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ASM Block 8
Painting and paint removal
| Question | Answer |
|---|---|
| Cleaning operations during paint surface prep will be IAW what TO ? | 1-1-8 |
| Which TO authorizes chemical removal of paint coatings on an advanced composite? | Chemical removal of of paint from composites is not authorized |
| What preferred grits of sandpaper are used for topcoat removal and primer removal? | Topcoat 120, primer 240 |
| What abrasive is preferred when attached to a random orbital sander? | Sandpaper, hook and loop, abrasive mat |
| What are the steps when operating the DA sander? | Tool must be triggered prior to touching the metal surface and stopped once the tools off the surface |
| What safety procedure must be adhered to when choosing abrasives for pneumatic drills? | Abrasive must have higher RPM than tool |
| What is the recommended method of coating removal from advanced composites? | Plastic media blasting |
| What grade of aluminum oxide/nylon abrasive mat would you use to remove topcoat mechanically from an advanced composite? | medium |
| What is the preferred method to remove powder/dust from paint removed surfaces? | HEPA Vacuum Cleaning |
| What are six recommended PPE items to be worn when removing coating systems. | Air purifying respirator with HEPA cartridges Disposable nitrile gloves Ear plugs Safety goggles Tyvek or cotton coveralls Safety toe boots |
| What TO outlines procedures for using PMB? | 1-1-8 in general. 1-1-690 for composites |
| What are the three major components of the PMB cabinet/booth? | Dust collector blasts/reclaimer assembly metal cabinet |
| How far should the nozzle be held from the surface when using Type I media in the booth? | 12 to 24 inches |
| What nozzle pressure is used when blasting with Type V media in the cabinet? | 25 to 40 PSI |
| Cleaning operations should be IAW what TO? | 1-1-691 |
| Once the aircraft is centered in the blasting booth, what should be done next? | Aircraft must be properly grounded |
| The dust created from blasting will be treated as? | Hazardous waste |
| How often should the filters on the blasting cabinet be shook? | 4 hrs |
| What mixes blast media with compressed air? | Adjustable metering valve |
| What PPE is required when operating the PMB cabinet? | Safety glasses hearing protection dust/particular type respirator mask steel toed shoes coveralls |
| What PPE is required when operating the PMB booth? | Tyvek or cotton coveralls; leather shoulder cover Leather and disposable nitrile gloves steel toe boots earplugs blasting helmet with supplied air |
| How do you determine if the surface of a metal is clean? | Water break test |
| What happens if oil is present while performing a water break test on metal? | Water gathers into discrete separate droplets with in 25 seconds |
| How long should the alodine dwell on the surface when you chemically passivate aluminum? | 1-5 minutes |
| If the surface turns green when applying the alodine, what should you do next? | Clean surface again |
| What is the recommended PE for applying alodine? | Air purifying respirator with HEPA filter Butyl rubber gloves earplugs safety goggles or face shield rain suit and safety Toe boots |
| How do you control the amount of fluid sprayed? | fluid needle adjustment screw |
| How much fluid does the standard fluid cup hold? | one quart |
| What are the parts of the nozzle assembly? | air cap and fluid tip |
| What low pressure air PSI is used to atomize the coating material at the spray head? | between 1 & 10 |
| When adjusting the gun to obtain the proper spray pattern, What must you do to adjust the flow of at the gun to obtain desired spraying characteristics? | Air and fluid |
| Why should barrels of hazardous waste be opened slowly? | to release pressure |
| What safety equipment should be worn when conducting cleaning operations? | face shield/ goggles, respirator, rubber gloves, acid-resistant apron |
| What are two methods of cleaning spray guns? | manual cleaning and spray gun cleaning unit |
| Why must you operate the gun-cleaning unit with screen and canister filters? | failure to do so will result in clogged nozzles and reduced pump efficiency |
| What seven defects can occur from inadequate surface treatment? | Pinhole cavities peeling, blistering, fisheyes, pitting or cupping, crazing, mud cracking, checking, and sandpaper finish |
