Preliminary Requirements

Safety Requirements

WARNING

SATISFACTORY FUME EXTRACTION IS NECESSARY WHERE THE COATINGS ARE SPRAYED. AN AIR SPEED OF 2.3 FT/SEC (0.7 M/SEC) IS RECOMMENDED.

YOU MUST NOT SMOKE.

IT IS THE RESPONSIBILITY OF THE OPERATOR TO OBTAIN AND OBSERVE THE CONSUMABLE MATERIAL MANUFACTURER’S SAFETY DATA SHEETS FOR CONSUMABLE MATERIALS INFORMATION (SUCH AS, HAZARDOUS INGREDIENTS, PHYSICAL/CHEMICAL CHARACTERISTICS, FIRE HAZARD DATA, EXPLOSION HAZARD DATA, REACTIVITY HAZARD DATA, HEALTH HAZARD DATA, PRECAUTIONS FOR SAFE HANDLING, USE, AND CONTROL MEASURES) AND ALSO TO TAKE LOCAL REGULATIONS INTO CONSIDERATION.

WARNING

WET BACK-SPRAY BOOTH.

YOU MUST KEEP THE PH VALUE OF THE CIRCULATION WATER IN THE RANGE OF PH 5 TO PH 10.

A CHECK MUST BE DONE FREQUENTLY OF THE PH VALUE OF THE CIRCULATION WATER. IT MUST BE CORRECTED IF NECESSARY. THE CHECK IS DONE BY THE CONTROLLING LABORATORY.

THE EXHAUST UNIT MUST BE INSTALLED SO THAT THE HYDROGEN CONTENT OF THE AIR STAYS BELOW THE LOWER EXPLOSION LIMIT (FOUR PERCENT BY VOLUME).

DO NOT ADD OTHER SUBSTANCES TO THE CIRCULATION WATER UNLESS THE CONTROLLING LABORATORY PERMITS IT.

THE DIVIDED ALUMINUM POWDER CONTAINED IN CoMat 07-035 CORROSION RESISTANT COATING and CoMat 07-104 ALUMINIUM HIGH HEAT RESISTANT PAINT GOES INTO THE SPRAY PLANT CIRCULATION SYSTEM THROUGH THE SPRAY BOOTH WATER CURTAIN.

THE ALUMINUM CAN, IN ACIDIC OR ALKALINE CONDITIONS, GIVE OFF HYDROGEN WITH THE DANGER OF AN OXYGEN/HYDROGEN EXPLOSION.

WARNING

DRY BACK-SPRAY BOOTH.

FILTERS THAT CAN BE DISCARDED MUST BE USED IN THE EXTRACTION SYSTEM AND MUST BE FREQUENTLY REPLACED WITH CLEAN FILTERS.

WARNING

WET AND DRY BACK-SPRAY BOOTHS.

THE EXTRACTION FAN MUST BE ON DURING SHUT DOWN

THE SPRAY BOOTHS OF EACH TYPE MUST BE CLEANED REGUARLY. UNWANTED MATERIAL MUST BE PUT IN DRUMS. THE DRUMS MUST BE PUT IN AN EXTERNAL STORE WITH A VENT INSTALLED TO LET HYDROGEN GAS GET OUT.

THE DRUMS MUST BE CLEARLY LABELLED AND DISCARDED WITH AN APPROVED PROCEDURE

Procedure

1. SUBTASK 70-38-21-380-001 Deleted

2. SUBTASK 70-38-21-380-002 Deleted

3. SUBTASK 70-38-21-380-003 Deleted

4. SUBTASK 70-38-21-380-004 The Make-up of High Heat and Corrosion Resistant Coatings

   1. The maximum continuous operation temperature of these coatings is as follows:

      1. 12 percent chromium steel - 1112 deg F (600 deg C).

      2. Mild and low alloy steels - 932 deg F (500 deg C).

   2. NOTE

      CoMat 07-039 CORROSION RESISTANT COATING, is thinner than CoMat 07-035 CORROSION RESISTANT COATING. It is used on areas where the dimensional tolerances prevent the use of thicker coatings. It is only to be used when recommended in the applicable Engine Manual.

