Sealing

Where required, fillet seal electrical fittings in accordance with procedures described in the fillet sealing
section (p. 21). In wire bundle sealing, coat each individual wire with the specified sealant prior to
installation. Installation must be completed within the sealant application time. (Sealing of some wire bundles
that pass through bulkhead fittings is done according to a special injection method. See the electrical se
section, p. 28.)

Integral fuel tank sealing

Fuel Tank Sealing Methods

· Fillet sealing is the basic method used for fuel retention within the integral tank. This is the
only method that provides a reliable barrier against fuel leakage.
·
Injection seals are used where fillet backup is required or where structural complexi
prevents a continuous fillet.
· Prepack seals are used for large structural fittings, such as at tank corners. A structure that
is prepacked will always be fillet sealed as well.
·
Faying surface seals are used for isolating leakage. These seals are applied at regula

15 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

intervals along a joint during the assembly phase prior to installation of fasteners. An
leakage that may occur through a subsequently applied fillet will be confined to the
distance between two isolation seals, making the source of leakage easy to locate. (Som
leak isolation seals are made from thin rubber gaskets. These are installed by mechanic
prior to automatic riveting of stringers to wing skins.) Upon rare occasions, faying surfa
seals are also used as primary fuel seals where it is impossible to apply a fillet seal
structural deflections will not damage the seal.

Apply all seals in the fuel tank in accordance with the methods previously described. All seals except fa
surface seals require application of a Class A brush coat (precoat) prior to application of the basic seal.

Special Fillet Sealing Requirements

A three-phase system can be used for sealing the integral fuel tank. The process sequence is as follows:

· Apply brush coat.

· Apply small first fillet. Use fairing tool to force sealant into corner of joint.
· Apply full-size final fillet.

Fastener Sealing

Some fasteners within the fuel tank require sealing to prevent leakage. Metal seal caps are generally used
These are lightweight aluminum shells that fit over the protruding end of the fastener. Follow standard
cleaning procedures, and then fill the cap with an excess of sealant and press into place on the fastener. When
the cap is pressed into position, excess sealant will extrude from around the bottom and from the hole in the
top of the cap. Fair the extruded sealant to blend smoothly onto and around the cap. Where seal caps are n
used, fillet seal the fasteners, as previously described.

AERODYNAMIC SMOOTHING AND WEATHER SEALING

Purpose

On the exterior of the aircraft, skin gaps are filled and surface discontinuities faired in with sealant to provide
an aerodynamically smooth surface and to exclude water.

Summary of Process

Clean surfaces where sealant will be applied, including gaps. Mask as required. Apply sealant to completely
fill gaps, taking care to avoid air entrapment. Smooth uncured sealant flush with skin or masking tape. To
bring cured sealant flush with skin, shave with a plastic or wooden tool or abrade by using a rubber wh
mounted on an air motor. Standard fillet sealing methods apply to sealing most skin overlaps an
discontinuities. Fair sealant to the required configuration within the application time.

LEAK TESTING

Integral Fuel Tank

Leak testing of integral fuel tanks is accomplished by coating the exterior with indicator paint, filling the tank
with an ammonia/air mixture, and applying a positive pressure. Colour change of the indicator paint indicates
a leak. If the source is not immediately apparent, a leak is traced by applying air pressure to the point where

16 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

the leak appears and brushing a soap solution on the fillet in the suspected area between isolation seals. Th
point where soap bubbles are generated is the source of the leak. In addition to the ammonia test, pressure
drop tests are also conducted. Final verification occurs when the aircraft is fuelled and inspected for leakage.

Body Pressure Vessel

A positive pressure is applied to the cabin area. A drop in pressure to less than a specified level indic
excessive leakage. Leak sources in this area can usually be located by the noise of escaping air.

REPAIR

Repair procedures refer to fillet seals only.

Uncured Sealant (within application time)

Remove the defective material with a clean tool and apply fresh sealant.

