Mil STD 1687a PDF

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MIL-STD-l687A(SH) 11 F e b r a r y 1987 SUPERSEDING MIL-STD-l687(SH) 24 November 1 9 8 0 ( S e e 6.5)
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MILITARY STANDARD THERMAL SPRAY PKOCESSES FOR NAVAL, SHIP MACHINERY APPLICATIONS
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MIL-STD-Lb7A
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7777733 OOL34 7
MIL-STD-l687A(SH) 11 February 1987

DEPARTMENT OF THE NAVY NAVAL SEA SYSTEMS COMMANI)
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Washington, DC
20362-5101
Thermal Spray Processes f o r Naval Ship Machinery A p p l i c a t i o n s

1. This M i l i t a r y Standard i s approved f o r u s e by t h e Naval Sea Systems Command, Department of t h e Navy, and i s a v a i l a b l e f o r u s e by a l l Departments and Agencies of t h e Department of Defense.
2. B e n e f i c i a l comments (recommendations, a d d i t i o n s , d e l e t i o n s ) and any p e r t i n e n t d a t a which may be of u s e i n improving t h i s document should be addressed to: Commander, Naval Sea Systems Command, SEA 5523, Department of t h e Navy, Washington, DC 20362-5101 by u s i n g t h e self-addressed S t a n d a r d i z a t i o n Document Improvement Proposal (DD Form 1426) appearing a t t h e end of t h i s document o r by l e t t e r .
ii
FOREWORD
This standard covers thermal spray processes f o r repair or overhaul of Naval ship machinery.
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CONTENTS Page Paragraph 1 1 . 1 1 . 2
2 2
. 4. 4.1
4.1.1 4.1.2 4.1.3
4.1.4
4.1.5 4.1.6 4.2 4.2.1 4.2.1.1 4.2.1.2 4.2.2 4.2.2.1 4.2.2.2 4.203 4.2.301 4.2.3.2 4.2.3.3 4.3 4.3.1 4.3.1.1 4.3.2 4.3.3 4.3.3.1 4.3.3.2 4.3.3.3 4.3.3.4 4.3.3.5 4.3.4 4.3.4.1 4.3.4.2 4.3.4.3
5 5
6 6 6 6
10
10 10
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2 2.1 2.1.1 2.1.2 2 02 2.3
............................................... .............................................. 1 ......................................... REFERENCED DOCUMENTS ................................ 1 Government documents ............................... Specifications and standard ........................ 1 Other Government publications ...................... Other publications ................................. Order of precedence ................................ DEFINITIONS ......................................... 3 GENERAL REQUIREMENTS ................................ 4 Quality assurance system ........................... 4 Management ......................................... 4 Inspection system .................................. 5 Records ............................................ Record form ........................................ Maintenance of records ............................. 6 Noncompliance ...................................... 6 Qualification and certification requirements ....... 6 Facility certification requirements ................ Naval shipyards .................................... 6 Other Government and commercial activities ......... 6 Quality control program approval ................... Naval shipyards .................................... Other Government and commercial activities ......... Thermal spray procedure approval ................... 6 Naval shipyards .................................... Ships Intermediate Maintenance Activities (SIMA) and Afloat IMAs ................................... Other Government and commercial activities ......... 6 Spraying procedure qualification ................... 7 Spraying procedures ................................ 7 Submittal for approval ............................. 7 Procedure qualification testing .................... 7 Qualification test requirements .................... 7 Visual examination requirement ..................... 7 Microscopic examination ............................ 7 Bend test .......................................... Bond test .......................................... 10 Non-established requirements ....................... 10 Extent of use of qualified spraying procedure ...... 10 Substrate material ................................. Spray procedure .................................... Essential elements ................................. 10
SCOPE Scope Application
1.
3.
CONTENTS
. Continued
Page
Paragraph 4 . 4
4 . 4 . 1 4 . 4 . 2 4 . 4 . 2 . 1 4 . 4 . 2 . 2 4 . 4 . 2 . 3 4 . 4 . 2 . 4 4 . 4 . 2 . 5 4 . 4 . 2 . 6 4 . 4 . 3 4 . 4 . 4 4 . 4 . 5 4 . 4 . 5 . 1 4 . 4 . 5 . 2 4 . 4 . 5 . 3 4 . 4 . 5 . 4 4 . 4 . 5 . 5 4 . 4 . 5 . 6 4 . 4 . 6
4 . 5
4 . 5 . 1 4 . 5 . 2 4 . 5 . 2 . 1 4 . 5 . 3 4 . 6 4 . 6 . 1 4 . 6 . 1 . 1 4 . 6 . 1 . 2 4 . 6 . 1 . 3 4 . 6 . 2 4 . 6 . 3 4 . 6 . 4 4 . 6 . 5 4 . 6 . 5 . 1 4 . 6 . 5 . 2
P e r s o n n e l t r a i n i n g . q u a l i f i c a t i o n . and c e r t i f i c a t i o n General T r a i n i n g f o r o p e r a t o r s and i n s p e c t o r s General Operators Operator w r i t t e n test Vision test requirements Inspector training Inspector written test Operator q u a l i f i c a t i o n t e s t i n g A l t e r n a t i v e q u a l i f i c a t i o n methods Q u a l i f i c a t i o n test examinations V i s u a l examination Microscopic examination Bend t e s t examination Bond test examination Limits of c e r t i f i c a t i o n Maintenance of c e r t i f i c a t i o n Records f o r o p e r a t o r q u a l i f i c a t i o n Quality control In-process i n s p e c t i o n End i t e m requirement Inspection T e s t specimens f o r q u a l i t y c o n t r o l T e s t procedures P r e p a r a t i o n of test specimens Specimens f o r m i c r o s c o p i c examination Specimens f o r v i s u a l and bend tests Specimens f o r bond t e s t V i s u a l examination Microscopic examination Bend test Bond test Spraying Application
DETAILED REQUIREMENTS Equipment Spraying systems Wire oxygen-fuel spray Powder oxygen-fuel gas s p r a y A r c spray Plasma s p r a y Thermal s p r a y systems Abrasive b l a s t i n g equipment Air equipment F i x t u r i n g f o r mechanical p o s i t i o n i n g
5.1 5.1.1 5.1.1.1 5 . 1 . 1 . 2 5 . 1 01.3 5.1.1.4 5 . 1 . 1 5 5.1.2 5.1.2.1 5.1.3
11 11 ........................................... 11 ............. 11 ........................................... 11 ......................................... 11 ............................. 11 .......................... 11 ................................ 12 ............................ 12 .................... 12 ................. 12 ................... 12 ................................ 12 ........................... 12 ............................. 12 ............................. 12 ........................... 12 ...................... 13 ................ 13 ................................... ............................. 13 13 .............................. 13 ........................................ 13 ................ 13 ................................... 13 ..................... ............. 13 14 ............... 14 ........................... 14 ................................ 14 ........................... 14 ......................................... 14 ......................................... 14 .......................................... 14 ....................................... .............................. 14 ......................................... 14 14 .................................. 14 gas ........................ 15 ...................... 15 ......................................... 15 ...................................... 15 . ............................. 15 ....................... ..................................... 15 .............. 15
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. . . . . . MIL-STD-Lb7A M F W 77777LL O O B B L L B b

CONTENTS
. Continued
Page
Paragraph 5 . 2
5 . 2 . 1 5 . 2 . 1 . 1 5 . 2 . 1 . 2 5 . 2 . 1 . 2 . 1 5 . 2 . 1 . 2 . 2 5 . 2 . 2 5 . 2 . 3 5 . 2 . 4 5 . 2 . 5 5 . 3 5 . 3 . 1 5 . 3 . 1 . 1 5 . 3 . 1 . 2 5 . 3 . 1 . 3 5 . 3 . 2 5 . 3 . 2 . 1 5 . 3 . 2 . 2 5 . 3 . 3 5 . 3 . 3 . 1 5 . 3 . 3 . 2 5 . 3 . 4 5 . 3 . 4 . 1 5 . 3 . 4 . 2 5 . 3 . 4 . 3 5 . 3 . 5 5 . 4 5 . 4 . 1 5 . 4 . 1 . 1 5 . 4 . 1 . 2 5 . 4 . 2 5 . 4 . 2 . 1 5 . 4 . 2 . 2 5 . 4 . 2 . 3 5 . 4 . 3
5 . 4 . 4
5 . 4 . 5 5 . 4 . 6 5 . 4 . 7 5 . 4 . 8 5 . 5 5 . 5 . 1 5 . 5 . 2 5 . 5 . 2 . 1 5 . 5 . 2 . 1 . 1 5 . 5 . 2 . 2
Coating materials Coating t y p e Thermal s p r a y wire and powder Storage. i d e n t i f i c a t i o n . and s e p a r a t i o n of w i r e and powder Thermal s p r a y gases For flame s p r a y i n g For plasma spraying Abrasive b l a s t i n g p a r t i c l e s Requirements Restrictions Masking materials For a b r a s i v e b l a s t i n g For thermal s p r a y i n g I r r e g u l a r shapes Sealants Process Surface c o n d i t i o n Solvent c l e a n i n g Heat c l e a n i n g Machining f o r s u r f a c e p r e p a r a t i o n Undercutting Threading or grooving of c y l i n d r i c a l s u r f a c e s Shoulders Masking Abrasive b l a s t i n g f o r s u r f a c e p r e p a r a t i o n Spraying Application of s e a l a n t Surface f i n i s h i n g Safety precautions Thermal spray a p p l i c a t i o n s General Approved a p p l i c a t i o n s Machinery Equipment Proposed a p p l i c a t i o n s
........................................ 15 ..................................... 15 ........................... 15 ............................ 16 .................................... 16 ........................................ 16 ....................... 16 ........................... .............................. 16 .............. 16 Materials ......................................... 17 ................................. 17 ...................................... 17 17 ..................... ....................................... 17 ............................... 17 ................................ 17 ............................... 17 ....................... ...................................... 18 ...................................... 18 ................................. 18 ............................. 18 .............................. 18 18 .................................. .......................................... 18 18 ........................................... ................................. 18 18 .................................. ..................................... 19 ................. 19 ...................................... 19 ..... 19 ......................................... 19 ........................................... 19 ......... 20 19 .......................................... ............................ 21 ................................. 21 ................................ 21 ........................ 23 ........................................... 23 ............................. 26 ......................................... 26 ......................................... 26 ............................. 26
Facilities Working areas Abrasive b l a s t i n g areas Thermal s p r a y i n g areas Enclosed areas Open areas Abrasive b l a s t i n g equipment Thermal s p r a y equipment P r o t e c t i v e equipment F i x t u r i n g f o r mechanical p o s i t i o n i n g 16
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CONTENTS
- Continued
Page
Paragraph 6. 6.1
6 . 2 6 . 3 6 . 4 6 . 5
NOTES . . . . . . . . . . . . . . . . . . . . o o o o o o o o o o o * o o o * o o . o o o o o o o Intended u s e General r e q u i r e m e n t s Data r e q u i r e m e n t s S u b j e c t term (key word) l i s t i n g Changes from p r e v i o u s i s s u e

FIGUKES
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26 26 26 27 27 27
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Figure
1.
