PROCESSES — GENERAL 1. Individual Process and Finish Codes A. General Information This specification contains finish and process letters that have been assigned to individual finishes and processes. Control specifications such as government, industry or Gulfstream are listed, where applicable, along with finish and process description. Gulfstream specifications refer only to those contained elsewhere in this manual. Where two specifications are listed for an item, the upper specification is the material and the lower the application specification. Color numbers shall be in accordance with FED-STD-595, except as otherwise noted. This specification is not intended to be a complete and comprehensive listing of existing process and finish information for Gulfstream aircraft. It pertains only to those finishes and processes that are relevant to the repair of structural components covered in the preceding chapters of this manual. Contact Gulfstream Technical Operations for information not directly available in this specification. See Table 1. B. Specification Cross Reference List The following information is provided to ease communication when dealing with Gulfstream Technical Operations department in regard to specifications provided in this manual. Although it has been attempted to relate the intent of the specification, they have not always been translated in full. Should it be necessary to request or refer to the internal Gulfstream document (original), the following list shall provide the relevant document information to make the correct request. In and of itself, the following listing conveys no information of use to an operator beyond above mentioned communication with Gulfstream. See Table 2 for cross reference list. Table 1: Individual Process And Finish Codes CODE FINISH / PROCESS GOVERNMENT / INDUSTRY GULFSTREAM 1 Abrasive method, surface prep ____ Preparation of Surfaces by Abrasive Methods, 51-28-10, Repair 2 Cadmium plating up to 180 - 200 ksi QQ-P-416,Type II, Class 2 20 Corrosion preventative compound MIL-C-16173 Corrosion Inhibitors, 51-13-10, General 35 Black oxide coating MIL-C-13924, Class 1 36 Chemical corrosion treatment of magnesium and magnesium alloys MIL-M-3171 Contact Gulfstream Technical Operations 75 Cadmium coating - Vacuum deposited MIL-C-8837, Type II, Class 2 76 Chemical film - Alodine 1200 MIL-C-5541, Class 1A Chromate Conversion Coating of Aluminum Alloys, 51-21-00, Repair STRUCTURAL REPAIR MANUAL 51-20-00 Page 1 February 29/04
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STRUCTURAL REPAIR MANUAL PROCESSES — GENERAL · 2. Finishes, Processes and Nondestructive Test (NDT) Inspection — Methodology and Equipment A. Protective Treatment of Aluminum
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PROCESSES — GENERAL
1. Individual Process and Finish Codes
A. General Information
This specification contains finish and process letters that have been assigned to individual finishesand processes.
Control specifications such as government, industry or Gulfstream are listed, where applicable, alongwith finish and process description. Gulfstream specifications refer only to those contained elsewherein this manual.
Where two specifications are listed for an item, the upper specification is the material and the lowerthe application specification.
Color numbers shall be in accordance with FED-STD-595, except as otherwise noted.
This specification is not intended to be a complete and comprehensive listing of existing process andfinish information for Gulfstream aircraft. It pertains only to those finishes and processes that arerelevant to the repair of structural components covered in the preceding chapters of this manual.Contact Gulfstream Technical Operations for information not directly available in this specification.See Table 1.
B. Specification Cross Reference List
The following information is provided to ease communication when dealing with Gulfstream TechnicalOperations department in regard to specifications provided in this manual.
Although it has been attempted to relate the intent of the specification, they have not always beentranslated in full.
Should it be necessary to request or refer to the internal Gulfstream document (original), the followinglist shall provide the relevant document information to make the correct request.
In and of itself, the following listing conveys no information of use to an operator beyond abovementioned communication with Gulfstream. See Table 2 for cross reference list.
Table 1: Individual Process And Finish Codes
CODE FINISH / PROCESS GOVERNMENT /INDUSTRY GULFSTREAM
1 Abrasive method, surface prep ____ Preparation of Surfaces by Abrasive Methods,51-28-10, Repair
2 Cadmium plating up to 180 - 200ksi QQ-P-416,Type II, Class 2
20 Corrosion preventative compound MIL-C-16173 Corrosion Inhibitors, 51-13-10, General
35 Black oxide coating MIL-C-13924, Class 1
36Chemical corrosion treatment ofmagnesium and magnesiumalloys
Metal Honeycomb and Metal to Metal Bonded Assemblies, 51-79-10, GeneralComposite Components, 51-78-10, General
GAMPS 4104
GAMPS 4108
GAMPS 8101
GAMPS 8109
GAMPS 8110
GAMPS 8115
GAMPS 8118
2. Finishes, Processes and Nondestructive Test (NDT) Inspection — Methodology and Equipment
A. Protective Treatment of Aluminum (Optional)
Where chromic acid anodize, MIL-A-8625, Type I is specified, sulfuric acid anodize, nondyed andsealed, per MIL-A-8625, Type II, Class 1 may be substituted.
