Aircraft Sealants: Types and Identification SM3

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Questions and Answers

Why are aircraft sealants used in aircraft construction and maintenance?

  • To ensure proper pressurization, fuel sealing, and prevent corrosion. (correct)
  • To prevent corrosion between dissimilar metals.
  • To allow for rapid disassembly of aircraft components.
  • To facilitate the aesthetic design of the aircraft's exterior.

What distinguishes two-part sealants from one-part sealants?

  • Two-part sealants come pre-mixed from the manufacturer, ensuring consistency.
  • Two-part sealants are less frequently used due to their complexity.
  • Two-part sealants consist of an accelerator and a base compound that must be mixed. (correct)
  • Two-part sealants are applied using a specialized heat curing process.

In a two-part sealant system, what is the specific role of Part A?

  • Part A is the base compound, providing the primary structural integrity of the sealant.
  • Part A is the accelerator compound, initiating the curing process when mixed with Part B. (correct)
  • Part A serves as a coloring agent, allowing for visual confirmation of proper mixing.
  • Part A acts as a solvent, controlling the viscosity of the sealant for ease of application.

Why is it important to mix two-part sealants according to the manufacturer's specified ratios?

<p>Incorrect ratios may prevent the sealant from achieving its intended performance characteristics. (D)</p> Signup and view all the answers

What mixing method is generally preferred for two-part aircraft sealants, according to best practices?

<p>Mixing by weight, to achieve more precise proportions of the components. (A)</p> Signup and view all the answers

According to the classification system described, what property primarily defines the 'Class' of an aircraft sealant?

<p>The sealant's viscosity, affecting its application method. (C)</p> Signup and view all the answers

How does a 'Class A' sealant differ in application from a 'Class B' sealant?

<p>Class A sealants are designed for brush application due to their thin viscosity, while Class B sealants are applied via extrusion. (B)</p> Signup and view all the answers

What is the typical application method for a Class B sealant?

<p>Extrusion using a pneumatic Semco gun. (A)</p> Signup and view all the answers

What specific characteristic makes Class B sealants suitable for application on vertical surfaces?

<p>Their high viscosity which prevents slumping or sagging. (D)</p> Signup and view all the answers

For what type of application is a 'Class C' sealant most often specified?

<p>Fay surface sealing, ensuring a thin, even layer between mating surfaces. (A)</p> Signup and view all the answers

What is 'working life' in the context of applying aircraft sealants?

<p>The period during which the sealant remains workable and can be properly applied. (C)</p> Signup and view all the answers

How does increasing the ambient temperature typically affect the working time of an aircraft sealant?

<p>It cuts the working time in half by accelerating the curing process. (C)</p> Signup and view all the answers

What is the recommended method for cleaning surfaces prior to applying aircraft sealant?

<p>Cleaning with a solvent such as MEK using a lint-free cloth. (D)</p> Signup and view all the answers

Which of the following steps is crucial to avoid contaminating surfaces after they have been cleaned with a solvent during sealant application?

<p>Avoiding touching the cleaned surfaces to prevent oil contamination. (D)</p> Signup and view all the answers

What visual indicator confirms that a two-part sealant has been properly mixed?

<p>A uniform grey color is obtained. (C)</p> Signup and view all the answers

What action should be taken if the sealant mixture exhibits white or black streaks?

<p>Discard the batch, as the streaks indicate improper mixing that will compromise sealant performance. (C)</p> Signup and view all the answers

Why is it important to avoid vigorous mixing when using a machine to mix aircraft sealants?

<p>Vigorous mixing may heat the mixture and reduce the sealant's working time. (C)</p> Signup and view all the answers

What adjustment should be made to the sealant application process when working in an environment with increased ambient temperature?

<p>Work more quickly due to the reduced working time. (B)</p> Signup and view all the answers

In the context of sealant application, what is a 'fillet'?

<p>A smooth, concave application of sealant at the intersection of two surfaces. (C)</p> Signup and view all the answers

Why is it important to apply a small dab of sealant to the shop head of each rivet?