Cured Sealant

Cut away the defective material with a sharp plastic or wooden tool. Be careful not to scratch or otherw
damage the surface. Make cuts in the sealant so that edges are scarfed.

Clean all surfaces, including sealant, and apply fresh material. Overlap fresh sealant onto previously cur
sealant and fair in as smoothly as possible.

SAFETY

USE THE SAFETY DEVICES SUPPLIED FOR YOUR PROTECTION.

BE AWARE THAT SOLVENTS AND SEALANTS CAN BE BOTH TOXIC AND FLAMMABLE.

SEE YOUR SUPERVISOR ABOUT HANDLING AND DISPOSING OF SOLVENTS IN YOUR AREA.

ALWAYS CHECK THE MSDS FOR THE PARTICULAR MATERIALS YOU ARE

WORKING WITH. REMEMBER IT IS YOUR RESPONSIBILITY TO ENSURE YOU ARE USIN

CORRECT PROTECTIVE EQUIPMENT.

WARNING: COMPONENTS OF SOME SEALANTS ARE TOXIC AND CAN BE

ABSORBED THROUGH THE SKIN. SKIN CONTACT SHOULD BE AVOIDED. USE GLOVE
REQUIRED. WHEN SKIN CONTACT OCCURS, REMOVE THE SEALANT AND WASH THE
AFFECTED AREA. NEVER USE YOUR FINGERS TO SMOOTH FILLETS—ALWAYS USE A

17 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

FAIRING TOOL.

DEFINITIONS OF TERMS USED IN SEALING

ACCELERATOR—The material that is mixed into the sealant base compound to make it cure. It is
sometimes referred to as curing agent, activator, or catalyst.

ADHESION—The property of a material that makes it stick to another material.

APPLICATION TIME—The stated minimum time within which the sealant must remain usable. T
application time begins immediately following mixing or thawing of sealant.

BACKUP SEAL—A secondary seal giving physical support to a primary seal.

BASE COMPOUND—A synthetic rubber-based compound that is the major component of a sealant.

BLOCK-OFF-SEAL—-See ISOLATION SEAL.

BRUSH COAT—See PRECOAT.

CURE—The change in a sealing compound from a soft state to a firm rubbery condition.

FAIR—To shape and smooth uncured sealant.

FAYING SURFACE SEAL—A seal made by sandwiching sealant between mating surfaces of an assembly.

FILLET—A shaped bead of sealant applied to joints or fasteners after assembly.

PRECOAT—A thin layer of brushable sealant applied on the surface to be sealed (used in IFT seal
Sometimes referred to as BRUSH COAT.

PREPACK SEAL—Sealant applied to fill holes or cavities in a part immediately prior to structural
assembly.

PRIMARY SEAL—The sealant barrier that prevents leakage. It is applied directly in line of contact with
fuel or pressure.

REENTRANT FILLET EDGE-An overlapping quantity of sealant not in intimate contact with the adjacent
structure. This may provide a path for leakage through the seal plane.

RELEASE AGENT—see PARTING AGENT.

SEAL APPLICATION DRAWING—A drawing that shows placement and type of sealant application.
SEAL COVER (SEAL CAP)—A rigid cover used to contain and protect sealant over a protruding fastener.

SEAL LEVEL—A definition of the amount of leakage control required (absolute, extensive, intermediate, or
limited).

SEAL PLANE—The structure on which the continuity of seal is established. When sealed, it blocks the
escape of gas or liquid.

18 of 19 10/26/2010 9:10 AM
Sealants & Sealing http://www.mlevel3.com/BCIT/Sealants.htm

TACK-FREE TIME—Cure stage at which the sealant will not stick to clean polyethylene.

UNDERHEAD FASTERNER SEALING—Application of sealant to the underside of the head or t

countersink immediately before installing the fastener.

SEALING SYMBOLS:

FAYING SURFACE SEAL

FILLET SEAL

FILLET SEAL CONTINUATION

INJECTION SEAL

PREPACK SEAL

HOLE FILLING SEAL

19 of 19 10/26/2010 9:10 AM