SAE AS 5502D-2016 Standard Requirements for Aerospace Sealants and Adhesion Promoters.pdf

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1、_ SAE Technical Standards Board Rules provide that: “This report is published by SAE to advance the state of technical and engineering sciences. The use of this report is entirely voluntary, and its applicability and suitability for any particular use, including any patent infringement arising there

2、from, is the sole responsibility of the user.” SAE reviews each technical report at least every five years at which time it may be revised, reaffirmed, stabilized, or cancelled. SAE invites your written comments and suggestions. Copyright 2016 SAE International All rights reserved. No part of this p

3、ublication may be reproduced, stored in a retrieval system or transmitted, in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of SAE. TO PLACE A DOCUMENT ORDER: Tel: 877-606-7323 (inside USA and Canada) Tel: +1 724-776-497

4、0 (outside USA) Fax: 724-776-0790 Email: CustomerServicesae.org SAE WEB ADDRESS: http:/www.sae.org SAE values your input. To provide feedback on this Technical Report, please visit http:/www.sae.org/technical/standards/AS5502D AEROSPACE STANDARD AS5502 REV. D Issued 2000-11 Revised 2016-04Supersedin

5、g AS5502C Standard Requirements for Aerospace Sealants and Adhesion Promoters RATIONALE Updated Source Inspection Requirements and added Calibration Requirements for sealant manufacturers and repackagers. Redefined lot and added testing requirements for a batch or lot of material. Added Mix on Deman

6、d Kit Final Acceptance Test requirements. 1. SCOPE This document establishes standard requirements for aerospace sealants and adhesion promoters, which may be incorporated as part of Aerospace Material Specifications (AMS) for such products. This document provides for commonality of methods and proc

7、edures for responsibility for inspection, source inspection, classification of tests, establishment of/and qualification to qualified products lists, approval, reports, resampling and retesting, packaging, and marking. 1.1 Safety - Hazardous Materials While the materials, methods, applications, and

8、processes described or referenced in this standard may involve the use of hazardous materials, this standard does not address the hazards which may be involved in such use. It is the sole responsibility of the user to ensure familiarity with the safe and proper use of any hazardous materials and to

9、take necessary precautionary measures to ensure the health and safety of all personnel involved. Refer to the specific products Materials Safety Data Sheet (MSDS) or Safety Data Sheet (SDS) for health and safety information. 2. APPLICABLE DOCUMENTS The following publications form a part of this docu

10、ment to the extent specified herein. The latest issue of SAE publications shall apply. The applicable issue of other publications shall be the issue in effect on the date of the purchase order. In the event of conflict between the text of this document and references cited herein, the text of this d

11、ocument takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained. SAE INTERNATIONAL AS5502D Page 2 of 10 2.1 SAE Publications Available from SAE International, 400 Commonwealth Drive, Warrendale, PA 15096-0001, Tel:

12、 877-606-7323 (inside USA and Canada) or +1 724-776-4970 (outside USA), www.sae.org. AMS3100 Adhesion Promoter For Polysulfide Sealing Compounds AS9100 Quality Management Systems - Requirements for Aviation, Space and Defense Organizations AS9120 Quality Management Systems - Requirements for Aviatio

13、n, Space and Defense Distributors 2.2 BSI Publications Available from British Standards Institution, 389 Chiswick High Road, London, United Kingdom W4 4AL, Tel: +44 (0)20 8996 9001, . BS EN 9100 Quality Management Systems - Requirements for Aviation, Space and Defense Organizations BS EN ISO 10012 M

14、easurement Management Systems Requirements for Measurement Processes and Measuring Equipment BS EN ISO/IEC 17025 General Requirements for the Competence of Testing and Calibration Laboratories 2.3 ISO Publications Available from International Organization for Standardization, Chemin de Blandonnet 8,

15、 CP 401, 1214 Vernier, Geneva, Switzerland, Tel: +41 22 749 01 11, www.iso.org. ISO 10012 Measurement Management Systems - Requirements for Measurement Processes and Measuring Equipment ISO/IEC 17025 General Requirements for the Competence of Testing and Calibration Laboratories 2.4 PRI Publications

16、 Available from Performance Review Institute, 161 Thorn Hill Road, Warrendale, PA 15086-7527, Tel: 724-772-1616, www.pri-network.org. AC7200/1 Nadcap Requirements for the Sealant Manufacturers Accreditation Program AC7202 Nadcap Requirements for the Sealant Value Added Distributor Accreditation Prog

17、ram OP 1114 APP SLT Additional Requirements for the Sealants Task Group PD2000 Governance and Administration of an Industry Managed Product Qualification Program PD2001 Manufacturer Request for Product Approval and Qualification Process PD2103 Aerospace Quality Assurance, Product Standards, Qualific