<p>To provide additional corrosion protection and sealing. (D)</p> Signup and view all the answers

What should be done with excess sealant that oozes out of a joint after riveting?

<p>Smooth it into a fillet around the joint. (D)</p> Signup and view all the answers

According to the information provided, what are the primary functions of aircraft sealants?

<p>Bonding, pressurization, fuel sealing, fume sealing, and corrosion prevention. (C)</p> Signup and view all the answers

What does the term 'tack time' refer to regarding sealant application?

<p>The time after which the sealant is no longer sticky. (C)</p> Signup and view all the answers

What is the meaning of 'cure time' in the context of sealant application?

<p>The duration it takes for the sealant to fully harden and achieve its intended properties. (B)</p> Signup and view all the answers

When applying sealant, what is meant by 'fay surface sealing'?

<p>Sealing the mating surfaces between two overlapping materials. (C)</p> Signup and view all the answers

Based on the provided information, which of the following is NOT a recognized application for aircraft sealants?

<p>Enhancing the radar reflectivity of the aircraft's surface. (D)</p> Signup and view all the answers

If the ambient temperature is significantly lower than the specified working temperature, how should application practices be adjusted?

<p>The working time will likely be longer. (B)</p> Signup and view all the answers

What characteristic defines sealants classified as 'RV'?

<p>Reduced viscosity, suitable for spray applications. (A)</p> Signup and view all the answers

What quality indicates when a sealant batch affected by white or black streaks should be discarded?

<p>Improper mixing. (D)</p> Signup and view all the answers

Sealant 700 is related to what sealant type?

<p>Corrosion inhibitor (B)</p> Signup and view all the answers

Where should the excess sealant be spread after it oozes out from the joints?

<p>It must be smoothened into a fillet (A)</p> Signup and view all the answers

Why is it important for the surfaces to be cleaned from dirt and grease if they are to be applied with sealant?

<p>The bond will not be as strong. (C)</p> Signup and view all the answers

How does temperature affect the working time of the sealant?

<p>Increasing the ambient temperature by 20°F will cut the working time in half. (A)</p> Signup and view all the answers

What ratio parts of A vs parts of B should sealant be mixed in?

<p>10:100 (B)</p> Signup and view all the answers

What primary function differentiates sealants used for fuel tanks from those used for fuselage sealing?

<p>Resistance to degradation from fuel exposure, whereas fuselage sealants focus on maintaining structural integrity. (D)</p> Signup and view all the answers

If the standard mixing ratio for a two-part sealant is 10 parts A to 100 parts B by weight, what adjustment, if any, needs to be made if mixing by volume instead?

<p>Decrease the proportion of Part A to compensate for the possible lower density. (A)</p> Signup and view all the answers

How would increasing the ambient temperature from 77°F to 97°F likely affect the working time of a sealant, and what practical step should be taken?

<p>The working time will be cut in half; mix smaller batches of sealant to avoid waste. (B)</p> Signup and view all the answers

What is the correct method for cleaning surfaces before sealant application, and why is each step important?

<p>Apply solvent with a lint-free cloth, then dry with a second clean rag before the solvent evaporates; this prevents re-deposition of contaminants. (B)</p> Signup and view all the answers

Proper sealant mixing of parts A and B is essential. Prior to combining the parts, what crucial step ensures optimal curing and performance of the sealant?

<p>Stirring each part separately. (D)</p> Signup and view all the answers

What does the term 'working life' refer to when discussing sealant application, and how does it influence application practices?

<p>The time during which the sealant remains usable after mixing; dictates the batch size and application speed. (A)</p> Signup and view all the answers

Which sealant application technique is used, and why, to seal the edges and corners of assembled components, ensuring no gaps or voids remain?

<p>Application of a sealant 'fillet', to create a smooth, concave seal. (A)</p> Signup and view all the answers

What is the purpose of applying a small dab of sealant to the shop head of each rivet, and why is this step important?

