TO 1-1-700 - Robins Air Force Base

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TO 1-1-700 doors, and other corrosion-prone areas should also be carefully examined. When corrosion occurs beneath a paint system, the surface of the paint often appears blistered or distorted. Further inspect areas showing corrosion stains, coating blistering, or other coating irregularities to determine the extent of corrosion. If blisters or other coating irregularities are present, attempt to dislodge the paint by scraping with a sharp plastic tool. If the paint is not easily dislodged and corrosion is not suspected, the irregularity is probably confined to the paint film itself, and no further action should be taken. Where paint is removed, inspect the area and determine the degree of corrosion. Corrosion removal and surface preparation should be carried out as described in Chapter 11 of this manual. Repaint the surfaces with one of the coating systems listed in Chapter 7 of this manual per procedures outlined in TO 1-1-8. 9.2.1.2 Evidence of Corrosion. Aluminum corrosion products are white, gray, or black and may appear as a paste when wet or as either a hard, adherent film or easily crumbled deposits when dry. Steel corrosion products (rust) are red, brown, or black deposits either in the form of a powder or when severe as flakes that spall off easily. Stainless steels do not produce significant amounts of visible corrosion products on their surfaces, but they exhibit small amounts of rust and/or discolored areas and sometimes cracking. Copper corrosion products (patina) are blue or blue-green deposits that adhere tightly to the surface. Magnesium corrosion products are white and powdery and form in large amounts with significant losses of the base metal. When corrosion occurs beneath a paint system, the surface of the paint appears blistered, bubbled, or distorted. 9.2.2 Depth Gauge, Mechanical Type. Depth gages are tools used to measure the depth of corrosion pits and areas reworked for pitting, exfoliation, and other types of corrosion to determine the extent of corrosion damage and the amount of metal removed during rework. If there is a special requirement to use depth gauges for shelters, radomes, or C-E-M equipment, see Figure 4-1 in Chapter 4 of TO 1-1-691. Figure 9-1. Visual Evidence of Corrosion 9.2.3 Optical Depth Micrometers. See Chapter 4 of TO 1- 1-691 if it is necessary to use a micrometer. The apparent simplicity of the fluorescent penetrant inspection is deceptive. Very slight variations in the inspection process can invalidate the inspection by failing to indicate serious flaws. It is essential that personnel performing penetrant inspection be trained and experienced in the penetrant process. NOTE The following inspection methods shall be accomplished only by qualified and certified NDI technicians. Refer to TO 33B-1-1 and the system specific NDI manual for more detailed inspection procedures. 9.2.4 Fluorescent Penetrate Inspection. Fluorescent penetrate inspections require components to be cleaned and then treated with a fluorescent penetrating liquid which is capable of entering surface cracks and/or flaws. After removing the penetrant from the surface, a developer (powder or liquid suspension of powder) is applied to absorb penetrant trapped in the cracks or flaws. Under ultraviolet light, the absorbed penetrant is visible directly above the cracks or flaws from which it was drawn out. The penetrant inspection method is used to detect cracking (fatigue and/or other types), intergranular corrosion, and residual corrosion following corrosion removal by grinding or sanding. Intergranular corrosion attack at metallic grain boundaries and the network of very fine cracks it forms are visible in the early stages only with 10X or greater magnification, and developer is not used when evaluating a penetrant indication with a magnifying glass. In addition, if penetrant inspection is used to monitor a surface for adequacy of corrosion removal by grinding or sanding, caution must be exercised because mechanical removal methods can cause smearing which may obscure indications of remaining corrosion. When monitoring corrosion grind-out areas with penetrant, a developer is not used following removal of excess surface penetrant because the area must also be examined with a 10X magnifying glass after a minimum five minute dwell time. When corrosion is no longer detected in a corrosion grind-out area, the inspection process shall be repeated using non-aqueous developer to determine if any cracks are present. See TO 33B-1-1 for further information on fluorescent penetrant inspection 9.2.4.1 Limitations of Penetrate Inspection. Penetrates inspection is applicable to all solid, non-porous materials provided the flaw being inspected for is open to the surface of the part. To detect subsurface flaws, another inspection method must be used. 9-2