2 . 3 .
4 . 5 .
Wire oxy-fuel s p r a y p r o c e s s and parameter r e c o r d Wire arc s p r a y p r o c e s s and parameter r e c o r d Powder oxygen f u e l s p r a y p r o c e s s and parameter record Plasma s p r a y p r o c e s s and parameter r e c o r d Oxide, p o r o s i t y comparison c h a r t (200X)
TABLES
... ........ ............................................ .......... ............

................... ....................... ........................
28 29
30 32 34
Table
I.
II
III.
Thermal s p r a y c o a t i n g p r o p e r t i e s Recommended s p r a y procedures Spray material compositions
8 24 25
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MIL-STD-l687A( SH) 11 February 1987
1 .
SCOPE
1 . 1 Scope. This standard covers thermal spray processes for machinery repair and corrosion protection of Naval ship machinery, except the spraying of aluminum for corrosion protection which is covered in DOD-STD-2138; This standard does not apply to primary and secondary systems of nuclear ships. Included are requirements for the qualification of thermal spray procedures and operators, requirements and guidance for use of thermal spray material and equipment, quality assurance requirements, and descriptions of applicable qualification tests.
The thermal spray processes covered by this standard are: (a) wire 1 . 1 . 1 spraying of consumable coating material using oxygen-fuel gas, or using two consumable electrodes in an electric arc system, and (b) powder spraying, using oxygen-fuel gas or plasma arc. 1 . 2 Application. Thermal spray coatings shall be used only for machinery applications specifically permitted herein (see 5.5.2) or for which prior approval has been obtained from the Naval Sea Systems Command (NAVSEA). 1 . 2 . 1 Requirements of this standard pertain only to the thermal spray coatings applied to ferrous and non-ferrous metal substrates. 2 . REFERENCED DOCUMENTS Government documents.
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2.1
2 . 1 . 1 Specifications and standard. Unless otherwise specified, the following specifications and standard of the issue listed in that issue of the Department of Defense Index of Specifications and Standards (DoDISS) specified in the solicitation form a part of this standard to the extent specified herein. SPECIFICATIONS FEDERAL, 0-T-620 BB-A- 1O6 BB-A-1034 BB-H-886 BB-H-1168 BB-0-925 TT-T-5 48 MILITARY MIL-M-3800 MIL-W-6712 MIL-A-18455 l,l,l-Trichloroethane, Technical, Inhibited (Methyl Chloroform). Acetylene, Technical, Dissolved. Air, Compressed, for Breathing Purposes. Hydrogen. Helium, Technical. Oxygen, Technical, Gas and Liquid. Toluene, Technical. Metallizing Outfits (Wire-Gas), Guns and Accessories. Wire; Metallizing. Argon, Technical.
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MILITARY (Continued) MIL-P-80109 Plasma Spray Systems, Powder, Guns, and Accessories MIL-M-80141 M e t a l l i z i n g O u t f i t s , Powder-Gas, Guns and Accessories. MIL-M-80226 M e t a l l i z i n g System, Wire, Electric A r c , Guns and Accessories. MIL-P-83348 Powders, Plasma Spray.
STANDARD
MILITARY DOD-STD-2138
- Metal
Sprayed Coating Systems f o r Corrosion P r o t e c t i o n Aboard Naval Ships. (Metric)
(Copies of s p e c i f i c a t i o n s and s t a n d a r d s r e q u i r e d by c o n t r a c t o r s i n connection w i t h s p e c i f i c a c q u i s i t i o n f u n c t i o n s should be o b t a i n e d from t h e c o n t r a c t i n g a c t i v i t y o r as d i r e c t e d by t h e c o n t r a c t i n g o f f i c e r . )

2.1.2 Other Government p u b l i c a t i o n . The f o l l o w i n g o t h e r Government p u b l i c a t i o n forms a p a r t of t h i s s p e c i f i c a t i o n t o t h e e x t e n t s p e c i f i e d h e r e i n . n l e s s otherwise s p e c i f i e d , t h e i s s u e s s h a l l be t h o s e i n e f f e c t on t h e d a t e of the solicitation.
PUBLICATIONS
DEPARTMENT O F TRANSPORTATION (DOT) Code of Federal Regulations (CFR) 29, 1910.107
- Spray
booths.
(The Code of F e d e r a l Regulations (CFR) and t h e F e d e r a l Register (FR) are f o r s a l e on a s u b s c r i p t i o n b a s i s by t h e Superintendent of Documents, U.S. Government P r i n t i n g O f f i c e , Washington, DC 20402.) 2.2 Other p u b l i c a t i o n s . The following documents form a p a r t of t h i s s t a n dard t o t h e e x t e n t s p e c i f i e d herein. Unless otherwise s p e c i f i e d , t h e i s s u e s of t h e documents which are DoD adopted s h a l l be t h o s e l i s t e d i n t h e i s s u e of t h e DoDISS s p e c i f i e d i n t h e s o l i c i t a t i o n . The i s s u e s of documents which have n o t been adopted s h a l l be those i n e f f e c t on t h e d a t e of t h e c i t e d DoDISS.
AMERICAN SOCIETY FOK TESTING AND MATERIALS (ASTM) C 633 Standard Test Method f o r Adhesion o r Cohesive S t r e n g t h of Flame-Sprayed Coatings. (DoD adopted) D 4285 Standard Test Method f o r I n d i c a t i n g O i l o r Water i n Compressed Air.
( A p p l i c a t i o n f o r copies should be addressed t o t h e American S o c i e t y f o r T e s t i n g and Materials, 1916 Race S t r e e t , P h i l a d e l p h i a , PA 19103.)
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AMERICAN WELDING SOCIETY (AWS) Thermal Spraying P r a c t i c e , Theory and A p p l i c a t i o n . OPP A 3 . 0 Standard Welding Terms and D e f i n i t i o n s I n c l u d i n g Terms f o r Brazing, S o l d e r i n g , Thermal Spraying and Thermal C u t t i n g
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( A p p l i c a t i o n or c o p i e s should be addressed t o t h e American Welding S o c i e t y , Inc., 550 NW LeJeune Road, P.O. Box 351040, Miami, FL 33135.) STEEL STRUCTURES PAINTING COUNCIL (SSPC) SP 5 White Metal Blast Cleaning.
( A p p l i c a t i o n f o r c o p i e s should be addressed t o t h e S t e e l S t r u c t u r e s P a i n t i n g Council, 4400 F i f t h Avenue, P i t t s b u r g h , PA 15213.) (Nongovernment s t a n d a r d s are g e n e r a l l y a v a i l a b l e f o r r e f e r e n c e from l i b r a r i e s . They are a l s o d i s t r i b u t e d among nongovernment s t a n d a r d s b o d i e s and u s i n g F e d e r a l a g e n c i e s . )
2.3 Order of precedence. In t h e e v e n t of a c o n f l i c t between t h e text of t h i s s t a n d a r d and t h e r e f e r e n c e s c i t e d h e r e i n , t h e t e x t of t h i s s t a n d a r d s h a l l t a k e precedence.
3 .
DEFINITIONS
3.1 D e f i n i t i o n s used i n t h e p r e p a r a t i o n of drawings, s p r a y i n g procedures, s p e c i f i c a t i o n s , and correspondence r e l a t e d t o t h e thermal s p r a y i n g s h a l l conform t o A W S A3.0 and OPP.
3 . 2
The f o l l o w i n g d e f i n i t i o n s are a p p l i c a b l e t o t h i s s t a n d a r d :
(a)
(b) (c)
(d)
(e)
(f)
B l a s t i n g . A method of c l e a n i n g o r s u r f a c e roughening by a f o r c i b l y p r o j e c t e d s t r e a m of s h a r p a n g u l a r a b r a s i v e . Bond c o a t . A p r e l i m i n a r y ( o r prime) c o a t of material which improves adherence of t h e subsequent thermal s p r a y d e p o s i t . Coating system. One o r more thermal s p r a y c o a t i n g s t h a t are q u a l i f i e d f o r u s e s i n g l y o r i n combination. An example of a one-coati n g system i s a s t a i n l e s s s t e e l c o a t i n g a p p l i e d f o r r e s t o r a t i o n of dimensions. An example of a two-coating system i s a nickel-base bond c o a t and ceramic f i n i s h c o a t f o r a steam seal. Composite powder. Powder p a r t i c l e s t h a t are formed by p h y s i c a l l y combining two o r more materials i n i n t i m a t e c o n t a c t , s o t h a t t h e end particles f u n c t i o n as a u n i t . E l e c t r i c arc spraying. A t h e r m a l s p r a y i n g p r o c e s s wherein t h e h e a t source i s an e l e c t r i c arc s t r u c k between two consumable e l e c t r o d e s of a c o a t i n g material, and compressed g a s ( u s u a l l y a i r ) i s used t o atomize and p r o p e l t h e material t o t h e work piece. F l a m e s A p thermal r a y sp i r n a y ig ng . p r o c e s s wherein an oxy-fuel g a s flame i s u t i l i z e d a s t h e s o u r c e of h e a t f o r m e l t i n g t h e c o a t i n g materials i n powder, wire, r o d , o r cored form. Compressed g a s may o r may n o t be used f o r atomizing and p r o p e l l i n g t h e material t o t h e work piece.