<p>To prevent corrosion at the rivet site. (D)</p> Signup and view all the answers

Why is it important to avoid vigorous mixing when using a machine to mix two-part aircraft sealants, and what is a likely consequence of doing so?

<p>To prevent overheating the mixture, which reduces the working time. (A)</p> Signup and view all the answers

When applying sealant, what distinguishes 'fay surface sealing' from other methods, and where is it typically applied?

<p>Sealing surfaces that will be in direct contact when assembled; applied between mating surfaces. (D)</p> Signup and view all the answers

What should be done with excess sealant that oozes out of a joint after riveting, and why is this step necessary?

<p>Smooth it into a fillet around the joint; it ensures a complete seal. (A)</p> Signup and view all the answers

Compared to sealants designed for other applications, what specialized characteristic do fuel tank sealants possess?

<p>Resistance to prolonged exposure to aviation fuels. (A)</p> Signup and view all the answers

In sealant application, what is the meaning of 'tack time', and why is it important to consider?

<p>The time after application when the sealant is no longer sticky; relevant for overcoating or further assembly. (B)</p> Signup and view all the answers

What distinguishes one-part sealants from two-part sealants in terms of preparation for application?

<p>One-part sealants come pre-prepared from the manufacturer, ready for use. (C)</p> Signup and view all the answers

What role does Part A play in a two-part sealant system?

<p>It serves as the accelerator compound, initiating the curing process. (A)</p> Signup and view all the answers

What is the main reason for mixing two-part sealants according to the ratios specified by the manufacturer?

<p>To ensure proper curing and achieve optimal performance properties. (C)</p> Signup and view all the answers

What mixing method is generally recommended for two-part aircraft sealants and why?

<p>By weight, because it typically provides more accurate proportions. (B)</p> Signup and view all the answers

According to the classification system, what property primarily defines the 'Class' of an aircraft sealant?

<p>Its viscosity or flow characteristics. (D)</p> Signup and view all the answers

What application method is generally used for Class B sealants, given their viscosity characteristics?

<p>Extruded using a pneumatic Semco gun. (A)</p> Signup and view all the answers

What unique characteristic makes Class B sealants well-suited for application on vertical surfaces?

<p>Their non-flowing characteristic prevents running or sagging. (D)</p> Signup and view all the answers

For what specific type of application is a 'Class C' sealant most often specified?

<p>Sealing fay surfaces. (C)</p> Signup and view all the answers

What does 'cure time' mean in the context of sealant application, and why is it important to consider?

<p>The time it takes for the sealant to achieve its full strength and properties; affects when the sealed component can be used or tested. (C)</p> Signup and view all the answers

Why is it important to apply all sealants to surfaces cleaned from dirt, grease, and other contaminents?

<p>Better adhesion (D)</p> Signup and view all the answers

Why is the family/ type important when choosing a sealant?

<p>They outline what applications the sealant should be used for (D)</p> Signup and view all the answers

In order to seal a section of the fuselage together, what family/type of sealant should be used?

<p>600/700 series (A)</p> Signup and view all the answers

To help ensure against corrosion in aircraft components, what family/ type should be used?

<p>700 series (B)</p> Signup and view all the answers

What is the correct order for a rivet surface to be sealed?

<ol> <li>Fay Seal 2. Fillet sealant 3. sealant under manufactured rivet head 4. Rivet shop head encapsulation (A)</li> </ol> Signup and view all the answers

After cleaning a surface with an approved solvent, why is it crucial to avoid touching the cleaned area with bare hands before applying sealant?

<p>To avoid re-depositing oils and contaminants from the skin. (D)</p> Signup and view all the answers

In the context of sealant classifications, what does 'RV' typically designate?

<p>Reduced Viscosity, for easier spray application over large areas. (D)</p> Signup and view all the answers

If no uniform color is observed after mixing, what can be said about the mix?

<p>May Not Be Proper (B)</p> Signup and view all the answers

What are the signs of an improperly mixed sealant

<p>It has white or black streaks (B)</p> Signup and view all the answers

What should you do with sealant if it becomes improperly mixed?