TO 1-1-700 9.2.4.1.1 Restricted Flaw Openings. The penetrate inspection process depends upon the ability of the penetrant to enter and exit the flaw opening. Any factor that interferes with the entry or exit reduces its effectiveness. Organic coatings, such as paint, oil, grease, and resin, are examples of this interference. Any coating that covers or bridges the flaw opening prevents penetrant entry, and even if it does not cover the opening, material at the edge of the opening affects the mechanism of penetrant entry and exit and greatly reduces the reliability of the inspection. Coatings at the edge of the flaw may also retain penetrant causing background fluorescence. An inspection method other than penetrant must be used if the organic coating cannot be stripped or removed from the surface in the area to be inspected. 9.2.4.1.2 Smeared Metal. Mechanical operations, such as abrasive blasting, buffing, wire brushing, grinding, or sanding, can smear or peen the surface of metals. This mechanical working closes or reduces the surface opening of any existing discontinuities or flaws. Mechanical working (smearing or peening) also occurs during service when parts contact or rub against each other. Penetrant inspection will not reliably indicate discontinuities or flaws when it is performed after a mechanical operation or service that smears or peens the surface. Chemical etching per procedures in TO 33B-1-1 and/or system specific equipment manual is recommended prior to penetrant operations to improve test sensitivity when smeared metal is present. 9.2.4.1.3 Porous Surfaces. Penetrate inspection is impractical on porous materials with interconnected subsurface porosity. The penetrant rapidly enters the pores and migrates through the network. This results in an overall fluorescence or color that masks any potential discontinuity or flaw indications. In addition, removal of the penetrant after the inspection may be impossible. If it is necessary to use an eddy current or an ultrasonic inspection for an unusual requirement, see TO 1- 1-691, Chapter 4. 9.2.5 Coin Tap-Test (Non-Destructive Inspection Method). The coin tap-test method is a non-destructive inspection method used to determine delaminations of the inside surfaces of tactical shelter panels (foam-beam and honeycomb) along and between the structural members. A tap hammer (see Chapter 2 of TO 35E4-1-162) shall be used in the inspection. The inspector shall be an experienced tapper. The tapping procedure consists of tapping lightly over the surface of the shelter wall. A hollow sound indicates a proper bond and a dull-thudding sound indicates areas of moisture or delamination. All shelters shall be non-destructively inspected on the inside of the shelter panels for corrosion. See TO 35E4- 1-162 for field level and depot instructions of the coin-tap inspection method. 9.3 EVALUATION OF CORROSION DAMAGE. Visually determine if the corrosion is present in an area which has previously been reworked. If the corrosion damage is in a previously reworked area, measure the damage to include the material which has previously been removed. A straight edge and a 10X magnifying glass may be used to assist in determining if an area has previously been reworked. Place the straight edge across the area being examined at various angles and check for irregularities, low spots, or depressions (see Figure 4-5 in Chapter 4 of TO 1-1-691). If any irregularities, low spots, or depressions are found, and a visual determination cannot verify previous rework, closely examine the suspected area and the surrounding area using the 10X magnifying glass. After determining that the area has been previously reworked, evaluate the depth of the previous rework (grind-out) to determine if further metal removal will exceed grind-out limits, affect structure integrity, and require replacement of the structure. Depth measurements can also be made using the depth gages as described in Chapter 4 of TO 1-1-691. 9.4 DEGREES OF CORROSION. Corrosion must be evaluated after the initial inspection and cleaning to determine the nature and extent of repair or rework needed. It is difficult to draw a distinct and specific dividing line among the degrees of corrosion, so reliable evaluation requires sound maintenance judgment. Use the following categories in reporting degrees of corrosion: 9.4.1 Light Corrosion. This degree of corrosion is indicated by the protective coating being scrapped, gouged, or chipped to bare metal or showing the tracks of filiform corrosion in the film and the bare metal showing is characterized by discoloration of surface corrosion and/or pitting to a depth of approximately one mil (0.001 inch) maximum. This type of damage can normally be removed by light hand sanding. 