NOTE: Approval from Gulfstream Technical Operations is required prior to substitution since thereare items where sulfuric acid anodizing may be questionable as a substitution (parts withjoints, seams, recesses, etc. that could entrap fluids or parts that will be adhesive bonded).
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Where Alodine 1000 is called out on drawings, sulfuric acid anodize, nondyed, unsealed, per MIL-A-8625, Type II, Class 1 may be substituted.
NOTE: Restricted to stair treads and associated hardware.
Where Alodine 1000 or MIL-C-5541, Class 1A is specified Alodine 600 may be substituted.
Where Alodine 600 / MIL-C-5541, Class 3 is specified, Alodine 1200 may be substituted.
NOTE: In order to maintain an equivalent electrical conductivity with the Alodine 1200 finish it iscritical that the proper solution concentrations and immersion dwell times per chromateconversion coating of aluminum alloys be adhered to. See Chromate Conversion Coating ofAluminum Alloys, 51-21-00, Repair.
B. Cadmium Plating of Steel Parts (Optional)
Where electro-deposited cadmium plating per QQ-P-416 is specified, vacuum deposited cadmiumplating per MIL-C-8837, Type II, Class 2 may be substituted.
NOTE: Vacuum cadmium plating of all steel parts heat treated above 180,000 psi requiresGulfstream Technical Operations review and approval.
When vacuum cadmium plating is utilized, parts must pass a dry tape adhesion test usingfresh (less than 6 months old) 3M No. 254 tape. Parts failing this test shall be stripped andreprocessed to attain satisfactory adhesion.
C. Age Control of Elastomeric Material (Mandatory)
Age sensitive elastomeric materials must meet the requirements of MIL-STD-1523.
D. Surface Finish Requirements
Surface roughness of routed sheet metal edges (mandatory) - Unless otherwise specified on theengineering drawing, all routed sheet metal edges shall be finished to 125 RMS.
E. Nondestructive Tests
Nondestructive Test (NDT) inspection procedures (methodology and equipment).
NOTE: Refer to GIV NDT Manual for inspection procedures.
F. Hardness Testing of Metals
Procedure - Hardness tester verification (to be performed by qualified personnel).
– Testers with Rockwell or Brinell scales shall be verified by using the correct side of a standardtest block on each instrument at the beginning of each investigation. Each time a new scale isused, it shall also be verified by the specific test block.
– Conductivity meters shall be operated only by qualified individuals who are well conversed withaerospace NDT procedures. Instrument calibration verification via standards attached to eachmeter shall constitute proper preliminary equipment testing.
Operation - Testers with Rockwell, Brinell and Barcol Scales:
NOTE: Surface finish is essential for obtaining accurate readings against the parts in question. Theprepared surface should not exceed (RMS) ME4V SQ 125 and or 125 micro inches orbetter.
– Valid hardness readings require proper combination of load and penetration, correct anvil and asmooth, flat, properly prepared surface normal to the axis of the indenter. See Figure 1 andFigure 2.
– Reading shall be taken in areas where indentations cannot later contribute to failure. Only
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material that will not be destroyed or mutilated beyond serviceability shall be tested by thismethod.
– Limit the number of indentations to the minimum necessary for accurate determination.– When testing curved surfaces correction factors must be added.– When a part cross section is relatively constant, hardness may be determined by a single
reading.– When part cross section changes significantly or when a narrow hardness range is required,
three readings are taken and averaged.– When three Rockwell readings are taken, they must be within two hardness points of each
other.– When three Brinell readings are taken, they must be within 20 hardness points of each other.– When evidence of a hardness indentation in contact with an anvil is observed on the reverse
side of the part, the hardness reading is not valid.– When decarburization or other surface condition is suspected of causing erroneous readings,
the surface condition can be removed provided the part tolerance is not exceeded.
Valid conductivity readings require a smooth, flat surface normal to the axis of the probe.