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MIL-STD-1687A(SH) 11 February 1987
Fused s p r a y d e p o s i t . A s e l f - f l u x i n g s p r a y d e p o s i t which i s subsequently heated t o coalescence w i t h i n i t s e l f and w i t h the substrate. ( h ) Gradated coating. A thermal sprayed d e p o s i t composed of mixed materials i n s u c c e s s i v e l a y e r s which p r o g r e s s i v e l y change i n composition from t h e c o n s t i t u e n t material of t h e s u b s t r a t e t o t h e s u r f a c e of t h e sprayed d e p o s i t . ( i ) Hard f a c i n g . A p r o c e s s of d e p o s i t i n g a c o a t i n g o n t o a s u r f a c e f o r t h e purpose of r e s i s t i n g a b r a s i o n , e r o s i o n , wear, g a l l i n g o r impact. Various c o a t i n g s may be used e i t h e r i n t h e assprayed c o n d i t i o n o r machined o r ground t o dimensions. ( j ) I n t e r f a c e . The c o n t a c t s u r f a c e between t h e s p r a y d e p o s i t and t h e s u b s t r a t e o r two d i f f e r e n t types of sprayed materials. ( k ) Masking. The method of p r o t e c t i n g areas a d j a c e n t t o t h e s u r f a c e t o be thermally sprayed o r b l a s t e d t o prevent adherence of a c o a t i n g o r s u r f a c e roughening. (1) Plasma spraying. A thermal s p r a y i n g process wherein a nont r a n s f e r r e d c o n s t r i c t e d e l e c t r i c arc-gas mixture ( c a l l e d a plasma) i s u t i l i z e d as t h e source of h e a t f o r melting and p r o p e l l i n g t h e c o a t i n g material t o t h e work piece. (m) Powder flame spraying, A method of flame s p r a y i n g wherein t h e material t o be sprayed i s i n powder form. ( n ) S e a l coat. Material a p p l i e d i n l i q u i d form, t o i n f i l t r a t e t h e pores of a thermal spray d e p o s i t . ( o ) S p a l l i n e The f l a k i n g o r s e p a r a t i o n of a sprayed c o a t i n g . ( p ) S u b s t r a t e , Any material upon which a thermal sprayed c o a t i n g i s deposited. ( 4 ) Thermal spraying. A group of processes wherein f i n e l y d i v i d e d metallic o r nonmetallic materials are d e p o s i t e d i n a molten or semi-molten c o n d i t i o n t o form a coating. The c o a t i n g may i n i t i a l l y be i n t h e form of powder, ceramic r o d , o r w i r e . ( r ) Wire flame spraying. A method of flame s p r a y i n g wherein t h e metallic material t o be sprayed i s i n wire form. (g) 4 , GENERAL REQUIREMENTS 4.1 Quality assurance system. A w r i t t e n q u a l i t y a s s u r a n c e system s h a l l be implemented and maintained which a s s u r e s t h a t t h e requirements of t h i s s t a n d a r d and t h e f u n c t i o n s of t h e thermal sprayed c o a t i n g s are m e t (see 6 . 3 ) .
4 . 1 . 1 Management. E f f e c t i v e management f o r q u a l i t y of thermal spray of machinery components s h a l l be c l e a r l y p r e s c r i b e d by w r i t t e n procedures. W r i t t e n procedures s h a l l be prepared which a s s i g n r e s p o n s i b i l i t y and provide accounta b i l i t y f o r performing work and i n s p e c t i o n . Personnel performing q u a l i t y f u n c t i o n s s h a l l have s u f f i c i e n t , well-defined r e s p o n s i b i l i t y , a u t h o r i t y and t h e o r g a n i z a t i o n a l freedom t o i d e n t i f y and e v a l u a t e problems and t o i n i t i a t e , recommend, o r provide s o l u t i o n s . Management s h a l l review t h e s t a t u s and adequacy of t h e q u a l i t y program through semi-annual documented a u d i t s .
4
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MIL-STD-l687A(SH) 11 February 1987 4.1.2 I n s p e c t i o n system, The performing a c t i v i t y s h a l l m a i n t a i n a n inspect i o n system adequate t o a s s u r e NAVSEA o r a u t h o r i z e d a g e n t t h a t a l l of t h e r e q u i r e ments of t h i s s t a n d a r d have been m e t . W r i t t e n procedures s h a l l be p r e p a r e d t o a s s i g n r e s p o n s i b i l i t y and p r o v i d e a c c o u n t a b i l i t y f o r performing work and inspect i o n s P e r s o n n e l performing a c c e p t a n c e i n s p e c t i o n s s h a l l be t r a i n e d and q u a l i f i e d f o r t h e work t h e y are t o perform. Records of such t r a i n i n g s h a l l be maintained.
4.1.3 Records. Unless o t h e r w i s e s p e c i f i e d h e r e i n , w r i t t e n r e c o r d s s h a l l The r e c o r d s be prepared and maintained f o r each sprayed component ( s e e 4.1.4). ~. s h a l l i n c l u d e a t least t h e f o l l o w i n g i n f o r m a t i o n :
I d e n t i f i c a t i o n of s p r a y i n g a c t i v i t y . S p e c i f i c i d e n t i f i c a t i o n of component and system ( s u c h as, no. 1 f i r e pump main). Component drawing o r p a r t number. Component material ( M i l i t a r y , ASTM, o r o t h e r s p e c i f i c a t i o n ) . Ship i d e n t i f i c a t i o n . J o b o r d e r o r work number. Cleaning method and method of base metal p r e p a r a t i o n ( a b r a s i v e blasting, threading). Sketch showing area t o be sprayed, undercut d e p t h and l e n g t h , s h o u l d e r s , masking l o c a t i o n s . Reason f o r spraying. Spray procedure i d e n t i f i c a t i o n (and r e v i s i o n ) . Bond and f i n i s h c o a t material g e n e r i c t y p e and m a n u f a c t u r e r ' s identification. As-sprayed c o a t i n g t h i c k n e s s (bond and f i n i s h ) . Final coating thickness. Method of s u r f a c e f i n i s h i n g ( g r i n d i n g , machining). I f ground, s t a t e g r i n d i n g wheel and s u r f a c e f i n i s h . S e a l a n t material and sequence of a p p l i c a t i o n . Date sprayed. Sprayer's i d e n t i f i c a t i o n . I n s p e c t i o n procedure and r e s u l t s . Inspection personnel i d e n t i f i c a t i o n . Cognizant NAVSEA equipment manager. NAVSEA Materials and Assurance Engineering O f f i c e a p p r o v a l d a t e . Date i n s t a l l e d . I n s t a l l a t i o n and alignment personnel. I n s t a l l e d s h i p compartment l o c a t i o n .
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4.1.4 Record form. A r e c o r d form s h a l l be prepared p r i o r t o commencement of t h e o p e r a t i o n which i t covers. Operations s h a l l be recorded p r i o r t o t h e commencement of the n e x t o p e r a t i o n . Each i t e m on t h e r e c o r d form s h a l l be s i g n e d and d a t e d by t h e o p e r a t o r , except f o r t h o s e checkpoints d e s i g n a t e d f o r v e r i f i c a t i o n by t h e i n s p e c t o r s . When a s p e c i f i c i t e m on t h e r e c o r d form i s n o t (Not a p p l i c a b l e ) s h a l l be e n t e r e d . P r i o r t o a p p l i c a b l e , t h e l e t t e r s "N.A." acceptance, a l l items on t h e r e c o r d forms s h a l l be marked as s p e c i f i e d (see 4.1.3).
5
MIL-STD-Lb87A
MF
m 9977711
0088125 3
MIL-STD-l687A(SH) 1 1 February 1987

4.1.5 Maintenance of records. Unless otherwise specified, the sprayed component record form shall be maintained by the performing activity and shall be available to NAVSEA upon request. Disposition of records shall be as agreed upon by the NAVSEA agent or the contractor. The performing activity shall maintain records to be made available to NAVSEA or its authorized agent. 4.1.6 Noncompliance. In the event of noncompliance with the requirements of this standard, the applicable work covered by this standard shall be suspended until the performing activity has demonstrated that work deficiencies have been corrected. 4.2
Qualification and certification requirements.
4.2.1 Facility certification requirements. Performing activities shall have thermal spray facilities that meet the requirements for working areas (see 5 . 2 - 1 through 5.2.5). 4.2.1.1 Naval shipyards. Prior to production implementation, Naval shipyards shall submit a request to NAVSEA Materials and Assurance Engineering Office for certification of their thermal spray facility. The request shall contain written evidence that the facility meets the requirements of this standard. 4.2.1.2 Other Government and commerical activities. Prior to contract award, activities shall submit a request to the Supervisor of Shipbuilding for certification of their thermal spray facility. The request shall contain written evidence that the facility meets requirements of this standard4.2.2 Quality control program approval. Performing activities shall have a quality control program that addresses requirements for management (see 4.1.1, 4.1.2, 4.1.4, 4.1.5, 4.3, 4.4, 5.3, and 6 . 3 ) . In addition, each activity shall have a written audit plan and audit the thermal spray operation on a periodic basis. 4.2.2.1 Naval shipyards. Prior to production work, Naval shipyards shall submit a request to NAVSEA Materials and Assurance Engineering Office for certification of their quality control program for thermal spray. 4.2.2-2 Other Government and commercial activities. Prior to contract award, activities shall submit a request to the Supervisor of Shipbuilding for certification of their quality control program for thermal spray (see 6 . 3 ) . 4.2.3 Thermal spray procedure approval. meet the requirements specified in 4.3. 4.2.3.1
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Thermal spray procedures shall
Naval shipyards.
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4.2.3.2 Ships Intermediate Maintenance Activities (SIMA) and Afloat IMAs. Thermal spray procedures shall be approved by NAVSEA. 4.2.3.3 Other Government and commercial activities. cedures shall be approved by NAVSEA.
Thermal spray pro-
6
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MIL-STD-l687A( SH) 11 February 1987 4 . 3 Spraying procedure q u a l i f i c a t i o n . Spraying procedure q u a l i f i c a t i o n s h a l l i n c l u d e p r e p a r a t i o n of s p r a y i n g procedure and procedure q u a l i f i c a t i o n test d a t a (see 4 . 3 . 1 . 1 ) . 4.3.1 Spraying procedures. Performing a c t i v i t i e s s h a l l p r e p a r e w r i t t e n s p r a y i n g procedures and perform t e s t s (see 4 . 3 . 3 ) as r e q u i r e d t o q u a l i f y t h e s e procedures. The procedures s h a l l i n c l u d e a t least t h e i t e m s l i s t e d on f i g u r e s 1 through 4 , and a l i s t i n g of t h e sequence i n which t h e v a r i o u s p r o c e s s e s ( s u c h as b l a s t i n g , i n s p e c t i o n s , and d e g r e a s i n g ) are performed. An approved s p r a y procedure may be used by a f a c i l i t y o t h e r t h a n t h e developing f a c i l i t y . Each s p r a y o p e r a t o r who w i l l be u s i n g a p r e v i o u s l y q u a l i f i e d procedure s h a l l be q u a l i f i e d on t h a t procedure i n accordance w i t h 4 . 4 . 3 . 4.3.1.1 S u b m i t t a l f o r approval. P r i o r t o t h e u t i l i z a t i o n of t h e s p r a y i n g procedure, t h e performing a c t i v i t y s h a l l submit and o b t a i n a p p r o v a l of t h e t e s t q u a l i f i c a t i o n d a t a from NAVSEA (see 6 . 3 ) . Procedures s h a l l be submitted w i t h t h e s u p p o r t i n g t e s t q u a l i f i c a t i o n d a t a . Data submitted s h a l l n o t r e l i e v e t h e performing a c t i v i t y of r e s p o n s i b i l i t y f o r conformance w i t h o t h e r requirements of t h i s s t a n d a r d . C o n t r a c t o r s s h a l l be r e s p o n s i b l e f o r similar q u a l i f i c a t i o n of a l 1 sub-contractors. 4 . 3 . 2 Procedure q u a l i f i c a t i o n t e s t i n g . Procedure q u a l i f i c a t i o n t e s t i n g s h a l l c o n s i s t of a v i s u a l examination, microscopic examination, bend t e s t and bond t e s t s of sprayed specimens prepared by a n o p e r a t o r u s i n g t h e proposed procedure. For t h e v i s u a l and bend examination, two specimens s h a l l be sprayed i n accordance w i t h 4 . 6 . 1 . 2 and examined and t e s t e d i n accordance w i t h 4 . 6 . 2 and 4 . 6 . 4 . R e s u l t s of t h e tests s h a l l conform t o t h e requirements of 4 . 3 . 3 . 1 and 4 . 3 . 3 . 3 . For t h e microscopic examination, two specimens s h a l l be prepared i n accordance w i t h 4 . 6 . 1 . 1 , and examined i n accordance w i t h 4 . 6 . 3 . R e s u l t s of t h e examination s h a l l conform t o t h e requirements of 4 . 3 . 3 . 2 . For t h e bond test, f i v e specimens s h a l l be prepared and t e s t e d i n accordance. w i t h 4 . 6 . 1 . 3 and 4 . 6 . 5 , and s h a l l m e e t t h e requirements of 4 . 3 . 3 . 4 . 4.3.3
Q u a l i f i c a t i o n test requirements.