| Pin holes are also known as? | Solvent pop |
| What type of painting defect is caused when silicone products are left on the surface? | Fish eyes |
| What TO would you use to look up an authorized cleaner? | Table 3-2 in 1-1-8 |
| What are the six proper spray techniques? | Do not arc or wave the gun, stay 90° to the surface, maintain 6 to 10 inches from the surface, use proper triggering, maintain the same speed with your strokes, always overlap 50% |
| What temps should the coating be before applying it? | Room temperature |
| What TO do you check for mixing instructions? | 1-1-8/manufacturers instructions |
| What causes paint to streak? | Not overlapping and not maintaining 90° to the surface |
| How often should you clean the spray gun? | Every time you paint |
| A buildup of paint in the center of the spray pattern is what defect? | Heavy center |
| What spray pattern defect occurs when the atomizing pressuring is too big high? | Split spray |
| If the pattern is heavy right or left, check to see if a wing port is clogged by turning the air cap to how many degrees? | 180 |
| What conditions may cause application method to be unworkable? | Unusual climatic or atmospheric conditions |
| What defect takes on a prune skin effect? | Wrinkling |
| Blushing is commonly referred to as? | Clouding or whitening |
| What is the first item you check if paint will not come from the spray gun? | Are you out of paint |
| If the needle and the fluid tip are not the exact same size, what problem will you have? | Paint leaking from the gun |
| Excessive fogging is caused by two factors. What are they? | Gun pressure may be too high or the coating may be thinned much |
| After ensuring all parts are tightened on the outside of the spray gun, you removed the air cap and tighten the what to stop gun from sputtering? | Fluid tip |
| What are used for volume painting? | Pressure fed tanks/pots |
| The pressure pot tanks vary in size, from how many gallons? | 2 quarts to 120 gallons |
| What must be increased or deceased to change the rate of flow, or the amount of material sprayed? | Air pressure |
| Name the two ways to power a paint agitator. | Pneumatic or electrically |
| Define spray booth. | Fireproof compartment room or enclosure built to confine and exhaust fumes and overspray from the painter and the coding system |
| If the speed of air in the spray booth is too low, what must be increased? | Air velocity |
| What removes overspray from the spray booth area by pulling air through baffles/filters? | Exhaust fan |
| What does an air replacement unit do? | Automatically provides make up air (filtered and heated) to eliminate the problems of air deficiency and airborne contaminants |
| Define manometer | A draft gauge that indicates when paint arrester filters or intake filters are filled to capacity, restricting airflow |
| A well maintained spray booth will provide positive results on a continuous basis with simple day-to-day ? and ? | Cleaning and maintenance |
| What is the minimum safety PPE requirement when changin used filters in a spray booth? | Eye and hand protection |
| The three primary goals of the Air Force's general policy on aircraft paint are? | Appearance, corrosion protection and prevention, and serviceability |
| How should cleaning the surface be accomplished to prevent smearing or transferring contaminants back to the surface? | Wipe from center out, turning cloth continuously |
| What should you use to scuff sand a painted surface? | Medium grade or 120 grit silicon carbide sandpaper |
| Define "tack rag" | acft wipe dampened with solvent |
| TO 1-1-8 requires between how many hours to topcoat after priming? | 5-8 hours |
| If primer has sat on the surface for more than 8 hours but less than 24, how is it reactivated? | With an approved solvent by wiping surface |
| What do you use to scuff sand primer if it has sat for over 24 hours? | 320-400 grit sandpaper, grade B abrasive mat, hook and loop or roloc discs |
| After selecting topcoat, how long do you agitate the resin on the mechanical paint shaker? | 3-5 mins |
| How long should primer "dwell" before a viscosity check? | 30 mins |
| Name two viscometers used to check viscosity IAW TO 1-1-8. | zahn cup and ford cup |
| How many seconds is the viscosity in a #2 Zahn cup when measuring aircraft topcoat? | 17-23 seconds |