<p>It need to be discarded (B)</p> Signup and view all the answers

Flashcards

Aircraft Sealant Uses

Aircraft sealants are used for bonding, pressurization, fuel sealing, fume sealing, and corrosion prevention in aircraft.

One-Part Sealants

One-part sealants are pre-mixed and ready to use directly from the manufacturer.

Two-Part Sealants

Two-part sealants consist of an accelerator (Part A) and a base compound (Part B), requiring separate packaging and mixing.

Two-Part Sealant: Part A

Part A is the accelerator compound in a two-part sealant.

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Two-Part Sealant: Part B

Part B is the base compound in a two-part sealant.

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Sealant Classifications

Sealant type classifications based on their varying viscosities.

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Class A Sealant

Class A sealants have a thin viscosity, ideal for brush application.

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Class B Sealant

Class B sealants have a higher viscosity, designed for extrusion via a pneumatic Semco gun and forming fillets.

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Class C Sealant

Class C sealants have a medium viscosity, often for fay surface sealing, applied with a roller or combed tool.

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Working Life of Sealant

Working life is the time during which a sealant can be effectively applied.

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Tack Time

Tack time is the point when the sealant is no longer sticky.

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Cure Time

Cure time is the time required for a sealant to fully harden.

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Preparing Surfaces for Sealant

All surfaces must be cleaned with a solvent, like MEK, to remove dirt, grease, and oils before applying sealant.

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Mixing Two-Part Sealants

Two-part sealants need precise mixing, a 10 to 100 ratio of Part A to Part B by weight is required .

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Checking Sealant Mixture

Ensure a uniform grey color is obtained when mixing two-part sealants.

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Temperature Effects on Sealant

Increasing ambient temperature cuts working time, while decreasing ambient temperature doubles it.

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Applying Sealant to Components

Apply sealant sufficiently so it slightly oozes when components are pressed together, then rivet normally.

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Creating a Fillet

Use a fillet to smooth excess sealant, ensuring edges and corners are sealed without voids.

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Rivet Sealing

Apply a small dab of sealant to each rivet shop head and clean excess with solvent.

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Aircraft Sealant Manufactures

Few manufactures produce aircraft sealant.

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Aircraft Sealants

Sealants used on aircraft for bonding, sealing, and corrosion prevention.

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Part A (Sealant)

Part of two-part sealant, the accelerator compound.

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Part B (Sealant)

Part of two-part sealant, the base compound.

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Sealant Working Life

Time available to apply sealant before it hardens

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Sealant Tack Time

The time when sealant loses its stickiness.

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Sealant Cure Time

Time for sealant to achieve full strength and hardness.

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Surface Preparation (Sealant)

Cleaning surfaces with solvent before applying sealant.

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Sealant Mixing Ratio

Sealants require a specific proportion of its parts.

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Uniform Sealant Color

Consistent color indicates proper sealant mixing.

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Sealant Fillet

Excess sealant smoothed along joint edges.

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Rivet Shop Head Encapsulation

Small dab of sealant covering each rivet after installation.

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Sealant Fume Sealing

Preventing leaks from a surface.

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Sealant Corrosion Protection

Preventing corrosion.

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Fastener Seal

Where the sealant is applied to rivets.

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Study Notes

  • Aircraft sealants serve multiple functions; bonding, pressurization, fuel sealing, fume sealing, and corrosion prevention.

Sealant Types

  • One-part sealants are pre-prepared by the manufacturer for immediate use
  • Two-part sealants require mixing before use, consisting of Part A (Accelerator) and Part B (Base).
  • Two-part sealants must always be mixed according to the manufacturer's specified ratios, generally by weight.
  • Two-part sealants are more commonly used than one-part and require separate packaging

Sealant Identification

  • There exist a few manufacturers of aircraft sealant

  • PPG Aerospace - PRC / Proseal

  • Flamemaster - Chemseal

  • Advanced chemistry and technology - AC /MC

  • Each manufacturer uses its own identification system

  • AC-Tech sealants identification explained: AC - 123 B - 1/2

  • Application time: time(h) @ 25°C, 50% r.H.