18、ation Procedure, Sealants 3. TECHNICAL REQUIREMENTS For purposes of this standard, sealant shall be synonymous with “sealing compound“. Technical requirements for a specific class of sealant or adhesion promoter shall be defined by the AMS. In case of conflict in requirement(s), the AMS takes preced

19、ence over this Aerospace Standard (AS). SAE INTERNATIONAL AS5502D Page 3 of 10 3.1 Date of Manufacturing, Date of Packaging, and Conformance Testing 3.1.1 Date of Manufacturing (DOM) DOM is defined as the last day of Initial Acceptance Tests per 4.2.2 as dated on the applicable test report. 3.1.2 Da

20、te of Packaging (DOP) For sealants, the DOP is defined as the date that bulk sealant is packaged from its components, base compound and curing agent, by the manufacturer or value added distributor (repackager). DOP shall be no more than 90 days from the DOM or the most recent Conformance Testing per

21、 3.1.3. For adhesion promoters, the DOP is defined as the date that the bulk adhesion promoter is packaged into smaller container sizes per AMS3100 Section 5. (Note: The shelf life of the adhesion promoter is based on the DOM per AMS3100 paragraph 3.5). 3.1.3 Conformance Testing (CT) for Packaging E

22、xtensions - Sealant Only CT shall be performed within 90 days of the bulk material DOM to extend the time for packaging material. The material shall be limited to a maximum of two 90 day extensions, and shall be limited to a maximum of 270 days from the DOM. The 1st CT requires performing the Final

23、Acceptance Tests of the applicable AMS. The 1st CT may be performed by the manufacturer or, with the manufacturers approval, by approved value added distributors (repackagers). The 2nd CT requires performing the Initial Acceptance Tests of the applicable AMS, and shall be performed by the manufactur

24、er within 90 days of the 1st Conformance Testing. The following diagram describes the extension procedure for packaging: Figure 1 3.2 Toxicological Formulations The material shall have no adverse effects on the health of personnel when used for its intended purpose in accordance with manufacturers M

25、SDS or SDS and with appropriate handling procedures. Questions pertinent to this effect shall be referred by the contracting activity to the appropriate medical service who will act as an advisor to the contracting agency. 3.3 Quality 3.3.1 Sealant Quality The sealants base compound and curing agent

26、, as received by the purchaser, shall each be of uniform blend and shall be free of excessive air, skins, lumps, and gelled or coarse particles that could interfere with the application of the material and its function. There shall be no separation of ingredients which cannot be easily redispersed.

27、3.3.2 Adhesion Promoter Quality The adhesion promoter, as received by the purchaser, when visually examined, shall be uniform in quality and condition, free of sedimentation and turbidity, and free from foreign materials, particulate matter, and other contaminates detrimental to use of the adhesion

28、promoter. Material packaged in aerosol containers may be sprayed into a clear glass container to determine appearance. SAE INTERNATIONAL AS5502D Page 4 of 10 4. QUALITY ASSURANCE PROVISIONS 4.1 Responsibility for Inspection The manufacturer of the material shall supply all samples and shall be respo

29、nsible for performance of all required tests. 4.1.1 Source Inspection (Nadcap) Each batch of material procured under specifications referencing this standard shall be third party approved prior to shipment to ensure that material meets acceptance tests (as defined by the specification). Third party

30、approval shall be by a third party accreditation process in accordance with OP 1114 APP SLT (4.12.2). Also, the manufacturer of the sealant or adhesion promoter shall be certified in accordance with AS9100 and hold a third party accreditation in accordance with AC7200/1. Value added distributors (re

31、packagers) and pass-through distributors supplying sealant or adhesion promoter shall supply material from an accredited manufacturer and from a batch of material that has been third party source inspected. Value added distributors shall be certified in accordance with AS9100 and hold a third party

32、accreditation in accordance with AC7202, Pass-through distributors shall be certified in accordance with AS9100 or AS9120. NOTE: For AS9100 and AS9120, any accreditation body under the International Aerospace Quality Group (IAQG) umbrella using a national Quality Management Systems standard (e.g. BS

33、 EN 9100) is equivalent. 4.1.2 Sampling Shall be in accordance with 4.3.1. 4.2 Classification of Tests 4.2.1 Qualification Tests All technical requirements are qualification tests and shall be performed prior to or on the initial shipment of the material by the manufacturer. Compliance testing is re

34、quired when a change in ingredients and/or processing requires reapproval as in 4.4.2, or when the G-9 QPG (Qualified Products Group) deems it necessary per PD2000, PD2001, and PD2103. The compliance tests will be defined by the G-9 QPG. 4.2.2 Acceptance Tests 4.2.2.1 Initial Acceptance Tests Techni