| Define tack free time. | time that the surface film will not finger print, or can be moved |
| Prior to topcoating, what should you do one more time to remove any dust or debris off the surface? | tack rag |
| At 75°F, when can a part be handled, taped, or masked? | 6 hours |
| At 75°F, how long should the paint cure before a wet tape test is performed? | 48 hours |
| Before aircraft's first flight after full paint, the coating system should cure at 75° F for how many hours? | 72 hours |
| For safety guidance, what publication is used for respiratory protection? | AFI 48-137 |
| What PPE is required for coating application? | Air purifying with OV / N95 cartridges, disposable nitrile gloves, ear pro, safety goggles, tyvek /cotton coveralls, safety toed boots |
| TO 1-1-8 outlines your local__________? | Bioenvironmental engineers more/less restrictive controls |
| When removing paint from composites how far should you remove the paint when using a dry abrasive? | only down to primer |
| What are the booth parameters for Type V Acrylic plastic media? | Nozzle pressure 25-40, stand-off 12-24", and impingement angle 30-90° |
| What are the cabinet parameters for Type V Acrylic plastic media? | Nozzle pressure 25-40, stand-off 3-5", and impingement angle 30-90° |
| What are the major components of a blasting cabinet? | cabinet or glove box, blast/reclaimer assembly, Dust collector |
| What are the major components of a blasting booth? | Blasting unit (booth), blast/reclaimer assembly, Dust collector |
| On the Theory of Operation of blasting, what should be in place prior to blasting? | clean dry compressed air mixed with clean dry media |
| What TO should you use to clean prior to blasting? | TO 1-1-691 |
| What does cleaning the surface before blasting help prevent? | prevents the media from clumping and becoming contaminated and possible damage to the blasting unit. |
| What important step is required before blasting on equipment? | Control leaks |
| What should you do to prevent a surface from direct impingement (blasting)? | Mask the area not wanted to be blasted |
| What areas are required to be masked prior to blasting? | ID plates, Crevices, Gaps/Seams |
| Once an aircraft or part has been positioned for blasting in the booth, what is the next step? | ground the aircraft or part |
| When maintaining the dust collector in the cabinet, how often should you clean the filter? | Shake filters every 4 hours of use |
| When maintaining the dust collector in the booth, how full should the barrel be? | no more than 90% |
| What type of things need to be checked prior to and after blasting? | Hoses and valves, vibrating screen, dust collector, media level, Breathing air (booth only), drain moisture separator, magnetic separator. respirator/helmet adjustments |
| What type of adjustments will need to be made before blasting? | air pressure according to media type, metering valve, nozzle pressure, respirator/ helmet |
| At what point will the blasting blasting system be shut off because of breathing air? | When breathing air is 20 parts per million |
| When cleaning up after blasting what is the preferred method of picking up remaining media? | vacuuming |
| When cleaning up after blasting what is the alternate method of picking up remaining media? | remove media with low pressure (under 30 PSI) or water wash |
| For safety measures in PMB operations what is done to prevent build up of explosive dust mixtures? | adequate air flow and ventilation |
| What PPE is required for cabinet blasting? | safety glasses, hearing protection, dust/particulate type respirator/mask, steel toed shoes, coveralls |
| What PPE is required for booth blasting? | Tyvek or cotton coveralls;leather shoulder cover, leather and disposable nitrile gloves, steel toed shoes, ear plugs, blasting helmet with supplied air. |
| Where should your blast direction be in the booth? | only at object being blasted |
| How far should sources of ignition be from the booth? | 50ft |
| For corrosion treatment what TO should you use to clean the surface? | TO 1-1-691 |
| For corrosion treatment what TO should you use to spot clean the surface using a solvent wipe? | TO 1-1-8 |
| What test should you use to verify a clean surface? | water break test |
| How would you know if the surface is dirty using the water break test? | water gathers into separate droplets within 25 seconds, water forms continuous film and flashes out suddenly over large area |
