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INSTITUT KEMAHIRAN BELIA NEGARA

KEMENTERIAN BELIA DAN SUKAN

KERTAS PENERANGAN
(INFORMATION SHEET)

KOD DAN NAMA TP-076-3:2012

PROGRAM /
PROGRAM’S CODE & NAME AIRCRAFT STRUCTURE REPAIR (COMPOSITE)

TAHAP / LEVEL THREE (3)

KOD DAN TAJUK UNIT

KOMPETENSI / TP-076-3:2012 (C08) COMPOSITE FINISHING
COMPETENCY UNIT CODE
AND TITLE
1. IDENTIFY EXPOSED SURFACE
2. PLAN SURFACE FINISHING ACTIVITIES.
NO. DAN PENYATAAN
3. PERFORM SURFACE FINISHING PREPARATION AND
AKTIVITI KERJA /
CLEANING
WORK ACTIVITIES NO. AND
4. CHECK ALL DETAILS IN WORK INSTRUCTIONS FOR
STATEMENT
CONFIRMATION OF SPECIFICATIONS.
5. RECORD WORK TRACEABILITY IN WORK INSTRUCTIONS

ID UNIT KOMPETENSI /
TP-076-3:2012 (C08)
COMPETENCY UNIT ID

Title : SURFACE FINISHING PAINTING SYSTEM

Objective : THE COMPETENT PERSONNEL, SHALL BE ABLE TO CARRY OUT

COMPOSITE FINISHING ACTIVITIES IN EITHER THE WORKSHOP OR ON-
SITE. COMPETENCIES INCLUDE PROFICIENCY IN TOOL HANDLINGS,
CORRECT USAGE FOR SPECIFIED PERFORMANCE AND ACHIEVING
QUALITY FINISHING FOR REPAIR WORKS.

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1.1 SURFACE FINISHING MATERIALS

A paint system is a combination of several coatings, some of them, but not all, being paint
layers. These systems are usually designated by the (chemical) name of the top coat. It
is the total paint system which gives the required protective properties to the (aircraft)
structure. Each element of the paint system serves one or more functions.

In a very general sense, a paint system can be looked as below:

a. Oxide Film, natural or man-made (also known as chemical conversion coating or etch
primer)
b. Primer
c. Intermediate coats (not often use)
d. Top coats (also called finishing coat)

It should be noted that not all elements have to be present in one particular system.
Often, when mention is made of paint (paint film or paint coatings), what is actually meant
is a paint system.

1.1.1 Solvent

Solvents are colorless liquid organic chemical compounds used for the solution of
the film-forming substances. In the lacquer production, the solvents are added but
during the last phase of the lacquering material preparation and serve to
complement the mixture of the components and for granting such a viscosity to it
which would ease off the painting process

After the application of the lacquering material layers on the surface, the solvent
would evaporate. The most important features, deciding over the application
possibility of the respective solvent in the lacquering material production are:

a. Solvency

Solvency depends on the type of the film-forming substances. The practical

solvent measure is this maximal solvent quantity, which does not precipitate
the film-forming substance from the solution. In practice, it is more convenient
to use high solvency solvents because they enable to prepare more
concentrated solutions and thus to obtain a thicker film

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b. Volatility

Volatility of a solvent decides over its evaporating rate. The quick evaporating
solvents abstracted during a short period, such large heat quantities that the
lacquer coat cooling down is causing the condensation of the atmospheric
humidity. The slow evaporating solvents prolongs lacquer drying time

c. Combustibility

Each combustible solvent possesses a dangerous range of its vapor mixture

concentration when mix with air. To prevent solvent vapor explosion, proper
ventilation should be applied during the painting process; naked fire should be
avoided and extra care should be taken for proper functioning of the fire-
fighting equipment.

d. Physiology

Physiological aspect of solvents concerns with the irritation to the respiratory

system, by breathing in the solvent vapors. The most injurious effects to
health is the benzene vapors which gradually destroys the erythrocytes. The
maximal admissible solvent vapor concentration in the air amounts from 0.01
to 0.3 mf per liter according to the type of the solvent.

1.1.2 Paint Stripper

There are two general categories of paint strippers that are commonly used for
aircraft structures. The two types of paint strippers are:
a. Solvent types removers
b. Wax type removers

No paint remover should be used on aircraft fabric or be allowed to come in

contact with any fiberglass reinforced parts such as radome, radio antenna, or any
component such as fiberglass-reinforced wheel pants or wing tips. Extra caution
should be taken at any time when using paint strippers; always wear protective
goggles and rubber gloves. Should paint stripper is splashed on the skin, wash it
off immediately with water. In case of the paint stripper comes in contact with the
eyes, flood the eyes repeatedly with water, and immediately call a physician.

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1.1.3 Primer

a. Wash Primers

These primers are designed to replace pre-treatments such as anodizing or

chemical conversion coating. The corrosion resistance of conventional etch
primers is poor and they should be over coated, preferably with another
primer followed by a topcoat if required. Recently, etch primers with an
improved resistance to filiform corrosion have been available (Sikkens
Metaflex FCR primer).

Etch primers consist basically of polyvinyl butyral resin, zinc tetroxychromate

(ZnCrO4), an oxidisable solvent and phosphoric acid. Although the reaction
mechanism is not yet fully understood, it seems to be somewhat similar to that
of chromate conversion coatings.

b. Alkyd Primers

Alkyd Primers have poor resistance to hydraulic fluids. Nevertheless, they

can be durable primers when sufficiently pigmented. They are cheap single
component paints and that multiple coatings are normally not required
because they have highly solid content. The fact that they are water
resistance, resistance to hydraulic fluids and adhesion does not equal that of
epoxies has made them almost obsolete.

c. Epoxy Primers

The most common primers currently in use are the epoxy primers. These
primers have good resistance to organic fluids and generally give good
corrosion protection to the metal. They adhere well to pre-treated metal
surfaces but are unsuitable for application to untreated aluminium. Epoxy
primers can be used with a variety of top coats to build up a paint system.