Requirements
– Table 3 establishes Rockwell correction factors which are added when testing convexcylindrically curved surfaces.
– Table 4 established minimum material thickness for each Rockwell hardness scale.– Table 5 establishes approximate equivalent Rockwell hardness values for steel.– Table 6 establishes approximate equivalent Rockwell hardness values for wrought aluminum.– Table 7 establishes Rockwell and Brinell hardness values for the following:
Wrought carbon steels (1015, 1018, 1020, 1025, 1065, 1095, drill rod and hi-carbon musicwire).Wrought low alloy steels (3312, 4130, 4140, 4330 Va. Modified, 4340, 6150, 8740, D6 AC,Graph-Mo, H-11 and hy-tuff).Wrought Martensitic stainless steels (410, 416, 420, 431 and 40-G).
– Table 8 establishes hardness to tensile strength values for wrought carbon and low alloy steels.– Table 9 establishes hardness requirements for wrought aluminum alloys.– Table 10 establishes electrical conductivity requirements for wrought aluminum alloys.– Table 11 establishes hardness requirements for aluminum alloy and magnesium alloy castings.– Table 12 establishes hardness requirements for wrought precipitation hardening, corrosion and
heat resistant alloys.– Table 13 establishes hardness requirements for copper alloys.– Table 14 establishes hardness requirements for titanium alloys.– Other approved type hardness testers may be used in accordance with the manufacturer’s
data.
Laboratory tensile testing - When the hardness check is carried out on a fire damaged structure andis inconclusive, a section of the damaged structure must be cut out and tensile tested to determinethe serviceability of the remaining part of the structure. When sending parts or samples to thelaboratory for analysis, include a descriptive report about the type and duration of the fire.
NOTE: Gulfstream Technical Operations review and approval required.
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Table 3: Rockwell Hardness Scale
ROCKWELL CORRECTION FACTORS ADDED FOR CYLINDRICALLY CURVED SURFACES (1)
Diameter Of Specimen Or Part (Inches)
Scale ObservedReading 1/4 3/8 1/2 5/8 3/4 7/8 1.0
EFG
100 3.3 2.5 1.3 1.5 1.0 1.0 0.5
90 4.0 3.0 2.0 1.5 1.5 1.5 1.0
80 5.0 3.5 2.5 2.0 1.5 1.5 1.5
70 6.0 4.0 3.0 2.5 2.0 2.0 1.5
60 7.0 5.0 3.5 3.0 2.5 2.0 2.0
50 8.0 5.5 4.0 3.5 3.0 2.5 2.0
40 9.0 6.0 4.5 4.0 3.0 2.5 2.5
30 10.0 6.5 5.0 4.5 3.5 3.0 2.5
20 11.0 7.5 5.5 4.5 4.0 3.5 3.0
10 12.0 8.0 6.0 5.0 4.0 3.5 3.0
0 12.5 8.5 6.5 5.5 4.5 3.5 3.0
ACD
80 0.5 0.5 0.5 0 0 0 0
70 1.0 1.0 0.5 0.5 0.5 0 0
60 1.5 1.0 1.0 0.5 0.5 0.5 0.5
50 2.5 2.0 1.5 1.0 1.0 0.5 0.5
40 3.5 2.5 2.0 1.5 1.0 1.0 1.0
30 5.0 3.5 2.5 2.0 1.5 1.5 1.0
20 6.0 4.5 3.5 2.5 2.0 1.5 1.5
Scale ObservedReading 1/8 1/4 3/8 1/2 5/8 3/4 1.0
15N30N45N
90 0.5 0.5 0 0 0 0 0
85 0.5 0.5 0.5 0 0 0 0
80 1.0 0.5 0.5 0.5 0 0 0
75 1.5 1.0 0.5 0.5 0.5 0.5 0
70 2.0 1.0 1.0 0.5 0.5 0.5 0.5
65 2.5 1.5 1.0 0.5 0.5 0.5 0.5
60 3.0 1.5 1.0 1.0 0.5 0.5 0.5
55 3.5 2.0 1.5 1.0 1.0 0.5 0.5
50 3.5 2.0 1.5 1.0 1.0 1.0 0.5
45 4.0 2.5 2.0 1.0 1.0 1.0 1.0
40 4.5 3.0 2.0 1.5 1.0 1.0 1.0
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ROCKWELL CORRECTION FACTORS ADDED FOR CYLINDRICALLY CURVED SURFACES (1)
Diameter Of Specimen Or Part (Inches)
15T30T45T
90 1.5 1.0 1.0 0.5 0.5 0.5 0.5
80 3.0 2.0 1.5 0.5 1.0 1.0 0.5
70 5.0 3.5 2.5 2.0 1.5 1.0 1.0
60 6.5 4.5 3.0 2.5 2.0 1.5 1.5
50 8.5 5.5 4.0 3.0 2.5 2.0 1.5
40 10.0 6.5 4.5 3.5 3.0 2.5 2.0
30 11.5 7.5 5.0 4.0 3.5 2.5 2.0
20 13.0 9.0 6.0 4.5 3.5 3.0 2.0
(1) Per Wilson (Rockwell) Chart No. 55.