| How do you know if the surface is clean using a water break test? | water droplets merge into a continuous film without sudden flash out. |
| What is the next step once the surface has passed the water break test? | passivate |
| What is used to passivate the surface on aluminium and its alloys? | Chromate conversion coating (alodine) |
| What should you use to mix alodine? | clean stainless steel, plastic, or rubber container |
| How much should you alodine should be mixed? | only enough for the job |
| When should alodine be applied? | immediately after rinsing corrosion removal compound from surface |
| How can alodine be applied? | with a fiber bristle brush, sponge, cloth, spray or immersion |
| How long does passivation using alodine take? | 1-5 min |
| How do you know if the alodine is brand new? | takes only 1 min |
| When applying alodine to the surface, how would you know if the surface is dirty or corroded? | the surface turns green |
| How do you know if the passivation using alodine has been properly applied? | proper adhesion is indicated by a brassy yellow color |
| How long should the alodine coating air dry for? | 2 hours |
| Once passivation has been completed using alodine, when should the final paint system be applied? | within 48 hours |
| What do you have to do is the passivation has passed its maximum paint application time limit? | re-apply passivation |
| What should the passivation solution not come in contact with and what would result? | thinners, acetone, or other combustible materials as a fire could result |
| When applying alodine to the surface what PPE is required? | Air purifying with HEPA filter, butyl rubber gloves, ear plugs, safety goggles or face shield, rain suit, safety toed shoes. |
| What are the 3 classes of HVLP spray equipment? | suction feed, pressure feed, gravity feed |
| On the HVLP gun what pressure is used to assist in delivering paint to the spray nozzle? | low pressure air generally below 20 PSIG |
| What air pressure is used to atomize paint at the spray head? | 1-10 PSIG |
| What does low air pressure do to the coating material? | Atomizes coating material and increases transfer efficiency |
| What typically holds 1qt and is most convenient for painting in small areas? | Fluid cup |
| What are two ways the fluid supply in the fluid cup is fed to the HVLP gun? | Siphon/suction fed and Gravity fed |
| What are the three parts of the nozzle assembly on the HVLP gun? | Air cap, Fluid tip, and fluid needle |
| What does the air cap do on the HVLP gun? | Wing ports (horns) on the air cap push air out and the cap rotates 90° to desired direction of travel |
| What does the fluid tip do on the HVLP gun? | pushes coating material out and mixes with air to atomize fluid |
| What does the fluid needle do on the HVLP gun? | when the needle is moved back it releases the fluid |
| What is important about the fluid needle and air cap? | they should come as a matched set |
| What does the spray pattern adjustment screw do and where is it located on the HVLP gun? | adjusts the width of spray pattern and is located at the rear of the spray head assembly "top dial" |
| When adjusting the width of the spray pattern on the HVLP gun, what direction increases the width of the pattern and decreases the width of the pattern? | clockwise decreases width and counter clockwise increases width. |
| What does the fluid needle adjustment screw do and where is it located? | adjusts the flow of fluid and is located at the rear of the spray head assembly "lower dial" |
| When adjusting the width of the fluid flow on the HVLP gun, what direction increases the width of the flow and decreases the flow of the fluid? | clockwise decreases flow and counter clockwise increases flow. |
| What is the first step in inspecting your equipment before painting? | inspect the gun |
| What things should you inspect on the gun before painting? | defective hoses and couplings, loose connections, loose air cap, cleanliness, proper seating of the needle |
| What PPE is required when operating the HVLP gun? | Air-purifying with Organic Vapor (OV) cartridges, disposable nitrile gloves, ear plugs, safety goggles or face shield, tyvek or cotton coveralls, safety toed boots |
| When manually cleaning the HVLP suction fed gun what should you use to clean it? | thinner or solvent |
