PROCESS AND MATERIAL SPECIFICATION

PROCESS SPECIFICATION

01-02-53

Paint Coating in Interior Furnishing

Printed in Germany
 PROCESS AND MATERIAL SPECIFICATION

RECORD OF REVISIONS

REV ISSUE INSERTED REV. ISSUE INSERTED

NO. DATE DATE BY NO. DATE DATE BY
01 Feb 01/9

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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE

RECORD OF REVISION 1 Feb 01/09

LIST OF EFFECTIVE PAGES 1 Feb 01/09

TABLE OF CONTENTS 1 Feb 01/09

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 PROCESS AND MATERIAL SPECIFICATION

Previous issue: 10/2003

The reproduction, distribution and utilization of this document as well as the communication of its contents to others without explicit authorization is
prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design.

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Page 2 80-T-35-9123 (03/2006)

1 SCOPE AND APPLICATION

This process specification describes the coating of metallic and non-metallic surfaces in the aircraft
interior to obtain a decorative finish.

Example:

• Hatrack doors
• Parts of ceiling
• Stowage units
• Partitions
• Cove light panel (metal)
• Handrails, PSUs etc.
• Doors/doorframe linings

This specification shall be applied if the manufacturing documents specify paint coating per
80-T-35-9123.

The paint system described in this specification is distinguished not only by its simple and good
cleaning properties but also by its good resistance to wear and fire properties in accordance with
ABD0031 and FAR 25.853 (a-1) Amdt. 66 (OSU HEAT RELEASE RATE).

Only the products defined in the attached data sheets are permitted for this process.

2 RELATED DOCUMENTS
QVA-Z10-50-02 Thickness Measurement of Non-ferromagnetic Layers on Ferromagnetic Materials
by Magnetic Flux
QVA-Z10-50-03 Thickness Measurement of Electrically Non-Conducting Layers on Non-
ferromagnetic Alloys
80-T-35-0014 Cleaning with Organic Solvents (Cold Cleaning Agents)
80-T-35-5002 Coating with Two-component Primer, EP-based
80-T-35-5400 Application of Fine Powder Layers
80-T-35-9030 Application of Fillers
80-T-35-9120 Coating with Paints, General
80-T-35-9124 Repair of Paint Coatings on Metallic and Non-metallic Surfaces
I 80-T-35-9135 In-mould Coating of Interior Furnishing Components
TN 10003M Surface protection requirements for Airbus
AIMS 04-08-001 Airbus Industrie Material Specification: Pore filler for furnishing and equipment
components
ABD 0031 Airbus Directives: Fireworthiness Requirements - Pressurized Section of Fuselage
ABS 5650 Paint system for furnishing and equipment components
FAR 25.853 Amdt.66 Federal Aviation Regulation
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3 PREREQUISITES

3.1 Personnel
Skilled workers assigned to apply this special coating must be familiar with the spraying process of this
procedure.

3.2 Manufacturing documents

The manufacturing documents must contain the following reference to this process specification:

"Paint coating in interior furnishing per80-T-35-9123”

Note: The shade and surface finish shall be obtained by means of a master sample.

4 MATERIALS AND EQUIPMENT

4.1 Equipment
See 80-T-35-9120.

4.2 Components
4.2.1 Thermoplastics
The components must be free from release agents and other contaminants.

4.2.2 Metallic surfaces

As specified in the design documents.

4.2.3 GFRP surfaces

The components must be free from contaminants.

4.3 Paint materials

Only the products specified in the data sheets shall be used for coating.

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5 PROCESS
The sequence given in 8 is determining for the process.

Caution: If in-mould coating per 80-T-35-9135 was applied to the component to be decorated,
application of pore filler per AIMS 04-08-001 is not necessary.

5.1 Pretreatment
5.1.1 Non-metallic surfaces (composite surfaces)
5.1.1.1 Application of coating powder (per 80-T-35-5400)
The layer produced by application of the coating powder (60 urn to 150 urn) must be removed by
grinding after hardening until a layer thickness of 0 urn < s < 30 urn remains. (Grind to top layer at
honeycomb webs).

5.1.1.2 Application of filler (per 80-T-35-9030)

Coarse filler (Data Sheet 4 of 80-T-35-9030) is only partially suitable for voids in the edge and bead
area.

Fine filler per Data Sheet 7 of 80-T-35-9030 shall only be applied after application of the first layer of
fire protection filler (see process flow chart 8.1).

Fine filler may only be applied directly to the component if the component-specific fire properties have
already been demonstrated in advance.

5.1.2 Thermoplastics, [e.g. injection mouldings and extrusions]

Cleaning with cleaning agent as per 80-T-35-0014.

If necessary, fine filler per Data Sheet 7 of 80-T-35-9030 can be applied to butt edges and transitions.

5.1.3 Metallic surfaces

As specified in the design documents (e.g. for Airbus TN 10003M, lines 304/305/307/308).

If necessary, fine filler per Data Sheet 7 of 80-T-35-9030 can be applied to butt edges and transitions.

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5.2 Paint application

The paint system shall be applied by spraying with a gun per 80-T-35-9120 so as to obtain a complete
coating with a uniform structure in accordance with the master sample. The prerequisite for this is that
only complete batches are sprayed.