      CoMat 07-035 CORROSION RESISTANT COATING (SermeTel 'W'), CoMat 07-039 CORROSION RESISTANT COATING (SermeTel 709), and CoMat 07-104 ALUMINIUM HIGH HEAT RESISTANT PAINT are heavily pigmented and separation occurs quickly, which causes the pigment to "cake". The paints should be agitated during storage in the sealed containers every 3 months to prevent excess "caking". It is important for the materials to be fully mixed before they are sprayed. To do this put the containers on mechanical rollers for two to three hours before use.

   3. Remove the material from its container and put it in a different container. Mix the material again with a mechanical mixer.

   4. CoMat 07-041 CORROSION RESISTANT SEALINGVCOATING (Sermaseal 570A) is an inorganic water based chromate/phosphate coating. It soaks into the porosity of the primary coatings, seals them and extends their lives. It can be applied when recommended in the applicable Engine Manual.

   5. CoMat 07-041 CORROSION RESISTANT SEALINGVCOATING is supplied in two parts. Part 1 must be fully mixed before it is mixed with Part 2. The two parts are mixed to a ratio of ten parts of Part 1 to one part of Part 2 (by volume). The two parts must be fully mixed until the higher layer goes into solution with none remaining on the surface. The pot life of this material when mixed is 48 hours. It can be applied to Type A Coatings or B Coatings when recommended in the applicable Engine Manual.

5. SUBTASK 70-38-21-380-005 Deleted

6. SUBTASK 70-38-21-380-006 Prepare the Part

   
   CAUTION
   DO NOT PUT LOW ALLOY STEELS IN THE ALKALI DERUSTER FOR MORE THAN 20 MINUTES. THEY CAN BE PUT BACK AGAIN FOR 20 MINUTES AT A TIME, WHEN THEY ARE CLEANED WITH WATER.

   1. Remove all the paint and corrosion particles (refer to the SPM TASK 70-11-05-300-503).

      1. If the parts are oxidized remove the oxidation (refer to the SPM TASK 70-11-13-300-503).

   2. Degrease the parts. Refer to the SPM TASK 70-11-01-300-503 or SPM TASK 70-11-03-300-503.

   3. Install mechanical blanking plates to the areas of the part that are not to be coated. If this is not possible use CoMat 02-001 ADHESIVE TAPE (MASKING), CoMat 02-005 ADHESIVE TAPE (MASKING), or a tape from SPM TASK 70-34-18-380-501. It is important to make sure all holes have mechanical blanks installed (or masking tape applied) if it is possible for the abrasive to get caught.

   4. 

      CAUTION

      SURFACES MUST BE CLEAN FOR THE CORROSION RESISTANT COATING TO BOND SATISFACTORILY. DO NOT USE ABRASIVE BLAST TO REMOVE PAINT OR OXIDES.

      NOTE

      The coating must be applied as quickly as possible when the dry abrasive blast is completed. If the parts are contained in polythene or brown paper the coating must be applied in not more than 16 hours.

      To keep contamination to a minimum, it is recommended that the blasting cabinet is only used for the preparation before you paint the parts.

      Dry abrasive blast the areas to be coated, with CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE or CoMat 05-004 ABRASIVE MEDIUM, ALUMINUM OXIDE, 140/400 GRADE. Refer to the SPM TASK 70-12-02-120-501.

   5. 

      CAUTION

      DO NOT TOUCH THE BLASTED SURFACE UNLESS YOU HAVE CLEAN POLYTHENE OR COTTON GLOVES ON YOUR HANDS. IF CONTAMINATION OCCURS DO STEPS A, B AND D, AGAIN.

      Remove the mechanical blanking plates or masking tape. Make sure all the abrasive is removed. Do this with clean, dry compressed air; or use a clean, dry brush.

   6. NOTE

      Make sure you keep the parts very clean.

      NOTE

      It is recommended to apply a mask or maskants again after blasting, but if the masking is in good condition the existing masking can be used for painting.

      Install mechanical blanking plates, CoMat 02-019 TAPE, ADHESIVE PAPER HEAT RESISTING MASKING tapes from SPM TASK 70-34-18-380-501, or tapes from SPM TASK 70-38-24-300-503 to areas of the part that are not to be coated.

7. SUBTASK 70-38-21-380-007 The Procedure to Apply CoMat 07-035 Corrosion Resistant Coating

   1. NOTE

      The type of coating (A, B or C) will be specified in the applicable Engine Manual.