9.4.2 Moderate Corrosion. This degree of corrosion looks somewhat like light corrosion except some blisters or evidence of scaling and flaking of the coating or paint system is present, and the pitting depths may be as deep as 10 mils (0.010 inch). This type of damage is normally removed by extensive hand sanding or light mechanical sanding. 9.4.3 Severe Corrosion. The general appearance of this degree of corrosion is similar to moderate corrosion in the appearance of the coating system but with severe intergranular corrosion cracks and blistering exfoliation with scaling or flaking of the metal surface. The pitting depths are deeper than 10 mils (0.010 inch). This damage must be removed by extensive mechanical sanding or grinding and may require a patch type repair or component replacement. 9-3/(9-4 blank)
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TO 1-1-700 TECHNICAL MANUAL CORROSI
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TO 1-1-700 TABLE OF CONTENTS Chapte
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TO 1-1-700 TABLE OF CONTENTS - CONT
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TO 1-1-700 LIST OF ILLUSTRATIONS -
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TO 1-1-700 FOREWORD 1. PURPOSE. The
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TO 1-1-700 List of Related Publicat
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TO 1-1-700 SAFETY SUMMARY 1. GENERA
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TO 1-1-700 AMS-G-6032, GREASE, PLUG
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TO 1-1-700 MIL-DTL-64159, COATING,
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TO 1-1-700 MIL-PRF-27617, GREASE, A
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TO 1-1-700 O-L-164, DRESSING, LEATH
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TO 1-1-700 MIL-T-81772, THINNER, PO
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TO 1-1-700 tronics equipment and th
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TO 1-1-700 cleaning situation, syst
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TO 1-1-700 c. Riveted joints shall
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TO 1-1-700 c. Remove and replace an
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TO 1-1-700 MIL-L-87177, LUBRICANT,
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TO 1-1-700 Figure 3-1. Simplified C
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TO 1-1-700 resistant, and also at t
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TO 1-1-700 is first noticeable as a
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TO 1-1-700 3.7.8 Oxygen Concentrati
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TO 1-1-700 Figure 3-14. Concentrati
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TO 1-1-700 Figure 3-17. Galvanic Se
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TO 1-1-700 Figure 3-20. Aluminum Su
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TO 1-1-700 3.8.7 CRES/Stainless Ste
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TO 1-1-700 3.9.10 Climate. Warm, mo
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TO 1-1-700 3.11 PREVENTATIVE MAINTE
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TO 1-1-700 CHAPTER 4 COMPOSITE AND
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TO 1-1-700 4.4.4.4 Glass parts shal
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TO 1-1-700 CHAPTER 5 PACKAGING (STO
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TO 1-1-700 extent of damage dependi
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TO 1-1-700 5.15 PRECAUTIONS FOR VCI
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TO 1-1-700 c. Secure the desiccant
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TO 1-1-700 Figure 5-8. Shock Isolat
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TO 1-1-700 Figure 5-9. Examples of
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TO 1-1-700 5.24.10 Rigid or Flexibl
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TO 1-1-700 CHAPTER 6 MOISTURE AND F
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TO 1-1-700 c. 6.2.6 Felt. Examine f
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TO 1-1-700 a. After first directing
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TO 1-1-700 6.4.5.14 Terminals, scre