  • Class

    • A = paste, by brush (fastener)
    • B = non-flowing, by gun (fillet & injection seal)
    • C = liquid, by gun & roller (fay surface)
    • RV = reduced viscosity, by spray (larger areas)
  • Family/Type describes application

  • 100 = first generation, non-sealing products

  • 200 = second generation & special sealants

  • 2xx/3xx = fuel tank sealants

  • 300 = third generation

  • 6xx/7xx = fuselage sealants

  • 700 = with corrosion inhibitor

  • The manufacturer of the AC-Tech sealants is AC-Tech, Garden Grove, US

Family/Type Applications

  • 100 is for first-generation sealants
  • 200 is for second-generation sealants
  • 300 is for third-generation sealants
  • 200/300 are for fuel tank sealants
  • 600/700 are for fuselage sealants
  • 700 corrosion inhibitor sealants

Sealant Classification

  • Class A sealants have a thin viscosity, between 150-500 Poise
    • They are designed for brush application
  • Class A is designated by U.S. specifications
  • Class A sealants are about the consistency of cold chocolate syrup
  • Class B sealants have a higher viscosity, between 8,000-16,000 Poise
  • Application via extrusion with a pneumatic Semco gun is preferable
    • Class B sealants form fillets and seals on vertical surfaces
  • Class B sealants are about the consistency of peanut butter
  • Class C sealants have a medium viscosity, between 1000-4000 Poise
  • Application by a roller or combed tooth spreader, most often specified for fay surface sealing
  • Often called Class C or Fay Surface sealants
    • Class C sealants are about the consistency of sour cream

Application and Time

  • Working life is the time during which the sealant can be applied effectively.
  • After the working time passes, the sealant may not adhere correctly.
  • Examples of working life include 1/2 hours, 2 hours, and 4 hours.
  • Tack time refers to the point when the sealant is no longer sticky.
  • Cure time is the time required for the sealant to be completely cured.

Applying Protocol

  • To apply sealant effectively, the surface must be free of all contaminants like dirt, grease, and oils
  • Clean surfaces with a solvent, like MEK.
  • Apply solvent with a new, lint-free cloth.
  • Dry the surface with a second clean rag before the solvent evaporates.
  • This prevents redepositing contaminates on the surface.
  • Rivets should be soaked to remove oils.
  • Avoid touching surfaces after cleaning to prevent contamination from body oils.

Mixing Protocols

  • Measure sealant parts accurately for proper curing.
  • Parts A and B must be stirred separately before weighing, then Part B should be added to Part A, and mixed thoroughly until a uniform grey color is achieved.
    • The sealant must be mixed in the proportion of 10 parts of Part A to 100 parts of Part B, by weight
  • When mixing by volume the ratio would then be 8.3:100
  • The mixture should not have any white or black streaks.
  • Ensure no unmixed material remains on the container's sides or bottom. The application depends on multiple factors; Leak and fume proof requires attention to detail:
  • Fay Seal
  • Fillet Seal
  • Sealant under (manufactured) rivet head
  • Rivet (shop head) encapsulation
  • If machine mixing, avoid vigorous mixing to prevent overheating which reduces working time
  • Pre-filled tubes (sem kits) have pre-measured proportions and must be mixed according to the instructions on the tube.
  • Only mix the amount of sealant that can be used within its working time.
  • Working time is affected by temperature and humidity
  • Specified working time is typically at 77°F.
  • Increase of ambient temperature by 20°F cuts the working time by half.
  • Decrease of ambient temperature by 20°F doubles the working time.
  • Apply mixed sealant in a thin layer.
  • When pressed together, the sealant should ooze slightly out of the edges.
  • Rivet the joint in the normal manner.
  • Smooth the excess sealant into a fillet around the joint.
  • Apply a fillet of sealant to the edges and corners of all components.
  • Ensure that there are no voids and apply a small dab to shop head of each rivet.
  • Clean up any excess or smeared sealant with solvent.

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