4.3.3.1 Visual examination requirement. The as sprayed c o a t i n g s h a l l have a uniform appearance and s h a l l be f r e e of t h e following:
(a) (b) (c) (d) (e) (f) (g)
Blisters Cracks. Chips o r l o o s e l y a d h e r i n g p a r t i c l e s . Evidence of o i l o r o t h e r contaminants. P i t s exposing t h e u n d e r c o a t o r s u b s t r a t e . Coating s e p a r a t i o n . S p a t t e r , o r ummelted p a r t i c l e s .
4.3.3.2 Microscopic examination. The c o n s t i t u e n t s of t h e c o a t i n g s h a l l be uniformly d i s t r i b u t e d and t h e r e s h a l l be no s e p a r a t i o n s between t h e c o a t i n g and s u b s t r a t e . The p o r o s i t y and o x i d e c o n t e n t s h a l l n o t exceed t h e l i m i t s s p e c i f i e d i n table I (see 4 . 3 . 3 . 5 ) . Bondline contamination (such as, a b r a s i v e b l a s t i n g g r i t , disbonds, and o x i d a t i o n a t t h e s u b s t r a t e and c o a t i n g i n t e r f a c e ) s h a l l be less t h a n 10 percent. Unreacted g l o b u l a r p a r t i c l e s s h a l l be less t h a n 10 p e r c e n t of the c o a t i n g c r o s s - s e c t i o n a l area w i t h t h e average diameter of t h e p a r t i c l e s n o t exceeding 0 . 0 0 2 inch.
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Bend test. No f l a k i n g , delamination o r g r o s s c r a c k i n g of t h e 4.3.3.3 c o a t i n g s h a l l occur due t o bending (see 4 . 6 . 4 ) . Small h a i r l i n e c r a c k s o r a l l i g a t o r i n g of t h e c o a t i n g i n t h e v i c i n i t y of t h e bend are p e r m i s s i b l e . Ceramic c o a t i n g s may e x h i b i t f l a k i n g a s s o c i a t e d only w i t h t h e edges of t h e bend specimen.
4.3.3.4 Bond test. The average and minimum s i n g l e specimen bond s t r e n g t h s of t h e f i v e t e s t e d specimens s h a l l meet o r exceed t h e a p p l i c a b l e bond s t r e n g t h s s p e c i f i e d i n t a b l e I (see 4 . 3 . 3 . 5 ) .
Non-established requirements. When l i m i t s f o r comparison are n o t 4.3.3.5 s p e c i f i e d i n t a b l e I , t h e t e s t d a t a s h a l l be submitted t o NAVSEA f o r a p p r o v a l (see 6 . 3 ) .
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4.3.4
Extent of u s e of q u a l i f i e d s p r a y i n g procedure.
4.3.4.1 S u b s t r a t e material. A q u a l i f i e d procedure f o r a c o a t i n g o r c o a t i n g system may be used on any s u b s t r a t e which i s i n t h e same g e n e r a l composition group (see 4 . 3 . 4 . 1 . 1 ) as t h e s u b s t r a t e used i n t h e q u a l i f i c a t i o n tests. Changes i n t h e a b r a s i v e b l a s t i n g parameters may be needed t o a c h i e v e t h e r e q u i r e d s u r f a c e roughness p r o f i l e f o r s u b s t r a t e s w i t h a hardness v a l u e g r e a t e r than 10 Rockwell C p o i n t s h i g h e r t h a n t h a t of t h e s u b s t r a t e used i n t h e q u a l i f i c a t i o n tests. For each sprayed component t h e r e s h a l l be v e r i f i c a t i o n t h a t t h e anchor t o o t h p r o f i l e meets t h e requirements of 5 . 4 . 4 ( s e e 4 . 5 . 1 ) . 4.3.4.1.1 Materials s h a l l be grouped as f o l l o w s : carbon, low a l l o y , s t a i n l e s s steels, and cast i r o n ; n i c k e l base a l l o y s ; copper base a l l o y s ; aluminum base a l l o y s ; t i n base a l l o y s ; and t i t a n i u m a l l o y s . 4.3.4.2 Spray procedure. The u s i n g a c t i v i t y s h a l l v e r i f y by demonstration t h a t t h e procedure meets t h e requirements of t h i s s t a n d a r d . T e s t parameters and r e s u l t s s h a l l be documented. 4.3.4.3 E s s e n t i a l elements. A change i n any of t h e e s s e n t i a l elements l i s t e d below r e q u i r e s r e q u a l i f i c a t i o n of t h e procedure. However, minor changes i n parameters are allowed, provided t h e t e s t r e s u l t s of t h e o r i g i n a l procedure o r t a b l e I are met o r exceeded.
Material type. G r i t type and s i z e . Gun t y p e and model ( f o r plasma and oxy-fuel powder). Nozzle t y p e and s i z e . Primary gas t y p e , p r e s s u r e , and flow r a t e ( f o r plasma). Secondary gas t y p e and p r e s s u r e ( f o r plasma). Powder p o r t ( f o r plasma). Operating v o l t a g e ( f o r plasma). L i n e a r s u r f a c e speed ( f e e t p e r minute same as r e v o l u t i o n s p e r minute (r/min) times circumference times t r a v e r s e speed). Deposition r a t e (pounds p e r hour). Coating t h i c k n e s s p e r pass. Change of f u e l gas t y p e ( f o r oxy-fuel powder and oxy-fuel w i r e ) .
10
MIL-STD-Lb87A NF W 7777733 008330 7 m

~~~ ~ ~~ ~ ~~
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MIL-STD-l687A(SH) 11 February 1987 4.4 Personnel t r a i n i n g , q u a l i f i c a t i o n , and c e r t i f i c a t i o n .
4.4.1 General. This s e c t i o n provides t h e requirements f o r t r a i n i n g , q u a l i f i c a t i o n , and c e r t i f i c a t i o n of s p r a y o p e r a t o r s . A s p r a y o p e r a t o r s h a l l be q u a l i f i e d by demonstrating, as s p e c i f i e d h e r e i n , t h e a b i l i t y t o apply t h e s p e c i f i e d c o a t i n g system, u s i n g t h e a p p l i c a b l e approved thermal s p r a y p r o c e s s . 4.4-2 T r a i n i n g f o r o p e r a t o r s and i n s p e c t o r s .
4.4.2.1 General. The f o l l o w i n g minimum t r a i n i n g and w r i t t e n tests are r e q u i r e d f o r q u a l i f i c a t i o n and c e r t i f i c a t i o n . A c t i v i t i e s s h a l l m a i n t a i n r e c o r d s of t h e i r t r a i n i n g program and w r i t t e n tests. 4.4.2.2 t r a i n i n g on: (a) (b) Operators. Spray o p e r a t o r s s h a l l r e c e i v e classroom and hands-on
(c)
Basic s a f e t y , equipment and t o o l handling. The g e n e r a l t h e o r y and a p p l i c a b i l i t y of thermal sprayed c o a t i n g systems; s u r f a c e p r e p a r a t i o n ; t h e flame, e l e c t r i c arc and plasma s p r a y c o a t i n g p r o c e s s e s and maintenance and r e p a i r of equipment; s e a l a n t s ; f i n i s h i n g ; q u a l i t y c o n t r o l ; d i a g n o s i s of good and degraded c o a t i n g s . S p e c i f i c t r a i n i n g on t h e thermal s p r a y equipment and c o a t i n g p r o c e s s e s f o r which o p e r a t o r s are being q u a l i f i e d . The minimum t r a i n i n g t i m e f o r t h e v a r i o u s p r o c e s s e s s h a l l be:
Training t i m e (hours) Coating p r o c e s s Flame Electric arc Plasma

Basic
Classroom
On-the-job
40 20 80
20 20 20
--20
---
4.4.2.3 Operator w r i t t e n test. The o p e r a t o r s h a l l s a t i s f a c t o r i l y complete a written t e s t covering t h e c r i t i c a l aspects of t h e t h e o r y , a p p l i c a t i o n s c r i t e r i a , t h i s s t a n d a r d , and aspects of t h e c o a t i n g p r o c e s s e s and equipment o p e r a t i o n f o r which he is being q u a l i f i e d . The w r i t t e n t e s t s h a l l be approved by NAVSEA. 4.4.2.4 Vision t e s t requirements. Each s p r a y o p e r a t o r and i n s p e c t o r s h a l l pass a n annual v i s i o n t e s t . Vision t e s t s s h a l l be conducted u s i n g s t a n d a r d test methods f o r determining v i s u a l a c u i t y . The s t a n d a r d of acceptance f o r v i s i o n tests s h a l l be n a t u r a l o r c o r r e c t e d n e a r d i s t a n c e a c u i t y such t h a t t h e i n d i v i d u a l i s c a p a b l e of r e a d i n g JI letters on t h e s t a n d a r d J a e g a r t y p e c h a r t f o r n e a r vision. Other e q u i v a l e n t v i s u a l t e s t s may be s u b s t i t u t e d f o r t h e J a e g a r c h a r t . 4.4.2.5 Inspector training. I n s p e c t o r s s h a l l be given a t l e a s t 6 hours of classroom i n s t r u c t i o n on t h e g e n e r a l t h e o r y , a p p l i c a t i o n and c o a t i n g p r o c e s s e s , q u a l i t y a s s u r a n c e , and requirements of t h i s s t a n d a r d w i t h emphasis on t h e inspect i o n i n f o r m a t i o n and a c t i o n . The t r a i n i n g s h a l l i n c l u d e hands-on t r a i n i n g w i t h t h e i n s p e c t i o n t o o l s ( s u c h as, 1OX m a g n i f i e r , c o a t i n g t h i c k n e s s gauge, p r o f i l e t a p e ) on good and bad c o a t i n g s on r e p r e s e n t a t i v e p a r t s .