      Apply one layer of CoMat 07-035 CORROSION RESISTANT COATING with the specified spray equipment at a pressure of 25 to 35 psi (175 to 245 KPa).

   2. Dry with air in clean, warm conditions; with a humidity range of 35 to 60 relative humidity for 15 - 20 minutes or until the coating has a matte grey finish.

   3. Do steps A. and B. again to get a coating thickness of 0.002 in (0.05 mm) approximately.

   4. Heat the parts to a temperature of 140 to 212 deg F (60 to 100 deg C) for 15 minutes minimum.

   5. Remove masking tape if applied.

      NOTE

      It is possible that it will be necessary to remove the blanking plates to make it possible to remove the tape.
   6. 

      WARNING

      THE STOVING OVEN MUST HAVE SUFFICIENT VENTILATION.

      UNWANTED GASES FROM THE OVEN HEATING SYSTEM MUST NOT GO INTO THE STOVING OVEN.

      YOU MUST NOT DO OTHER PAINT STOVING AT THE SAME TIME AS YOU STOVE OR HEAT TREAT COMAT 07-035, CoMat 07-039 CORROSION RESISTANT COATING AND COMAT 07-042 CORROSION RESISTANT COATINGS.

      NOTE

      Mechanical blanking plates can be installed when the part is stoved.

      Put the parts into an oven at a maximum temperature of 185 deg F (85 deg C). Increase the temperature of the oven to 648 to 676 deg F (342 to 358 deg C) and keep it at this temperature for a minimum of one hour.

   7. Let the parts become cool (to a temperature of 59 to 77 deg F (15 to 25 deg C)).

   8. Do a check on the coating to make sure it is constant and is the correct thickness. It must not be peeled or have runs. The complete procedure must give a thickness of 0.0016 to 0.003 in. (0.04 to 0.08 mm).

   9. Remove the mechanical blanking plates. Do this carefully to prevent contamination to the surface coating.

   10. The heat treatment to complete this procedure will depend on the coating type, as recommended in the applicable Engine Manual.

       1. Type A Coating - Gives sacrificial corrosion protection to steel. Do one of the subsequent procedures:

          1. 

             WARNING

             THE STOVING OVEN MUST HAVE SUFFICIENT VENTILATION.

             UNWANTED GASES FROM THE OVEN HEATING SYSTEM MUST NOT GO INTO THE STOVING OVEN.

             YOU MUST NOT DO OTHER PAINT STOVING AT THE SAME TIME AS YOU STOVE OR HEAT TREAT COMAT 07-035, COMAT 07-039 AND COMAT 07-042 CORROSION RESISTANT COATINGS.

             Put the parts into the oven at a temperature not exceeding 662 deg F (350 deg C), heat to 1026 to 1054 deg F (552 to 568 deg C) for one hour.

          2. Unless specified differently by the engine manual, it is permitted to do this alternative procedure: Put the parts into the oven at 662 deg F (350 deg C) maximum, then increase the temperature to 945 to 973 deg F (507 to 523 deg C) for four hours.

       2. Type B Coating - Gives sacrificial corrosion protection to steel.

          1. Burnish the parts with CoMat 05-009 GLASS BEADS or CoMat 05-184 CERAMIC BEADS at a pressure of 5 psi (35 KPa) for a pressure fed unit, or 35 psi (245 KPa) for a suction type unit. Refer to SPM TASK 70-12-03-120-501. The nozzle diameter must be 0.47 in. (12 mm) and the nozzle to part distance is to be 6 in. (150 mm).

       3. Type C Coating - Does not give sacrificial corrosion protection it is only a barrier coating. No heat or surface treatment burnish is necessary.

8. SUBTASK 70-38-21-220-001 Examine the Surface Coating

   1. Examine the coating for damage, quality and thickness. Make sure only the specified areas are coated.

   2. Do an approved conductivity check on Type A Coatings and Type B Coatings. Use one of the procedures in the subsequent list:

      NOTE

      The probe tips must not go fully through the coating to touch the part metal below the coating. If the probes touch the part metal below the coating, the conductivity check will not be correct.