35、cal requirements that are tested on each batch of material are initial acceptance tests. Initial acceptance tests are performed after production, but before repackaging. 4.2.2.2 Final Acceptance Tests Final acceptance tests shall be performed on each lot of material after packaging or repackaging as

36、 applicable. 4.2.2.2.1 Final Acceptance Tests for Sealant Can Kits (Cans, Pails, or Drums) 4.2.2.2.1.1 No final acceptance tests are required. 4.2.2.2.1.2 A fill weight check must be performed on a minimum of one kit per production run. 4.2.2.2.2 Final Acceptance Tests for Sealant Injection or Mix o

37、n Demand Kits SAE INTERNATIONAL AS5502D Page 5 of 10 4.2.2.2.2.1 Test one kit per base compound/curing agent combination, regardless of how many different sizes of kits are produced, in accordance with the following conditions: a. Dedicated Equipment: If the base compound/curing agent combination is

38、 run on dedicated equipment, kit testing does not need to be repeated if runs are done on different days. b. Non-dedicated Equipment: If another material was used on the equipment, another kit must be tested when the next run begins. c. Hand-filling: If the material is filled by hand, kit testing do

39、es not need to be performed if the same base compound/curing agent combination packaged by another process has been tested. If the base compound/curing agent combination has not been packaged by another process, then a kit must be tested. NOTE: A fill weight check must be done on at least one kit of

40、 each kit size per run. 4.2.2.2.2.2 The following tests are required, unless the AMS directs otherwise: a. Application time b. Tack-free time c. Cure time d. Flow (if applicable). 4.2.2.2.3 Final Acceptance for Pre-mixed and Frozen (PMF) Sealant Cartridges 4.2.2.2.3.1 Test a minimum of one PMF cartr

41、idge per run for Class B materials and three PMF cartridges (from the beginning, middle, and end of the run) for Class A and Class C materials. The Classes are defined in the applicable AMS specification. NOTE: A weight ratio check is required at the start of each production run. 4.2.2.2.3.2 The fol

42、lowing tests are required, unless the AMS directs otherwise: a. Application time b. Tack-free time c. Cure time d. Flow (if applicable). 4.2.2.2.3.3 Button Board Inspection 4.2.2.2.3.3.1 For Class B materials in cartridges 2.5 ounces or larger, the operator extrudes a small amount of product from ea

43、ch sequentially numbered cartridge onto a correspondingly numbered square on the button board. For Class B materials in cartridges smaller than 2.5 ounces, a small amount of product from every tenth cartridge shall be extruded onto a correspondingly numbered square on the button board. 4.2.2.2.3.3.2

44、 Button board sealant may be subject to accelerated cure. SAE INTERNATIONAL AS5502D Page 6 of 10 4.2.2.2.3.3.3 Inspection criteria for all buttons. a. Visual: Uniform color, mix, and texture, no streaks, free of flakes, grit or foreign objects b. Cure: Uniform solid rubbery state, tack-free to touch

45、 c. Air: No sponginess or excessive air - “Excessive air” is defined as 20% or more porosity of the internal surface area of the halved button. NOTE: For PMF cartridges 2.5 ounces or larger being filled using a continuous mixing machine, either with dynamic or static mixing heads, the cartridge corr

46、esponding to a discrepant button and the one following shall be discarded. If another PMF cartridge filling process is used, the corresponding cartridge and the one before and after shall be discarded. For each discrepant button of cartridges smaller than 2.5 ounces, the corresponding cartridge and

47、the nine before and ten after, corresponding to the fill process shall be discarded. 4.2.2.2.4 Final Acceptance Tests for PMF Sealant Used to Fill Pre-Molded Sealant Caps The following tests are required to be performed on a sample of the PMF sealant, unless the AMS directs otherwise: a. Application

48、 time b. Tack-free time c. Cure time d. Flow (if applicable). 4.2.2.2.5 Final Acceptance Tests for One Part Cartridge The following tests are required, unless the AMS directs otherwise: a. Tack-free time b. Cure time c. Flow (if applicable). 4.2.2.2.6 Final Acceptance Tests for Adhesion Promoter are

49、 the following unless the AMS directs otherwise: 4.2.2.2.6.1 Color, when applicable, shall be uniform and impart a stain on the substrate when dried. 4.2.2.2.6.2 Appearance shall be uniform in quality and condition, free of sedimentation and turbidity, and free from foreign materials, particulate matter, and other contaminants detrimental the use of the adhesion promoter. 4.3 Sampling and Testing 4.3.1 For Init