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---
11
MIL-STD-Lb87A
MF W 7777733 0088333 7 E
MIL-STD-l687A(SH) 11 February 1987 4.4.2.6 I n s p e c t o r w r i t t e n test. The i n s p e c t o r s h a l l s a t i s f a c t o r i l y comp l e t e a w r i t t e n t e s t covering t h e t r a i n i n g material. The w r i t t e n t e s t s h a l l i n c l u d e , a t a minimum, q u e s t i o n s on t h e e s s e n t i a l elements s p e c i f i e d i n 4.4.2.2, and s h a l l be approved by NAVSEA. 4.4.3 Operator q u a l i f i c a t i o n t e s t i n g . The o p e r a t o r s h a l l p r e p a r e t e s t specimens i n accordance w i t h 4.6.1 f o r v i s u a l , microscopic, bend and bond t e s t s . Two specimens s h a l l be prepared f o r t h e v i s u a l , microscopic and bend examinations ( t h e same p a n e l s may be used f o r t h e s e examinations), and f i v e specimens f o r t h e bond t e s t . The specimens s h a l l be examined and t e s t e d i n accordance w i t h 4.6.2 through 4.6.5, and meet t h e requirements of 4.4.5.1 through 4.4.5.4. The o p e r a t o r s h a l l u s e a q u a l i f i e d procedure developed f o r t h e p a r t i c u l a r c o a t i n g and thermal spray process. The o p e r a t o r s h a l l s e t up t h e s p r a y i n g equipment The s u b s t r a t e according t o t h e parameters r e q u i r e d by t h e s p r a y i n g procedure. test specimens s h a l l be t h e s u b s t r a t e used i n t h e q u a l i f i c a t i o n of t h e procedure i n accordance w i t h 4.3.4.1. 4.4.4 A l t e r n a t i v e q u a l i f i c a t i o n methods. The o p e r a t o r may a l s o be q u a l i f i e d on a new procedure by demonstrating s a t i s f a c t o r y performance i n accordance w i t h 4.3.2. 4.4.5
Q u a l i f i c a t i o n t e s t examinations. The r e s u l t s of t h e v i s u a l examination s h a l l
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4.4.5.1 Visual examination. meet t h e requirements of 4.3.3.1.
4.4.5.2 Microscopic examination. The r e s u l t s of t h e microscopic examinat i o n s h a l l meet t h e requirements of t a b l e II. 4.4.5.3 Bend t e s t examination. requ rements of 4.3.3.3.
R e s u l t s of bend t e s t s s h a l l meet t h e
4.4.5.4 Bond t e s t examination. The average and minimum s i n g l e specimen bond s t r e n g t h s of t h e f i v e t e s t e d specimens s h a l l meet o r exceed t h e a p p l i c a b l e bond s t r e n g t h s s p e c i f i e d i n t a b l e I , o r t h e minimum average and s i n g l e specimen bond s t r e n g t h s approved f o r procedure q u a l i f i c a t i o n . 4.4.5.5 L i m i t s of c e r t i f i c a t i o n . Operators meeting t h e requirements f o r t h e performance tests s h a l l be c e r t i f i e d t o perform s p r a y i n g w i t h t h e c o a t i n g system and spray process used i n q u a l i f i c a t i o n t e s t i n g . 4.4.5.6 Maintenance of c e r t i i c a t i o n . C e r t i f i c a t i o n s h a l l be maintained i n accordance w i t h 4.4.5.6.1 through 4.4.5.6.3.
C e r t i f i c a t i o n of t h e o p e r a t o r s h a l l be r e t a i n e d u n l e s s a period of 6 months has elapsed s i n c e t h e l a s t production u s e of t h e thermal s p r a y process by t h a t operator.
4.4.5.6.1
4.4.5.6.2 Operators whose c e r t i f i c a t i o n has l a p s e d may be r e q u a l i f i e d by s a t i s f a c t o r i l y completing t h e q u a l i f i c a t i o n t e s t s of 4.4.3.
MIL-STD-Lb87A
~
__
MF
=~
7777711 0088132 O
~
~ ~ ~~ ~
~~
~~
__
i _
MIL-STD-l687A(SH) 11 February 1987 Q u a l i f i c a t i o n t e s t i n g may a l s o be r e q u i r e d a t any t i m e a n 4.4.5.6.3 o p e r a t o r ' s performance is q u e s t i o n a b l e as evidenced by documented r e j e c t e d d a t a o r as r e q u e s t e d by NAVSEA o r i t s d e l e g a t e d r e p r e s e n t a t i v e . 4.4.6 Records f o r o p e r a t o r q u a l i f i c a t i o n . Records of q u a l i f i c a t i o n and r e q u a l i f i c a t i o n t e s t d a t a r e s u l t s and a n n u a l eye examination r e s u l t s s h a l l be maintained by the t h e r m a l s p r a y shop o r a c t i v i t y , and s h a l l be s u b j e c t t o review and a u d i t by NAVSEA o r a u t h o r i z e d a g e n t . 4.5 Quality control.
4.5.1 In-process i n s p e c t i o n . I n - p r o c e s s i n s p e c t i o n of each s p r a y e d component s h a l l a s s u r e , as a minimum, v e r i f i c a t i o n of t h e anchor-tooth p r e p a r e d s u r f a c e w i t h a p r o f i l e t a p e test; no m o i s t u r e , o i l , g r i t , contaminants, b l i s t e r s , c r a c k s , c h i p s , p i t s , o r c o a t i n g s e p a r a t i o n are p r e s e n t b e f o r e o r d u r i n g s p r a y i n g ; c o a t i n g t h i c k n e s s p e r p a s s conforms t o t h e procedure, i f t h i s i s a n e s s e n t i a l element; and t h e c o a t i n g m a n u f a c t u r e r ' s recommended t e m p e r a t u r e range i s maintained. 4,5.2 End i t e m requirement. as s p e c i f i e d i n the c o n t r a c t . I n s p e c t i o n and t e s t i n g of end i t e m s h a l l be
4.5.2.1 I n s p e c t i o n . As a minimum, t h e end i t e m i n s p e c t i o n of sprayed c o a t i n g s s h a l l i n c l u d e a v i s u a l examination. The f i n i s h e d c o a t i n g , when examined w i t h a 1OX m a g n i f i c a t i o n , s h a l l be f r e e of d e f e c t s s u c h as c r a c k s , b l i s t e r s , c h i p s o r loosely-adhering p a r t i c l e s , o i l o r o t h e r contaminants which b l e e d o u t through the c o a t i n g , p i t s exposing t h e undercoat o r s u b s t r a t e , and c o a t i n g s e p a r a t i o n . The i t e m s h a l l be checked f o r c o r r e c t dimensions.
T e s t specimens f o r q u a l i t y c o n t r o l . P r i o r t o commencement of each 4.5.3 day's p r o d u c t i o n , a bend test specimen s h a l l be p r e p a r e d i n accordance w i t h 4.6.1.2 and t e s t e d i n accordance w i t h 4.6.4; t h e specimen s h a l l meet t h e r e q u i r e ments of 4.3.3.1. I n the e v e n t of f a i l u r e , the cause s h a l l be i d e n t i f i e d and the problem c o r r e c t e d , and a n o t h e r specimen s h a l l be sprayed and t e s t e d as above. The s p r a y procedure should b e changed as needed t o p r e v e n t f u t u r e f a i l u r e . When s p e c i f i e d by the c o n t r a c t , q u a l i t y c o n t r o l of i t e m s used i n c r i t i c a l a p p l i c a t i o n s s h a l l i n c l u d e t e s t i n g of specimens which are prepared d u r i n g t h e p r o d u c t i o n r u n and are r e p r e s e n t a t i v e of t h e p r o d u c t i o n p a r t whenever p o s s i b l e . The q u a l i t y c o n t r o l t e s t i n g , the sampling p l a n ( f o r s p r a y i n g of m u l t i p l e i t e m s ) and t h e r e q u i r e m e n t s f o r t h e specimens s h a l l be as s p e c i f i e d i n t h e c o n t r a c t .
4.6 4.6.1
T e s t procedures.
P r e p a r a t i o n of t e s t specimens.
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4.6.1.1 Specimens f o r m i c r o s c o p i c examination. P a n e l s approximately 3 by 2 inches by 0.050 i n c h (minimum) s h a l l be sprayed on one of t h e l a r g e f a c e s u s i n g t h e a p p r o p r i a t e s p r a y i n g procedure and m e t a l s u b s t r a t e . The c o a t i n g t h i c k n e s s shall be 0.008 i n c h (minimum).
13
MIL-STD-Lb87A
UP
7 7 7 7 7 3 3 0088333 2 W
_____
MIL-STD-l687A(SH) 11 February 1987 4.6.1.2 Specimens f o r v i s u a l and bend t e s t s . Panels approximately 3 by 2 inches by 0.050 i n c h (minimum) t o 0.063 i n c h (maximum) s h a l l be sprayed on one
of t h e l a r g e f a c e s u s i n g t h e a p p r o p r i a t e s p r a y i n g procedure and metal s u b s t r a t e . The c o a t i n g t h i c k n e s s s h a l l be 0.008 5 0.002 i n c h , o r t h e maximum t h i c k n e s s recommended by t h e c o a t i n g manufacturer, whichever i s smaller. Two-coat samples s h a l l have 0.002 t o 0.003 i n c h bond c o a t and a t l e a s t 0.005 i n c h t o p coat.
4.6.1.3 Specimens f o r bond t e s t . i n accordance w i t h ASTM C 633.
Specimens s h a l l be machined and tested
4.6.2 Visual examination. Each of t h e as-sprayed specimens s h a l l be examined a t 20 t o 50X magnification. 4.6.3 Microscopic examination. Por microscopic examination, a s e c t i o n 0.75 t o 1.00 i n c h long - by - 0.25 t o 0.50 i n c h wide s h a l l be c u t from each of t h e prepared panels. The s e c t i o n s h a l l be mounted on t h e longer s i d e of t h e crossCross-sections s h a l l be examined s e c t i o n and t h e n prepared m e t a l l o g r a p h i c a l l y . a t 100 t o 200X m a g n i f i c a t i o n f o r t h e f i n a l examination. The oxide and p o r o s i t y c o n t e n t s s h a l l be determined by t h e u s e of l i n e - i n t e r c e p t , grid-area, o r o p t i c a l comparison techniques, o r by using comparison photographs, as shown on f i g u r e 5 . Bend t e s t . The sprayed panels s h a l l be bent approximately 180 4.6.4 degrees on a 1/2-inch diameter rod. The c o a t i n g s h a l l be on t h e t e n s i l e s i d e of t h e bend. The bend specimen s h a l l be examined v i s u a l l y without t h e a i d of magnification.