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1.1.4 Top Coats

a. Nitrocellulose Based Paints

This class of paints has been used extensively in the past but is now almost
obsolete. This is at least partly due to the nitrocellulose based paints being
only resistant to a limited number of aircraft fluids. Nitrocellulose based paints
are made off nitrocellulose solution, plasticizers and resins. For drying they
depend on the solvent evaporation rate, and hence they are known as quick
drying paints.

b. Acrylic Paints

The main advantages of acrylic paints are:

a. Good stability to light and heat and good color retention
b. Relatively rapidly drying
c. One-pack material, easy application and repair
d. Some types of acrylic paints can be made more or less perpetually
resoluble. When these are used over resistant (epoxy) primers, the top
coat is selectively strippable.

Disadvantages are:

a. Considerable dilution is necessary before satisfactorily spraying is possible

because acrylics are highly polymeric.
b. Multiple coats are required for adequate thickness
c. No high gloss is obtained after spraying. To obtain this gloss polishing is
required.
d. Most acrylics perform badly on etch primers
e. Resistance to aircraft operating fluids is only fair
f. Brittleness and a tendency to crack in service.

c. Epoxy Paints
Epoxy paints are chemically very similar to the epoxy primers. Normally,
polyamides are preferred as crosslinking agents for these epoxy top coats.
Polyamides give good protections to their substrate and can be used directly
over etch primers, which greatly enhances the protective qualities of the top
coat.

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Epoxy coats have good durability. However, they have a tendency to chalk
and yellow, which makes them less suitable for exterior, decorative
applications. This effects is made worse in sunny climates. For exterior
application the effective life of epoxy top coats is limited to only 3 years.

Because epoxies are two-pack materials and cross-linking takes place after
spraying, they are relatively slow drying.

d. Polyurethane Paints

Polyurethane paints have good resistance to water and organic fluids. This
quality makes polyurethane paints better type of paints than the epoxy paint.
They have extremely good weathering properties, which are excellent
durability, vivid color and gloss retention. Polyurethane top coats can have an
effective life of some five years for external application.

The main disadvantages of polyurethanes are their susceptibility to filiform

corrosion. This is a direct result of their rather high diffusion coefficients of
some paints. Because of this susceptibility it is advised to use polyurethane
top coats over polyurethane compatible primers which have high leach rates.

The polyurethane used on aircraft are two pack materials, derived from a
hydroxyl (OH-) containing polyester and they are cross-linked with poly-
isocyanate. Because most simple di-isocyanates are volatile and toxic they
are modified to form non-volatile molecules which can be safely handled.
Good precaution has to be taken when polyurethanes are being sprayed. It
should be noted that some people are allergic to these particles and in such
cases asthmatic attack may follow.

1.1.5 Paint Material Mixing

Quality and durability of paint finishing depends, not only on the proper
preparation of the painted surface, but also in the mixing process of the paint
materials. Prior to mixing paint materials, the technical data sheet must be
read carefully in order to extract critical information as recommended by the
material manufacturers.
i. Ratio of base and hardener.
ii. Dilution.

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iii. Viscosity for application.

Figure 1: Sample Product Viscosity

iv. Time needed for mixture to ripen.

Figure 2: Pre-reaction Time

v. Pot life (after mixing).

Figure 3: Lifetime of mixture

The mixture must be made in a clean, oil-free recipient. Most products for
aircraft exteriors are measured by volume. Either uses the packaging
supplied or else a small ruler for measuring.

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QUESTION

1. List 4 important features in considering for the choice of solvent to be used in aircraft
painting
i. __________________________
ii. __________________________
iii. __________________________
iv. __________________________

2. What are the 2 types of paint stripper?

i. __________________________
ii. __________________________

3. List the main advantages of acrylic paints

i. _____________________________________________________
ii. _____________________________________________________
iii. _____________________________________________________
iv. _____________________________________________________

4. List 4 creterias which very important prior to mixing paint materials.

i. __________________________
ii. __________________________
iii. __________________________
iv. __________________________

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REFERENCES

1. Forbes Aird, HP Books (2006), Fiberglass & Other Composite Material: A Guide to High
Performace Non-Metallic Materials for Race Cars, Street Rods, Body Shops, Boats, and
Aircraft. ISBN: 9781557884985
2. Federal Aviation Administration, Aviation Supplies & Academics, Inc.; Rev ATB edition
(2008), Aviation Maintenance Technician Handbook – General, Aviation Supplies &
Academics. ISBN: 978-1560277163
3. Nick Bonacci, JEPPESEN (2003), Standard Aviation Maintenance Handbook, ISBN:
978-0884873242
4. Dale Crane, Aviation Supplies & Academics. Inc. (2008), Aviation Maintenance
Technician: Airframe Volume 1, Structures (Aviation Maintenance Technician Series),
ISBN: 9781560277125
5. Dale Crane, Aviation Supplies & Academics. Inc. (2007), Aviation Maintenance
Technician: Airframe Volume 2, Structures (Aviation Maintenance Technician Series),
ISBN: 9781560275497
6. Avotek Information Resources (2004), Introduction to Aircraft Maintenance, Revised
Edition, ISBN: 9780970810960
7. Michael Kroes, James Rardon, McGraw-Hill Higher Education (1993), Aircraft Basic
Science, ISBN: 978-0028018140
8. Michael Kroes, William Watkins, Frank Delp, McGraw-Hill Education (2002), Aircraft
Maintenance and Repair, ISBN: 9780071206778

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