      1. The coating must have sufficient electrical conductivity for a 3 to 4 volt, 0.3 amp lamp bulb to come on when you connect two probes in series with the lamp bulb and a 1.5 volt dry cell battery, and touch the probes to the coating 20 mm (0.8 inch) apart.

      2. The coating must show electrical resistance of 5 ohms maximum on a digital ohmmeter when you touch the two ohmmeter probes to the coating 20 mm (0.8 inch) minimum apart.

   3. If the conductivity check on a type A Coating is unsatisfactory, do the specified Type A Coating heat treatment Step again, then examine the coating again.

      1. If the conductivity check on a Type B Coating is unsatisfactory the part must be burnished again (refer to Step. Examine the part again.

      2. Coatings that are unsatisfactory after the second conductivity check or have large areas of damage, must have the coating completely removed (refer to Step) and replaced. Areas that only have small local damage can have a touch-up coating applied. Refer to Step.

9. SUBTASK 70-38-21-380-008 The Procedure to Apply CoMat 07-104 Aluminum High Heat Resistant Paint

   1. NOTE

      The type of coating (A, B or C) will be specified in the applicable Engine Manual.

      Prepare the part. Refer to Step.

   2. Apply one layer of CoMat 07-104 ALUMINIUM HIGH HEAT RESISTANT PAINT with the specified spray equipment at a pressure of 25 to 35 psi (175 to 245 KPa).

   3. Dry with air for a minimum of 15 minutes in clean, warm conditions. A matt grey finish is necessary.

   4. Do Step and Step again, if necessary, to get a coating thickness of 0.003 in. (0.08 mm) approximately.

   5. Remove CoMat 02-019 TAPE, ADHESIVE PAPER HEAT RESISTING MASKING if applied.

   6. 

      WARNING

      THE STOVING OVEN MUST HAVE SUFFICIENT VENTILATION.

      UNWANTED GASES FROM THE OVEN HEATING SYSTEM MUST NOT GO INTO THE STOVING OVEN.

      NOTE

      Mechanical blanking plates can be installed when the part is stoved.

      Put the parts into an oven at a temperature of 360 to 388 deg F (182 to 198 deg C) for one hour. Two hours are necessary for Type C Coatings.

   7. Let the parts become cool (to a temperature of 59 to 77 deg F (15 to 25 deg C)).

   8. Do a check on the coating to make sure it is constant, of the correct thickness and of good quality.

      1. The coating thickness must be 0.0015 to 0.004in. (0.038 to 0.10 mm). A depth of 0.001in. (0.03 mm) is permitted in small local areas.

      2. If the general thickness is less than that specified, do Step, Step, Step and Step again.

   9. Remove the mechanical blanking plates. Do this carefully to prevent contamination to the surface coating.

   10. The heat treatment to complete this procedure will depend on the coating type, as recommended in the applicable Engine Manual.

       1. Type A Coating - Gives sacrificial corrosion protection to steel.

          1. 

             WARNING

             THE STOVING OVEN MUST HAVE SUFFICIENT VENTILATION.

             UNWANTED GASES FROM THE OVEN HEATING SYSTEM MUST NOT GO INTO THE STOVING OVEN.

             Put the parts into the oven at a maximum temperature of 383 deg F (195 deg C). Then increase the temperature to 1026 to 1054 deg F (552 to 568 deg C) for one hour or 990 to 1018 deg F (532 to 548 deg C) for four hours.

       2. Type B Coating - Gives sacrificial corrosion protection to steel.

          1. 

             WARNING

             THE STOVING OVEN MUST HAVE SUFFICIENT VENTILATION.

             UNWANTED GASES FROM THE OVEN HEATING SYSTEM MUST NOT GO INTO THE STOVING OVEN.

             Put the parts into the oven at a maximum temperature of 383 deg F (195 deg C). Then increase the temperature to 900 to 928 deg F (482 to 498 deg C) for two hours.

          2. Burnish the parts with CoMat 05-009 GLASS BEADS or CoMat 05-184 CERAMIC BEADS at a pressure of 5 psi (35 KPa) for a pressure fed unit, or 35 psi (245 KPa) for a suction type unit. Refer to SPM TASK 70-12-03-120-501. The nozzle diameter must be 0.47 in. (12 mm) and the nozzle to part distance is to be 6 in. (150 mm).