4.6.5
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Bond test.
4.6.5.1 Spraying. Spraying s h a l l be performed u s i n g t h e a p p r o p r i a t e procedure and s u b s t r a t e . Areas n o t t o be sprayed s h a l l be masked on t h e o u t e r diameter t o prevent overspraying. The as-sprayed t h i c k n e s s s h a l l be g r e a t e r t h a n 0.015 inch. 4.6.5.2 Application. The c o a t i n g s h a l l be a p p l i e d as evenly and uniformly as p o s s i b l e t o maintain t h e squarenecs of t h e machined t e s t specimen. I f t h e squareness of t h e machined specimen cannot be maintained during t h e c o a t i n g , g r i n d i n g i s p e r m i s s i b l e t o r e s t o r e t h e squareness, provided t h e c o a t i n g t h i c k n e s s i s not reduced below t h e minimum t h i c k n e s s s t i p u l a t e d by t h e manufacturer. A f t e r g r i n d i n g , t h e specimen may be cleaned by vapor degreasing o r s o l v e n t washing. 5.
DETAILED REQUIREMENTS
5.1
5 . 1 . 1
Equipment, Spraying systems.
5.1.1.1 Wire oxygen-fuel gas spray. Equipment f o r t h e wire spray system s h a l l meet t h e requirements i n accordance w i t h MIL-M-3800. The atomizing a i r s h a l l meet t h e requirements of 5.lm2@l.
14
=~
= =
- ~~~
~=
= - =
= -
5.1.1.2 Powder oxygen-fuel g a s spray. The powder s p r a y system s h a l l i n c l u d e t h e powder s p r a y gun, n e c e s s a r y h o s e s , flowmeter, f u e l g a s and oxygen r e g u l a t o r s , and mechanical o r a s p i r a t o r f e e d f o r powder. Equipment s h a l l m e e t t h e requirements s p e c i f i e d i n MIL-M-80141.
5.1.1.3 A r c spray. The e l e c t r i c arc system s h a l l c o n s i s t of a n electric arc gun, flowmeter, compressed a i r , power s u p p l y u n i t and w i r e c o n t r o l u n i t .
Conversion Equipment s h a l l m e e t t h e requirements s p e c i f i e d i n MIL-M-80226. u n i t s t o a d a p t e x i s t i n g s u i t a b l e power s o u r c e s f o r e l e c t r i c arc s p r a y i n g are The a l s o a c c e p t a b l e as l o n g as performance i s i n accordance w i t h MIL-M-80226. atomizing a i r s h a l l meet t h e r e q u i r e m e n t s of 5.1.2.1. 5.1.1.4 Plasma spray. The plasma arc s p r a y system s h a l l i n c l u d e a plasma s p r a y gun, power u n i t , c o n t r o l c o n s o l e and f e e d hopper. Equipment s h a l l meet t h e requirements s p e c i f i e d i n MIL-P-80109. 5.1.1.5 Thermal s p r a y systems. Equipment n o t covered by t h e M i l i t a r y S p e c i f i c a t i o n s s p e c i f i e d i n 5.1.1.1 through 5.1.1.4 s h a l l be q u a l i f i e d by t h e performing a c t i v i t y . 5.1.2 Abrasive b l a s t i n g equipment.
sary t o roughen areas which are t o be t h e r m a l sprayed.

s h a l l meet t h e requirements of 5.2.2 i n a n t s.
5.1.2.1 Air equipment. The a i r equipment used f o r t h e a b r a s i v e b l a s t , wire-oxygen-fuel g a s s p r a y and arc s p r a y p r o c e s s e s s h a l l u t i l i z e a i r having a maximum of 5 m i l l i g r a m s condensed hydrocarbons p e r c u b i c meter and a dew p o i n t of p l u s 14'F o r lower a t s t a n d a r d t e m p e r a t u r e and p r e s s u r e (68'F, 14.5 l b / i n 2 a b s o l u t e ) p r i o r t o t h e f i n a l f i l t e r i n g and m o i s t u r e s e p a r a t i o n u n i t . S t a n d a r d s For a b r a s i v e b l a s t i n g , minimum a i r which a p p l y are ASTM D 4285 and BB-A-1034. p r e s s u r e a t t h e b l a s t g e n e r a t o r of 50 l b / i n 2 and 75 l b / i n 2 i s r e q u i r e d f o r p r e s s u r e t y p e and s u c t i o n t y p e b l a s t i n g u n i t s , r e s p e c t i v e l y . 5.1.3 F i x t u r i n g f o r mechanical p o s i t i o n i n g . F i x t u r e s f o r mechanical p o s i t i o n i n g s h a l l be used whenever p o s s i b l e t o s u p p o r t t h e work piece and t h e r m a l s p r a y gun i n o r d e r t o m a i n t a i n a c o n s t a n t , c o n t r o l l a b l e and r e p e a t a b l e gun-towork d i s t a n c e and angle. R e l a t i v e movement between work piece and gun s h a l l be a c c u r a t e l y c o n t r o l l e d and t h e p r o p e r s u r f a c e f e e t p e r minute maintained, as s p e c i f i e d i n t h e approved procedure. 5.2 Facilities.
5.2.1 Working areas. The f o l l o w i n g minimum r e q u i r e m e n t s s h a l l be m e t f o r t h e r m a l s p r a y working areas. 5.2.1.1 Abrasive b l a s t i n g areas. I f a b r a s i v e b l a s t i n g i s c a r r i e d o u t i n a n e n c l o s e d area o t h e r t h a n a d e s i g n a t e d b l a s t i n g booth, t h e a i r i n t h e e n c l o s e d areas s h a l l change a t least once p e r minute. A d d i t i o n a l s a f e b r e a t h i n g a p p a r a t u s ( o p e r a t o r ' s hood) s h a l l be used.
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Abrasive b l a s t i n g equipment i s necesAbrasive b l a s t equipment and s h a l l be f r e e of o i l and o t h e r contam-
15
MIL-STD-Lb87A
MF
9 7 9 7 9 3 3 00881i35 b
5.2.1.2
Thermal s p r a y i n g areas.
5.2.1.2.1 Enclosed areas. Enclosed areas s h a l l be equipped w i t h p o s i t i v e exhaust and wet d u s t c o l l e c t o r systems which provide adequate a i r flow i n accordance w i t h A W S OPP and CFR 29, p a r t 1910.107. An a i r r e s p i r a t o r mask and eye and ear p r o t e c t i o n s h a l l be provided f o r t h e o p e r a t o r . 5.2.1.2.2 Open areas. Thermal s p r a y i n g i n open areas s h a l l be c a r r i e d o u t o n l y when t h e components t o be sprayed are adequately p r o t e c t e d and t h e d u s t and n o i s e do n o t i n t e r f e r e w i t h a d j a c e n t o p e r a t i o n s . 5.2.2 Abrasive b l a s t i n g equipment. T h e . f o l l o w i n g l i s t of equipment i d e n t i f i e s t h e minimum r e q u i r e d f o r performing a b r a s i v e b l a s t i n g o p e r a t i o n s . Equipment s h a l l be i n s a t i s f a c t o r y working o r d e r . Gauges s h a l l be p r o p e r l y c a l i b r a t e d .
Blaster u t i l i z i n g a i r f r e e of o i l and m o i s t u r e according t o 5.1.2.1. S t e e l b l a s t i n g t a b l e o r cabinet. O i l and moisture s e p a r a t o r . A i r p r e s s u r e r e g u l a t o r s w i t h p r e s s u r e gauges. P r o f i l e tape. Blast n o z z l e equipped w i t h a dead-man switch. Abrasive ( s e e 5.3.3). Sample metal coupons. Caliper o r d i a l micrometer.
5.2.3 Thermal s p r a y equipment. The l i s t of equipment f o r thermal s p r a y o p e r a t i o n s s h a l l meet t h e requirements of 5.1.1 f o r t h e a p p l i c a b l e s p r a y i n g system. Equipment s h a l l be i n s a t i s f a c t o r y working o r d e r . Gauges and f l o w meters s h a l l be p r o p e r l y c a l i b r a t e d , and a l l gas and a i r connections s h a l l be soap t e s t e d f o r l e a k s every 3 months. I n - l i n e water and oil f i l t e r s s h a l l be l o c a t e d between t h e compressor and t h e metal s p r a y equipment. These f i l t e r s s h a l l be p e r i o d i c a l l y i n s p e c t e d and s e r v i c e d t o a s s u r e d e l i v e r y of uncontaminated d r y air. When g r e a t e r c o n t r o l i s r e q u i r e d , automatic dew p o i n t measuring i n s t r u ments w i t h feedback t o c o n t r o l t h e q u a l i t y of a i r s h a l l be i n s t a l l e d . O p t i o n a l equipment may be r e q u i r e d as s p e c i f i e d i n t h e c o n t r a c t f o r s p e c i a l a p p l i c a t i o n i n accordance w i t h MIL-M-3800. 5.2.4 P r o t e c t i v e equipment. worn by thermal spray o p e r a t o r s .
(a) (b) (c) (d)
The f o l l o w i n g p r o t e c t i v e equipment s h a l l be
Air r e s p i r a t o r . Noise p r o t e c t i o n ( e a r muffs and p l u g s ) . Eye p r o t e c t i o n . Protective clothing.

F i x t u r i n g f o r mechanical
5.2.5 F i x t u r i n g f o r mechanical p o s i t i o n i n g . p o s i t i o n i n g s h a l l be as s p e c i f i e d i n 5.1.3.
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MIL-STD-3687A flF
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77777LL 0088336 8 m
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5.3
Materials.
Coating materials.
5.3.1
5.3.1.1 Coating type. The c o a t i n g material s h a l l be as s p e c i f i e d i n t h e c o n t r a c t o r by e n g i n e e r i n g p e r s o n n e l of t h e performing a c t i v i t y .

Thermal s p r a y w i r e and powder. Wire and powder used f o r t h e r m a l 5.3.1.2 s p r a y i n g s h a l l be i n accordance w i t h MIL-W-6712 o r MIL-P-83348, r e s p e c t i v e l y . Materials n o t i n c l u d e d i n MIL-W-6712 o r MIL-P-83348 may be used, p r o v i d i n g a q u a l i f i e d s p r a y procedure h a s been e s t a b l i s h e d f o r t h e material ( s e e 4.3). Wire and powder s h a l l be t h e same as s p e c i f i e d i n t h e p r o c e d u r e t o be used.