Table 4: Minimum Material Thickness for Each Hardness Scale
Forgings AMS4928, MIL-T-9047,C-6, MIL-F-83142, T-3 C39 max
Extrusions AMS4935 C36 max
T1-6A1-6V-2SN
Sheet and plate MIL-T-9045, T-III, C-E
Annealed
C38 max
Bar and rod forgings MIL-T-9047, T-III, C-C,MIL-F-83142, T-3, C-8 C38 max
T1-8MN Sheet and plate MIL-T-9046, T-III, C-A Annealed C32 max
T1-8A1-1MO-IV Sheet and plate MMS-129, MIL-T-9046,T-II, C-F Annealed C38 max
NOTE: Hardness values do not provide a basis for verifying conformance to mechanical propertiesin applicable specifications or rejecting parts. Hardness values in excess of those indicatedmay be used to screen parts for material in STA condition or presence of alpha case.
The effect of heat on Titanium cannot be evaluated properly by hardness tests to evaluatethe properties of Titanium accurately, a metallurgical examination must be made. However,Titanium surfaces oxidize and change color with increasing heat and scale at hightemperatures. This characteristic can be used to assess the intensity of the heat imposedon the Titanium structure. Gulfstream Technical Operations review and approval required.
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Portable Hardness Tester - Barcol and ErnstFigure 1
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Portable Hardness Tester - RiehleFigure 2
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3. Original Finishes
Table 15: GIV Original Finishes
PART NAME PART SUBSTRATE
FINISHSUPPLEMENTAL
EXTERIOR FINISHINTERIOR(1)
EXTERIOR(2)
Fuselage
Radome Glass / EpoxyNomex Core None 92
95 (Ref AV-1159-TS360.0)(3)
Skins Aluminum 2012213 213 None
Gear well Aluminum88
2132012
2013 None
Aluminum bulkhead Aluminum 2012213 None 2012 as required by drwing
(1) All entries noting 2012 or 4012 primer are replaced by 2012, 4012 or 3012.(2) All entries noting 2013 are replaced by 2013 or 3013.(3) Environmental Protective Finish (EPF) for protection against ultra violet light, acid rain and bird damage.(4) Indicates graphite fiber with epoxy resin matrix.(5) 2012 and / or GAMPS 4000 Pratt & Lambert primer (usually). Topcoat (GAMPS 4000 Pratt & Lambert or
operator specified material.
NOTE: The following GAC codes pertain to Table 15.
• 2 - GAC code for Low Embrittlement Cadmium Plating per QQ-P-416 Type II, Class• 88 - GAC code for Anodize - Chromic Acid per MIL-A-8625, Type I, Class 1• 144 - GAC code for Corrosion Preventive Coating - Integral Fuel Tanks per MIL-C-27725• 213 - GAC code for Chromate Conversion Coating per MIL-C-5541, Class 3• 2012 - GAC code for Epoxy Primer - Skydrol Resistant, green - DeSoto 515X333 / 910X350• 2013 - GAC code for Epoxy, Fuel / Skydrol Resistant Topcoat, gloss white - DeSoto 521X315 / 190-
037 / 020-004• 4012 - GAC code for Epoxy Primer (Chlorinated Solvent), Skydrol Resistant (DeSoto 515X383 /
910X749 / 010 / 313) - Product Discontinued as of 1994• 3012 - GAC code for Epoxy Primer, Water Reducible, Low VOC, Di-phosphate Ester Hydraulic Fluid
Resistant• 3013 - GAC code for Epoxy Topcoat, High Solids, Di-phosphate Ester Hydraulic Fluid Resistant