| What should never use when cleaning the HVLP gun? | metal objects |
| After cleaning the gun what is done to clean any remaining paint in the gun? | reassemble and spray clean thinner through it |
| What PSI is used for the spray gun cleaning unit? | 50 PSI |
| How long should you operate the spray gun cleaning unit? | 1-5 min |
| What are the steps, when servicing the spray gun cleaning unit? | Drain fluid, dispose fluid IAW local, state, and federal guidelines, clean tank and replace fluid, replace filter and clean canister IAW manufacturer's specs. |
| Where should you dispose of excess cleaning or paint materials? | Accumulation points |
| When disposing of excess cleaning and paint materials what should you do first before pouring excess into containers? | ensure the container is grounded. |
| What are some paint defects? | pinhole cavities, peeling, blistering, fisheyes, pitting and cupping, crazing, mud cracking and checking, sand paper finish. |
| What causes pinholes? | incompatible thinner, insufficient primer dry time, oils and solvents trapped, dirty surface |
| What causes peeling? | grease, oil, or water on the surface |
| What causes blistering? | moisture in the air lines |
| What causes fisheyes? | silicon products or other contaminants left on the surface |
| What causes pitting and cupping? | corrosion left on the surface, poor surface prep, trapped solvents from improper proportions |
| What causes crazing, mud cracking, and checking? | painting over hard glossy coat, too much catalyst, too much heat when forced drying, insufficient drying times between coats |
| What causes a sandpaper finish? | insufficient scuffing, dry spray, overspray or painting too far from surface, excessive dirt in spray areas, improperly cleaned paint lines (pressure pot) |
| What are techniques of applying paint? | do not arc or wave, 90° from surface, 6-10 inches from surface, fully depress trigger, maintain speed, 50% overlap |
| What are causes of runs or sags? | not releasing the trigger, stroking too close, gun not at 90° angle, dirty air cap or fluid tip, coating material cold, coating applied to heavily |
| What are causes of streaks? | not overlapping correctly, not maintaining 90° to surface, air pressure too high |
| What are causes of orange peel? | using wrong air cap or fluid nozzle, stroking too far from surface, overspray, coating too thick, coating material too cold, insufficient air pressure |
| What are two adjustments that always need adjusting before painting on the HVLP gun? | spray pattern adjustment and fluid adjustment |
| What are some spray pattern defects? | heavy center, split spray, heavy top or bottom, wrinkling, blushing, faulty finishing material |
| What causes heavy center? | pattern too small, low atomizing pressure, fluid pressure too high, air nozzle too large for fluid used. |
| What causes split spray? | atomizing pressure high, fan patter too wide, |
| What causes heavy top or bottom? | air cap clogged |
| What causes wrinkling? | combination of factors: coatings applied too fast/too thick, possibly caused by humidity and rapidly rising TEMPS when painting out doors |
| What causes blushing? | result of moisture condensation from the atmosphere within / on drying organic film |
| What causes faulty finishing material? | improper storage, expired material |
| When troubleshooting a spray gun what is the first thing you check if paint doesn't spray and what are the other items you check? | Check if there is paint first then check if the tip is blocked and if the needle is operating. |
| When troubleshooting a spray gun, what do you check if the paint is not transferring from the cup? | dirty fluid tip and air cap, clogged air vent on the cup cover, incorrect air cap, leaking connector on fluid tube nozzle |
| What causes excessive fog? | pressure too high, coating too thin, spraying too far beyond surface, wrong air cap or fluid tip, stroking too far from the surface |
| What causes paint from leaks from the gun? | needle and the fluid tip different or damaged, packing is dried or nut for the needle is too tight |
| What causes the gun to sputter? | fluid tip loose. |
| What spray system has paint supply attached to the gun? | attached system |
| What spray system has paint supply separate from the gun? | separate system (pressure pot) |