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5.3.1.3 S t o r a g e , i d e n t i f i c a t i o n , and s e p a r a t i o n of w i r e and powder. Stored w i r e and powder s h a l l be p r o t e c t e d from environments t h a t can harm t h e q u a l i t y of sprayed c o a t i n g s . Powder s u s p e c t e d of b e i n g contaminated by f o r e i g n matter s h a l l n o t be used. S t o r a g e recommendations of t h e c o a t i n g manufacturer s h a l l be followed. Powders s h a l l be shaken p r i o r t o u s e t o b r e a k up any s e g r e g a t i o n o r agglomeration t h a t may have o c c u r r e d d u r i n g s t o r a g e . The c o n t e n t s of powder c o n t a i n e r s and w i r e reels s h a l l be i d e n t i f i e d .
5.3.2 Thermal s p r a y gases.
5.3.2.1 For flame s p r a y i n g . The g a s e s l i s t e d below are recommended f o r flame s p r a y i n g . Other g a s e s may be used f o r a s p r a y procedure i f t h a t s p r a y procedure has been q u a l i f i e d f o r t h a t g a s .
7
Gas
Specification BB-0-925 BB-A-106 Commercial Commercial
Oxygen Acetylene 5.3.2.2 For plasma s p r a y i n g .
Gases f o r t h e plasma s p r a y p r o c e s s s h a l l be
Specification
as follows:
Gas
Hydrogen
N it r o g e n
Argon Helium
BB-H-886 P r e - p u r i f i e d 99.95 p e r c e n t Maximum oxygen c o n t e n t 0.05 p e r c e n t Pre-purified Maximum oxygen c o n t e n t 0.002 p e r c e n t MIL-A- 1845 5 High p u r i t y Maximum dewpoint minus 76'F BB-H-1168, g r a d e A
5.3.3 Abrasive b l a s t i n g p a r t i c l e s . Abrasive b l a s t i n g p a r t i c l e s used f o r s u r f a c e p r e p a r a t i o n s h a l l be aluminum o x i d e g r i t t o p r o v i d e t h e anchor t o o t h p a t t e r n f o r thermal s p r a y a p p l i c a t i o n . C h i l l e d a n g u l a r i r o n g r i t may be used only on carbon and low a l l o y s t e e l s and aluminum s u b s t r a t e s . The aluminum o x i d e p a r t i c l e s s h a l l have a 16 t o 30 mesh s i z e . The c h i l l e d i r o n g r i t s h a l l have a 25 t o 40 mesh s i z e .
L i -
17
I _
I m _ _ _ -
MIL-STD-Lh7A
-MF W 9 7 9 7 9 3 3 0088137 T W
MIL-STD-l687A(SH) 11 February 1987 5.3.3.1 Requirements. Abrasive p a r t i c l e s s h a l l be c l e a n , d r y , s h a r p , and f r e e of e x c e s s i v e f i n e s . Excessive f i n e s are d e f i n e d as g r e a t e r t h a n 25 p e r c e n t fines
5.3.3.2 R e s t r i c t i o n s . Abrasive p a r t i c l e s s h a l l not c o n t a i n any f e l d s p a r o r o t h e r mineral c o n s t i t u e n t s t h a t tend t o break down and remain on t h e s u r f a c e . Abrasive p a r t i c l e s t h a t may have been used f o r c l e a n i n g h e a v i l y contaminated s u r f a c e s s h a l l n o t be used f o r f i n a l s u r f a c e p r e p a r a t i o n , even though t h e G r i t t h a t i s n o t i c e a b l y worn o r d u l l when coma b r a s i v e has been rescreened. pared with new g r i t under a m a g n i f i c a t i o n of 1 O X s h a l l n o t be used. 5.3.4 Masking materials.
5.3.4.2 For thermal spraying. Tapes, l i q u i d masking compounds, s i l i c o n e rubber o r metal s h i e l d i n g may be used as thermal spraying masking materials. Tapes used f o r spray masking s h a l l be designed f o r high temperature use. Materials s h a l l n o t cause c o r r o s i o n o r contamination of t h e sprayed c o a t i n g s . 5.3.4.3 I r r e g u l a r shapes. For i n s t a n c e s when h o l e s , s l o t s , keyways o r o t h e r types of recesses cannot be p r o t e c t e d by tapes o r s h i e l d s , i n s e r t s of These i n s e r t s are l e f t i n p l a c e d u r i n g a b r a s i v e carbon o r metal may be used. b l a s t i n g and spraying, and may be removed upon completion of s u r f a c e f i n i s h i n g . 5.3.5 Sealants. specific application. 5.4 Process. The s e a l a n t , i f r e q u i r e d , s h a l l be s p e c i f i e d f o r each
5.4.1 Surface condition. Areas t o be thermal sprayed, and a d j a c e n t areas, s h a l l be f r e e from g r e a s e , o i l , p a i n t , c o r r o s i o n products, moisture, o r any o t h e r substance which may contaminate t h e coating. 5.4.1.1 Solvent c l e a n i n g . P r i o r t o any b l a s t i n g o r s p r a y i n g , a l l s u r f a c e s which have come i n c o n t a c t w i t h any o i l o r g r e a s e s h a l l be s o l v e n t cleaned. Vapor degreasing i s p r e f e r r e d ; however, s o l v e n t washing may be used. S o l v e n t s s h a l l not cause any d e t r i m e n t a l a t t a c k s of t h e s u b s t r a t e material o r l e a v e any r e s i d u e f i l m on t h e s u b s t r a t e . T r i c h l o r o e t h a n e in accordance w i t h 0-T-620, o r t o l u e n e i n accordance w i t h TT-T-548 are a c c e p t a b l e c l e a n e r s . Due t o t h e flammable and t o x i c n a t u r e of most s o l v e n t s , proper p r e c a u t i o n s , such as adequate v e n t i l a t i o n s h a l l be followed d u r i n g s o l v e n t c l e a n i n g (see 5.4.8 f o r s a f e t y p r e c a u t i o n s ) . Precautions s h a l l a l s o be e x e r c i s e d t o p r o t e c t any p a r t s which may be a t t a c k e d by t h e s o l v e n t s . Any anchor t o o t h s u r f a c e t h a t h a s come i n c o n t a c t w i t h o i l o r g r e a s e s h a l l be s o l v e n t cleaned o r vapor degreased and t h e n r e b l a s t e d f o r new anchor tooth.
18
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5.3.4.1 For a b r a s i v e b l a s t i n g . Any masking material which provides adeq u a t e p r o t e c t i o n of t h e s u b s t r a t e and does n o t cause c o r r o s i o n o r contamination of t h e spray c o a t i n g o r s u b s t r a t e may be used. Following a b r a s i v e b l a s t i n g , any masking material which i s u n s u i t a b l e as a masking material f o r t h e thermal s p r a y process s h a l l be removed.
MIL-STD-Lb87A NF I77977L3 0088338 L

5.4.1.2 Heat c l e a n i n g . Porous materials which have been contaminated w i t h g r e a s e o r o i l s h a l l be s o l v e n t cleaned and t h e n h e a t e d f o r 4 hours t o c h a r and S t e e l c a s t i n g s s h a l l be h e a t e d d r i v e o u t t h e f o r e i g n materials from t h e pores. a t 650F maximum. For h e a t - t r e a t a b l e n o n f e r r o u s a l l o y s , e n g i n e e r i n g p e r s o n n e l of t h e performing a c t i v i t y s h a l l be c o n t a c t e d f o r baking temperature range.
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5.4.2
Machining f o r s u r f a c e p r e p a r a t i o n .
5.4.2.1 Undercutting. The s u b s t r a t e s h a l l be undercut when n e c e s s a r y , as l i s t e d below. The undercut s h a l l be l i m i t e d t o a d e p t h t h a t w i l l n o t reduce t h e component s t r e n g t h ( s e e 5.5.1.1). (a) (b) (c) Allow f o r a uniform f i n i s h c o a t i n g t h i c k n e s s . Remove e x i s t i n g sprayed o r p l a t e d c o a t i n g s . Remove damaged o r Contaminated base metal.
5.4.2.2 Threading o r grooving of c y l i n d r i c a l s u r f a c e s . For heavy b u i l d u p , t h e s u b s t r a t e may be threaded o r grooved t o c o u n t e r a c t s h r i n k a g e stresses i n t h e c o a t i n g . The s u b s t r a t e should be undercut b e f o r e t h r e a d i n g . A s m a l l r a d i u s s h a l l be machined a t t h e r o o t of each t h r e a d , o r U-shaped grooves s h a l l be used. The s u b s t r a t e s h a l l be a b r a s i v e b l a s t e d a f t e r t h r e a d i n g . 5.4.2.3 Shoulders. A t each of t h e undercut s e c t i o n s on a c y l i n d r i c a l p a r t , t h e s h o u l d e r s s h a l l be c u t a t a n a n g l e of 15 t o 45 degrees. D o v e t a i l s s h a l l n o t be used. A r a d i u s of 0.015 t o 0.020 i n c h should be c u t a t t h e c o r n e r of t h e undercut
5.4.2.3.1 The undercut s h o u l d n o t extend t o t h e end of t h e s h a f t . A w e l d bead may be d e p o s i t e d a t t h e end of t h e s h a f t t o p r o v i d e a s h o u l d e r , i f no mechanical o r m e t a l l u r g i c a l damage t o t h e s u b s t r a t e i s caused. 5.4.3 Masking, Masking s h a l l be performed on a l l a d j a c e n t areas which may be exposed o r a f f e c t e d by t h e b l a s t i n g o r thermal s p r a y i n g process. 5.4.4 Abrasive b l a s t i n g f o r s u r f a c e p r e p a r a t i o n . P r i o r t o t h e r m a l s p r a y i n g , t h e s u r f a c e s t o be coated s h a l l be prepared by a b r a s i v e b l a s t i n g t o a c l e a n metal s u r f a c e and a 2 t o 3 m i l s anchor-tooth s u r f a c e p r o f i l e . When d i s t o r t i o n may be encountered due t o t h e p a r t c o n f i g u r a t i o n , the anchor-tooth p a t t e r n may be reduced t o a 1 mil p r o f i l e , minimum, provided t h e o t h e r t e s t s (such as bend and bond t e s t s ) meet requirements. 5.4.4.1 P r i o r t o r e u s e , the aluminum o x i d e s h a l l be screened u s i n g a 30-mesh s c r e e n , v i s u a l l y i n s p e c t e d f o r d e b r i s and o i l contamination, and s h a l l p a s s t h e f o l l o w i n g oil-contamination t e s t : (a) (b) (c) (d) (e) F i l l a c l e a n 1 5 0 - m i l l i l i t e r (mL) (5-ounce) v i a l o r b o t t l e h a l f f u l l of screened a b r a s i v e particles. F i l l t h e remainder of t h e v i a l o r b o t t l e w i t h c l e a n water. Cap and shake v i a l o r b o t t l e . Inspect: water f o r o i l sheen. I f any o i l i s observed, t h e a b r a s i v e p a r t i c l e s s h a l l n o t be used i n t h e f i n a l anchor-tooth b l a s t i n g process. Clean b l a s t i n g equipment, r e p l a c e b l a s t i n g material, and retest.