I Note: Solvent-containing fire protection fillers must not be combined with water-based top
coats and vice versa.

When components are coated, traveler specimens of the batch shall be produced as follows:

Location - In case of components with cutouts (e.g. cassette frames), position the
specimen in the center of the cutout area.

In case of other parts, specimens should be positioned at locations where the

maximum coating thickness is applied. If this is not possible, position two
specimens in different areas so that the layer thickness on the specimens
represents the average thickness on the component.

Number - Two specimens are coated with each production batch.

5.2.1 Coating with solvent-containing fire protection filler

If the design documents specify the application of a fire protection filler (e.g. per AIMS 04-08-001), the
filler defined in Data Sheet 4 or 10 shall be applied with the processing parameters indicated.

5.2.2 Coating with solvent-containing top coat (non-structured)

The component is to be pre-sprayed with structural varnish (per Data Sheet 3 or 11) so as to obtain a
uniform coating. The fabric structure of composite components must not shine through. For spraying
parameters, refer to Table 1.

Make certain that the varnish coating is complete.

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5.2.3 Coating with solvent-containing top coat (structured)

| Ventilation time at RT is followed by application of a top coat (per Data Sheet 3 or 11). The applied top
coat (structured) must correspond to the master sample. For spraying parameters (standard values),
refer to Table 1.

Note: • Due to the fire properties, the total top coat thickness shall not exceed 50 urn to 90
µm .

BASE MATERIAL: Metals and thermoplastics (smooth)

BASE MATERIAL: Structural thermoplastics

BASE MATERIAL: Fiber composites (FRC)

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5.2.4 Coating with aqueous fire protection filler

When preparing the mixture, make sure that base and hardener are mixed with a high-speed mixer
before adding water. Subsequently, water shall be added manually or by using a mixer until a
homogenous mixture is obtained.
If the design documents specify the application of a fire protection filler (e.g. per AIMS 04-08-001), the
filler defined in Data Sheet 9 or 12 shall be applied with the processing parameters indicated.

5.2.5 Coating with aqueous top coat (non-structured)

When preparing the mixture, make sure that base and hardener are mixed with a high-speed mixer
before adding water. Subsequently, water shall be added manually or by using a mixer until a
homogenous mixture is obtained.
The component shall be pre-sprayed with top coat (per Data Sheet 8 or 13) to obtain a uniform
coating. The fabric structure of composite components must not shine through. For spraying
parameters, refer to Table 1.

Make certain that the varnish coating is complete.

5.2.6 Coating with aqueous top coat (structured)

Ventilation time at RT is followed by application of a top coat per Data Sheet 8 or 13. The applied top
coat (structured) must correspond to the master sample. For spraying parameters (standard values),
refer to Table 1.

Caution: • Due to the fire properties, the total top coat thickness shall not exceed 50 µm
to 90 µm.

5.2.7 Thin effect varnishes

In cases where thin effect varnish coatings are to be applied (see data sheet of this specification), the
application procedure must be described in a component-specific process specification.

5.2.8 Spraying parameters

For all coatings specified in 5, the spraying parameters indicated in the following Table 1 shall apply.

Table 1: Spraying parameters

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5.3 Subsequent treatment

5.3.1 Removal of damaged coatings
The coating must be in compliance with the maximum allowable layer thicknesses. If this is not
possible, the entire coating down to the base material must be removed mechanically, see also 80-T-
35-9124.

For the removal of damaged coatings, solvent-containing and aqueous top coats may be combined
with each other.

6 QUALITY ASSURANCE
Unless otherwise specified in process- or component-specific design, manufacturing or QA
documents, the competent organization unit shall ensure that the following measures are taken.

6.1 Inspection of the parts

With the coating application completed, the components shall be checked for

• color shade per ABS 5650

• gloss/spots
• degree of gloss and uniform structure in accordance with master sample
• waviness/telegraphing
• unevenness
• other optical flaws
• pores in the undercoat
• filler residues on the component (burr)

The color structure shall be assessed by comparison with the master sample.

6.2 Coating thickness measurement

6.2.1 Eddy current method
Layer thickness measurement of coating (non-structured) on traveler specimen or on component
(per QVA-Z10-50-03).

6.2.2 Magnetic induction measurement

Coating thickness measurement on ferro-magnetic base materials is carried out per QVA-Z10-50-02.
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6.2.3 Coating thickness measurement on transverse section

On samples of the batch traveler specimen

Dimension : 150 mm x 75 mm x 0,8 mm

Material : 3.1364 T3

6.3 Test of system

Test the system per 80-T-35-9120 prior to start of work.

7 SAFETY AND HEALTH

Apply the local safety regulations.

It is the responsibility of the user of this standard to establish appropriate safety and health practices
and determine the applicability of regulatory limitations prior to use.

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8 PROCESS FLOW CHART

8.1 Composite components

* Coating thickness: depending on the type of coating powder and set up of composite component, the FST values
must be proven in agreement with the production and design offices.

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8.2 Thermoplastic, smooth

(reinforced and non-reinforced)

* For butt edges and transitions

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8.3 Thermoplaste, strukturiert

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8.4 Metallic components

* If the primer application is older than 72 hours before application of the top coat, the surface
must be activated (see 80-T-35-9120).

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