| What system is used for large volume painting? | pressure pots |
| What is the capacity of pressure pots? | 2qts to 120 gallons |
| What on the pressure pot adjusts the material flow rate? | pressure/material regulator |
| What is the purpose for pressure pots? | large volume painting, uniform pressure, constant flow rate |
| When does the agitator do on the pressure pot? | keeps paint suspended |
| What is the purpose of a spray booth? | a fireproof compartment, room or enclosure built to confine and remove fumes and overspray during the paint spraying process |
| What does the partially enclosed spray booth called and what does it do? | cross flow and moves air towards filters across the booth |
| What direction does the air move in a down draft spray booth? | airflow in a downward direction |
| What air velocity do most spray booths operate on? | 100 FPM |
| What type of spray booth is the most common type in the Air Force? | dry filter/baffle |
| What are the major components of the spray booth? | exhaust fan, air replacement unit, manometer |
| What does a manometer do? | a draft gauge that monitors air velocity and indicates when paint arrestor filters or intake filters are filled to capacity |
| When cleaning and maintaining a spray booth, what will a well maintained booth provide? | A well maintained spray booth will provide positive results on continuous basis with simple day to day cleaning and maintenance |
| What is the minimum PPE used when handling materials and cleaning the booth? | eye and hand (nitrile gloves) protection is required |
| What TO should you use to clean the surface before painting? | 1-1-691 |
| What are the steps of surface prep for an unpainted surface? | clean, passivate, tack rag |
| What are the steps of surface prep for a painted surface? | Scuff sand, re-clean, passivate if needed, tack rag |
| What is required on a primer surface after it has dried for 8 hours? | wipe down with approved solvent to reactivate primer, tack rag |
| What is required on a primer surface after it has dried for 24 hours? | Scuff sand, wipe down with approved solvent to reactivate primer and tack rag |
| What is the preferred method to agitate the resin and stir the catalyst for the primer? | mechanical shaker for 3-5 min |
| How much primer should you mix? | only what can be used in 4 hours |
| What is the dwell time for primer? | 30 min |
| Why should you allow dwell time for primer? | allows resin and catalyst to combine |
| What do you use to check viscosity? | #4 ford cup or #2 ZAHN CUP |
| How long should the paint come out of the #2 Zahn cup to have the correct amount of viscosity? | 17-23 seconds |
| What TO should you use to select the proper top coating? | -23 TO |
| Once the surface is passivated when should you apply the primer? | within 48 hours |
| For a single coat or primer, what is the dry film thickness (DFT)? | .6.-.9 mils DFT |
| For drying times of primer, what is meant by tack free? | surface of the film will not finger print |
| When applying the top coat how should you apply the coating? | Apply one wet cross coat at 1.7 to 2.3 dry film thickness (DFT) |
| How long should you wait before handling, taping or masking the top coat? | 6 hours |
| How long should you wait for paint to cure before moving painted surfaces from a controlled environment? | 6 hours |
| How long should you wait for paint to cure before applying decals? | 8 hours |
| How long should you wait for paint to cure before engine run up? | 30 hours |
| How long should you wait for paint to cure before a wet tape test? | 48 hours |
| How long should you wait for paint to cure before first flight? | 72 hours @ above 75°F |
| When performing mx painting how long should paint cure on complete leading edges (all), complete control surface (all), major skin panels 9 sqft and over, and engine intakes? | 72 hours |
| When performing mx painting how long should paint cure on skin panels 9 sqft or less, fasteners, rivet heads, screw heads, and minor chipped and scratched areas less than 36 sq inches? | 30 hours |
| When cleaning the HVLP gun what should you not do and why? | submerge the gun in thinner because it will dry out needle packing and will cause gun to leak |
| What TO is used to apply and remove coating? | TO 1-1-8 |
| What TO is used to clean a surface? | TO 1-1-691 |
Created by:
comso9o
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