       3. Type C Coating - Does not give sacrificial corrosion protection it is only a barrier coating. No heat or surface treatment burnish is necessary.

   11. Examine the surface coating. Refer to Step.

10. SUBTASK 70-38-21-380-009 The Procedure to Apply CoMat 07-039 Corrosion Resistant Coating

    1. NOTE

       The type of coating (A, B or C) will be specified in the applicable Engine Manual.

       Prepare the part. Refer to Step.

    2. Apply one layer of CoMat 07-039 CORROSION RESISTANT COATING with the specified spray equipment at a pressure of 25 to 35 psi (175 to 245 kPa). The spray gun must be held at a distance of 8 to 10in. (203 to 254 mm) from the part. If surface defects occur remove the coating with clean water and apply the coating again.

    3. Dry with air for 15 to 20 minutes in clean, warm conditions with a humidity range of 35 to 60 relative humidity. A matt grey finish is necessary.

    4. Do steps B. and C. again, if necessary, to get a coating thickness of 0.0006in. (0.015 mm) approximately.

    5. Remove CoMat 02-019 TAPE, ADHESIVE PAPER HEAT RESISTING MASKING if applied.

    6. 

       WARNING

       THE STOVING OVEN MUST HAVE SUFFICIENT VENTILATION.

       UNWANTED GASES FROM THE OVEN HEATING SYSTEM MUST NOT GO INTO THE STOVING OVEN.

       YOU MUST NOT DO OTHER PAINT STOVING AT THE SAME TIME AS YOU STOVE OR HEAT TREAT CoMat 07-035 CORROSION RESISTANT COATING, CoMat 07-039 CORROSION RESISTANT COATING AND CoMat 07-042 AIR DRYING TOUCH-UP COATING CORROSION RESISTANT COATINGS.

       NOTE

       Mechanical blanking plates can be installed when the part is stoved.

       Put the parts into an oven at a maximum temperature of 185 deg F (85 deg C). Then increase the temperature to 648 to 676 deg F (342 to 358 deg C) and keep it at this temperature for one hour.

    7. Let the parts become cool (to a temperature of 59 to 77 deg F (15 to 25 deg C)).

    8. Do a check on the coating to make sure it is constant, of the correct thickness and of good quality. The complete procedure must give a coating thickness of 0.0004 to 0.0008in. (0.010 to 0.020 mm).

    9. Remove the mechanical blanking plates. Do this carefully to prevent contamination to the surface coating.

    10. The heat treatment to complete this procedure will depend on the coating type, as recommended in the applicable Engine Manual.

        1. Type A Coating - Gives sacrificial corrosion protection to steel. Do one of the subsequent procedures:

           1. 

              WARNING

              THE STOVING OVEN MUST HAVE SUFFICIENT VENTILATION.

              UNWANTED GASES FROM THE OVEN HEATING SYSTEM MUST NOT GO INTO THE STOVING OVEN.

              YOU MUST NOT DO OTHER PAINT STOVING AT THE SAME TIME AS YOU STOVE OR HEAT TREAT COMAT 07-035, COMAT 07-039 AND COMAT 07-042 CORROSION RESISTANT COATINGS.

              Put the parts into the oven at a maximum temperature of 383 deg F (195 deg C). Then increase the temperature to 1026 to 1054 deg F (552 to 568 deg C) for two hours.

        2. Unless specified differently by the engine manual, it is permitted to do this alternative procedure: Put the parts into the oven at 662 deg F (350 deg C) maximum, then increase the temperature to 945 to 973 deg F (507 to 523 deg C) for four hours.

        3. Type B Coating - Gives sacrificial corrosion protection to steel.

           1. Burnish the parts with CoMat 05-009 GLASS BEADS or CoMat 05-184 CERAMIC BEADS at pressure of 5 psi (35 KPa) (pressure fed unit) or 35 psi (245 KPa) for a suction type unit. Refer to SPM TASK 70-12-03-120-501. The nozzle diameter must be 0.47 in. (12 mm) and the nozzle to part distance is to be 6 in. (150 mm).

        4. Type C Coating - Does not give sacrificial corrosion protection it is only a barrier coating. No heat or surface treatment burnish is necessary.