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TO 1-1-700 NOTE • Authorized clea
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TO 1-1-700 Table 7-1. Cleaning of S
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TO 1-1-700 7.3.1.2.3 Portable, 45 g
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TO 1-1-700 Table 7-2. Common Milita
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TO 1-1-700 inactivity, storage, or
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TO 1-1-700 7.5.6.5.1 Grade 1 - A th
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TO 1-1-700 Table 7-4. Corrosion Pre
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TO 1-1-700 Table 7-5. Preservation
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TO 1-1-700 either case, MIL-PRF-269
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TO 1-1-700 MIL-PRF-85285, COATING,
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TO 1-1-700 c. Cadmium plated surfac
Page 120 and 121: TO 1-1-700 a. Scuff sand and feathe
Page 122 and 123: TO 1-1-700 7.7.7.2 If surface is no
Page 124 and 125: TO 1-1-700 7.7.9.2 Where only parti
Page 126 and 127: TO 1-1-700 7.8.1 Type I Application
Page 128 and 129: TO 1-1-700 Extend (Loctite) 32150 J
Page 130 and 131: TO 1-1-700 There are three ways to
Page 132 and 133: TO 1-1-700 vulnerable surfaces clea
Page 134 and 135: TO 1-1-700 Table 8-2. Materials, Th
Page 136 and 137: TO 1-1-700 Table 8-4. Electronic Cl
Page 150 and 151: TO 1-1-700 Table 8-5. Accessories o
Page 152 and 153: TO 1-1-700 Table 8-5. Accessories o
Page 154 and 155: TO 1-1-700 f. Devices with permanen
Page 156 and 157: TO 1-1-700 Table 8-7. Cleaning and
Page 158 and 159: TO 1-1-700 MIL-PRF-87937, CLEANING
Page 160 and 161: TO 1-1-700 of contamination). Maint
Page 162 and 163: TO 1-1-700 8.8.2 Protective Coating
Page 164 and 165: TO 1-1-700 • Tube clamps. • Min
Page 166 and 167: TO 1-1-700 a. For bonding/grounding
Page 168 and 169: TO 1-1-700 vertently destroy the mo
Page 173 and 174: TO 1-1-700 CHAPTER 10 CORROSION PRO
Page 175 and 176: TO 1-1-700 MIL-PRF-81733, SEALING A
Page 177 and 178: TO 1-1-700 d. After corrosion is re
Page 179 and 180: TO 1-1-700 (3) Stainless/CRES steel
Page 181 and 182: TO 1-1-700 10.9 WATER ENTRAPMENT AR
Page 183 and 184: TO 1-1-700 f. Shield equipment from
Page 185 and 186: TO 1-1-700 b. Use e-inch rivnuts of
Page 187 and 188: TO 1-1-700 10.17.3 If the plating s
Page 189: TO 1-1-700 Figure 10-16. Dissipatio
Page 192 and 193: TO 1-1-700 (2) If allowable damage
Page 194 and 195: TO 1-1-700 Table 11-1. Recommended
Page 196 and 197: TO 1-1-700 11.6 3M CO. SCOTCH-BRITE
Page 198 and 199: TO 1-1-700 11.11.2 Control of Mecha
Page 200 and 201: TO 1-1-700 11.12.2 Mechanical Damag
Page 202 and 203: TO 1-1-700 MIL-DTL-81706 (ALODINE),
Page 204 and 205: TO 1-1-700 11.13.2.3 Application of
Page 206 and 207: TO 1-1-700 only when there is no da
Page 208 and 209: TO 1-1-700 NOTE SEMCO PASA-JELL 101
Page 210 and 211: TO 1-1-700 (CRES), lead, ceramic, g
Page 212 and 213: TO 1-1-700 11.13.7.2 Treatment of C
Page 214 and 215: TO 1-1-700 MIL-A-46106, ADHESIVE/SE
Page 216 and 217: TO 1-1-700 Table 12-1. Sealing Comp
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TO 1-1-700 Table 12-1. Sealing Comp
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TO 1-1-700 Table 12-1. Sealing Comp
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TO 1-1-700 used to apply sealants i
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TO 1-1-700 Figure 12-2. Sealant App
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TO 1-1-700 Figure 12-4. Rivet Appli
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TO 1-1-700 Figure 12-6. Sealant Inj
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TO 1-1-700 below and adhere very po
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TO 1-1-700 Table 12-2. Time Require
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TO 1-1-700 Table 12-2. Time Require
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TO 1-1-700 of 20 to 25 seconds in a
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TO 1-1-700 d. Remove all uncured se
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TO 1-1-700 MIL-PRF-81733, SEALING A
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TO 1-1-700 MIL-PRF-81733, SEALING A
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TO 1-1-700 Figure 12-12. Typical Me
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TO 1-1-700 may be used for low temp
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TO 1-1-700 Figure 12-14. Sealing Pr
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TO 1-1-700 - Robins Air Force Base

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