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The Department of National Defence (DND) in Canada has implemented a revised maintenance program for aircraft weapon systems whose goal is to ensure that essential maintenance is accomplished and to assure the continued airworthiness of aeronautical products during in-service operation. The program especially affects legacy aircraft. A case study is being presented where an adhesion failure was detected during a scheduled inspection.
The Department of National Defence (DND) in Canada has implemented a revised maintenance program for aircraft weapon systems whose goal is to ensure that essential maintenance is accomplished and to assure the continued airworthiness of aeronautical products during in-service operation. The program especially affects legacy aircraft. A case study is being presented where an adhesion failure was detected during a scheduled inspection. After carrying out numerous wet adhesion tests which failed, followed by water break tests on the failed areas, surface contamination prior to organic coating application was suspected. Typical laboratory techniques could not detect any contamination. Use of state-of-the-art Time of Flight – Secondary Ion Mass Spectrometry (ToF-SIMS) with primary ion source, Bi3+, was needed to determine the presence of surface contamination as low as a monolayer. The contamination was positively identified as a cationic surfactant that is commonly used in aircraft cleaners and conversion coating solutions. Further analyses using Scanning Electron Microscopy – Energy Dispersive X-ray Analyses (SEM-EDX), Thermal Gravimetric Analyses (TGA), Differenctial Scanning Calorimetry (DSC) and Dynamic Mechanical Analyses (DMA) were used to ensure the bulk integrity of the failed coatings.
In this paper, I will discuss such an example of when the predicted service of the coating determines that a more dynamic method must be utilized. I will discuss testing that was conducted for immersion service where flow of water over the surface was a major consideration. The question of how well the adhesion would hold up in real life service could not be properly answered by the degree of failure in this case. I discovered that the more important consideration was the survivability of the coating if a defect were introduced.
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This presentation will outline the results and conclusions of a number of years of testing and experience in surface preparation for high-performance coatings. Testing has shown that there are a number of important surface preparation variables that are not routinely monitored and controlled on coating projects. These variables will be identified and guidance will be provided on appropriate treatment to achieve coating results.
Industrial and marine protective coating systems are most commonly applied without incident and perform as expected over their anticipated service life. However, occasionally, a coating system will fail prematurely, for unexpected reasons, and with expensive consequences. This paper addresses those unexpected failures and provides reasons and remedies for such occurrences.