    11. Examine the surface coating. Refer to Step.

11. SUBTASK 70-38-21-380-010 The Procedure to Touch-up Damaged Coating

    1. Rub the damaged area with CoMat 05-020 WATERPROOF SILICON CARBIDE or CoMat 05-021 WATERPROOF SILICON CARBIDE until the damaged area is smooth with the adjacent area.

    2. Solvent clean the part. Refer to the SPM TASK 70-11-14-300-503.

    3. Let the part dry in air or use clean, dry compressed air.

    4. Completely mix the CoMat 07-037 CORROSION RESISTANT TOUCH-UP COATING or CoMat 07-038 AIR DRYING ENAMEL and apply one layer with a brush. Let the part dry in air for 30 min.

12. SUBTASK 70-38-21-380-011 The Procedure to Apply CoMat 07-041 Corrosion Resistant Sealing Coating

    
    CAUTION
    CONDUCTIVITY CHECKS MUST BE DONE BEFORE YOU APPLY COMAT 07-041 CORROSION RESISTANT SEALING COATING. REFER TO Step.

    1. Prepare the part.

       1. Remove the grease from the part. Refer to the SPM TASK 70-11-01-300-503.

       2. Install mechanical blanking plates to areas of the part that are not to be coated. If this is not possible use CoMat 02-001 ADHESIVE TAPE (MASKING) or CoMat 02-005 ADHESIVE TAPE (MASKING).

       3. 

          CAUTION

          SURFACES MUST BE CLEAN BEFORE YOU APPLY COMAT 07-041 CORROSION RESISTANT SEALING COATING.

          THE ABRASIVE BLAST PROCEDURE MUST NOT BE USED FOR THE REMOVAL OF OXIDES AND PAINT.

          THE ABRASIVE BLAST PROCEDURE IS NECESSARY ON TYPE B COATINGS. THIS IS BECAUSE THEY ARE GLASS BEAD BURNISHED.

          Dry abrasive blast the areas to be coated with CoMat 05-003 ABRASIVE MEDIUM ALUMINUM OXIDE, 120/220 GRADE or CoMat 05-004 ABRASIVE MEDIUM, ALUMINUM OXIDE, 140/400 GRADE at a pressure of 7 to 14 psi (48 to 96 KPa) (pressure fed unit) or 20 to 25 psi (140 to 175 KPa) (suction type unit). The nozzle to part distance must be 10 to 12in. (250 to 305 mm).

       4. Remove remaining abrasive blast media with clean, dry compressed air.

    2. Prepare the CoMat 07-041 CORROSION RESISTANT SEALINGVCOATING for use. Refer to Step.

    3. With the approved spray equipment apply CoMat 07-041 CORROSION RESISTANT SEALINGVCOATING corrosion resistant sealing coating as a light spray. Two or four coats could be necessary to get a good constant color.

    4. Remove the mechanical blanking plates or CoMat 02-001 ADHESIVE TAPE (MASKING) or CoMat 02-005 ADHESIVE TAPE (MASKING). Do this carefully to prevent contamination of the surface coating.

    5. Let the parts dry for a minimum of 15 minutes.

    6. 

       WARNING

       THE STOVING OVEN MUST HAVE SUFFICIENT VENTILATION.

       UNWANTED GASES FROM THE OVEN HEATING SYSTEM MUST NOT GO INTO THE STOVING OVEN.

       Put the parts into an oven at a maximum temperature of 185 deg F (85 deg C) and keep it at this temperature for 30 minutes. Then increase the temperature to 648 to 676 deg F (342 to 358 deg C) for a minimum of 30 minutes.

    7. Examine the coating for damage and make sure the correct areas are coated. If small areas are damaged touch-up the coating as follows:

       1. Rub the damaged area with CoMat 05-020 WATERPROOF SILICON CARBIDE or CoMat 05-021 WATERPROOF SILICON CARBIDE until the damaged area is smooth with the adjacent area.

       2. Solvent clean the part. Refer to the SPM TASK 70-11-14-300-503.

       3. Let the part dry in air or use clean, dry compressed air.

       4. Completely mix the CoMat 07-042 AIR DRYING TOUCH-UP COATING or the CoMat 07-043 AIR DRYING TOUCH-UP COATING and apply one layer with a brush. Let the part dry for a minimum of 30 minutes.