(f)
-9 Provided by IHS No reproduction or networking permitted without license from IHS
- -.
19
MIL-STD-Lb7A MF U 7777721 0088L37 3 U

MIL-STD-l687A(SH) 11 February 1987 5 . 4 . 4 . 2 The b l a s t e d s u r f a c e s h a l l have a white metal b l a s t appearance w i t h . 4 . 4 and v a l i d a t e d an anchor-tooth ( n o t peened) s u r f a c e p r o f i l e a s s p e c i f i e d i n 5 (measured) w i t h p r o f i i e t a p e and a d i a l micrometer. B l a s t i n g s h a l l be done i n accordance w i t h SSPC 5. A w h i t e metal b l a s t cleaned s u r f a c e f i n i s h i s d e f i n e d as a s t e e l s u r f a c e w i t h a gray-white, uniform metallic c o l o r , s l i g h t l y roughened t o form a s u i t a b l e anchor p a t t e r n f o r c o a t i n g s . The s u r f a c e s h a l l be f r e e of o i l , g r e a s e , d i r t , m i l l scale, r u s t , c o r r o s i o n p r o d u c t s , o x i d e s , p a i n t , o r any o t h e r f o r e i g n matter. The c o l o r of t h e c l e a n s u r f a c e may be a f f e c t e d by t h e p a r t i c u l a r a b r a s i v e medium used. Photographic o r o t h e r v i s u a l s t a n d a r d s of s u r f a c e preparat i o n s h a l l be used t o f u r t h e r d e f i n e t h e s u r f a c e i f s p e c i f i e d i n t h e c o n t r a c t o r order. Abrasive b l a s t e d s u r f a c e s s h a l l n o t be allowed t o come i n c o n t a c t w i t h contaminated s u r f a c e s p r i o r t o completion of metal spray and s e a l i n g processes. Prepared s u r f a c e s s h a l l be handled only w i t h c l e a n g l o v e s , r a g s , o r s l i n g s . Contact w i t h any o i l o r g r e a s e (such as touching w i t h a bare hand) may r e s u l t i n f a i l u r e of t h e coating. The s l i g h t e s t presence of o i l , o x i d a t i o n o r o t h e r f o r e i g n material on t h e s u r f a c e t o be sprayed may r e s u l t i n s e p a r a t i o n of t h e thermal spray coating. The b l a s t e d s u r f a c e i s r e j e c t a b l e i f t h e w h i t e metal b l a s t condition i s l o s t . 5 . 4 . 5
Spraying.
The spraying o p e r a t i o n s h a l l be s t a r t e d w i t h i n 2 hours a f t e r prepa5 . 4 . 5 . 1 r a t i o n of t h e s u r f a c e h a s been completed. I f more t h a n 15 minutes, but n o t over 2 hours, i s expected t o e l a p s e between t h e p r e p a r a t i o n of t h e s u r f a c e and t h e s p r a y i n g o p e r a t i o n , o r where t h e p a r t s h a l l be removed t o a n o t h e r l o c a t i o n , t h e prepared s u r f a c e s h a l l be p r o t e c t e d from o x i d a t i o n and contamination and from h a n d l i n g and fingermarks. Wrapping w i t h c l e a n paper ( f r e e of newsprint) w i l l I f more than 2 hours e l a p s e between s u r f a c e u s u a l l y provide adequate p r o t e c t i o n . p r e p a r a t i o n and spraying, o r i f o x i d a t i o n o r contamination from any o t h e r s o u r c e occurs, t h e n t h e s u r f a c e s h a l l be cleaned and re-anchor-tooth b l a s t e d .
5 . 4 . 5 . 2 Components s h a l l n o t be sprayed i f t h e s u b s t r a t e temperature i s below 6 0 ' F , o r i f t h e s u b s t r a t e temperature i s less t h a n 10'F above t h e dew p o i n t of t h e ambient a i r . Wherever p o s s i b l e ( o r p r a c t i c a l ) t h e work s h a l l be 2 5 ' F t o e l i m i n a t e s u r f a c e moisture. Higher p r e h e a t s (350'F) preheated t o 200 t o 2 may be r e q u i r e d on a case b a s i s f o r s p e c i f i c s u b s t r a t e s o r c o a t i n g s which may develop d e f e c t s due t o t h i c k n e s s of c o a t i n g , thermal g r a d i e n t s , o r d i f f e r e n c e s i n c o e f f i c i e n t s of expansion. Temperature r e a d i n g s s h a l l be taken u s i n g a c o n t a c t pyrometer; temperature s t i c k s o r similar devices s h a l l not be used as d e t r i m e n t a l material contamination w i l l r e s u l t . I f p r e h e a t i n g i s done w i t h a gas flame, t h e flames s h a l l n o t be d i r e c t l y a p p l i e d onto t h e area t o be sprayed t o avoid p o s s i b l e s u r f a c e o x i d a t i o n and contamination by carbon d e p o s i t s . Gas flame p r e h e a t i n g i s a c c e p t a b l e i f t e s t specimens t h a t are preheated w i t h a gas flame pass t h e i r r e s p e c t i v e t e s t c r i t e r i a .
The spraying o p e r a t i o n s h a l l be i n t e r r u p t e d only t o measure thick5 . 4 . 5 . 3 n e s s o r temperature, t o change spraying material from bond o r undercoat t o f i n i s h c o a t , o r t o permit cooling t o prevent overheating. During s p r a y i n g , t h e temperat u r e of t h e work s h a l l n o t exceed 3 5 0 ' F o r t h e tempering o r aging temperature of t h e s u b s t r a t e , whichever i s lower. Cooling may be accomplished by use of b l a s t of c l e a n , dry a i r , carbon d i o x i d e o r o t h e r s u i t a b l e gas introduced n e a r , but n o t d i r e c t l y upon, t h e area being sprayed.
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20
MIL-STD-l687A(SH) 11 February 1987 5.4.5.4 The d i r e c t i o n of t h e t h e r m a l s p r a y s h a l l be as c l o s e as p o s s i b l e t o a n a n g l e of 90 degrees w i t h t h e s u r f a c e b e i n g c o a t e d and n o t less t h a n 45 degrees
5.4.5.5 The work s h a l l be allowed to c o o l normally t o room temperature a f t e r s p r a y i n g i s completed. I f i t i s n e c e s s a r y t o c o o l t h e work more q u i c k l y , a b l a s t of a i r , carbon d i o x i d e o r o t h e r s u i t a b l e g a s may be d i r e c t e d o n t o t h e work. The b l a s t s h a l l be maneuvered t o o b t a i n a uniform c o o l i n g r a t e over t h e e n t i r e s e c t i o n . There s h a l l n o t be any quenching w i t h l i q u i d .
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---
5.4.6 A p p l i c a t i o n of sealant. Thermal sprayed c o a t i n g s s h a l l be s e a l e d a f t e r s p r a y i n g and a g a i n a f t e r f i n i s h i n g t o minimize c o r r o s i o n of t h e s u b s t r a t e . The p a r t i c u l a r s e a l a n t s e l e c t e d w i l l depend on t h e maximum u s e temperature of t h e component and t h e purpose of s e a l i n g t h e c o a t i n g s . Some a p p l i c a t i o n s may n o t r e q u i r e t h a t a s e a l a n t be u s e d , b u t e l i m i n a t i o n of t h e s e a l a n t r e q u i r e s NAVSEA approval. 5.4.7 S u r f a c e f i n i s h i n g . S u r f a c e f i n i s h i n g s h a l l be used t o o b t a i n t h e s p e c i f i e d dimensions and t o provide a f i n e r s u r f a c e f i n i s h t h a n t h e as-sprayed c o n d i t i o n . Coatings may be used i n t h e as-sprayed c o n d i t i o n whenever p e r m i t t e d . The s e l e c t i o n o r f i n i s h i n g method depends on t h e t y p e , h a r d n e s s , and t h i c k n e s s of t h e c o a t i n g . The p r e f e r r e d method i s g r i n d i n g ; w e t g r i n d i n g i s recommended. S o f t materials, such as bronze and b a b b i t t , may be s i n g l e - p o i n t machined.
Care s h a l l be t a k e n i n any machining o r g r i n d i n g o p e r a t i o n i n 5.4.7.1 o r d e r t o avoid damage t o t h e c o a t i n g . Improper t e c h n i q u e s d u r i n g t h e f i n i s h i n g o p e r a t i o n could r e s u l t i n p u l l - o u t of p a r t i c l e s , t h u s producing a s e v e r e l y p i t t e d s u r f a c e o r h e a t checking. The sprayed p a r t i c l e s s h a l l be c l e a n l y s h e a r e d and n o t p u l l e d from t h e s u r f a c e as a r e s u l t of t h e f i n i s h i n g o p e r a t i o n .
5.4.8
Safety precautions.
S a f e t y p r a c t i c e s s h a l l be as f o l l o w s .
5.4.8.1 Thermal s p r a y i n g , l i k e any o t h e r i n d u s t r i a l p r o c e s s h a s i t s i n h e r e n t hazards. P o t e n t i a l h a z a r d s i n c l u d e vapors, d u s t s and fumes, g a s e s , t h e w i r e s p r a y gun, n o i s e and arc u l t r a v i o l e t r a d i a t i o n . These h a z a r d s can be e l i m i n a t e d o r minimized when proper s a f e t y p r e c a u t i o n s are taken. The r e q u i r e ments of AWS OPP s h a l l be complied w i t h .
5.4.8.2 Approved s o l v e n t s (such as, t o l u e n e , t r i c h l o r o e t h a n e and a l c o h o l ) have vapors t h a t are harmful and can be f a t a l ; and, t h e r e f o r e , s h a l l be used o n l y w i t h adequate v e n t i l a t i o n . Prolonged b r e a t h i n g of vapors and r e p e a t e d c o n t a c t of s o l v e n t w i t h t h e s k i n s h a l l be avoided. Toluene and a l c o h o l are a l s o flammable l i q u i d s and proper p r e c a u t i o n a r y measures s h a l l be taken. 5.4.8.3 Before opening any gas v a l v e , a s s u r e t h e r e i s adequate v e n t i l a t i o n i n t h e work area. Examine a l l gas equipment r e g u l a r l y f o r l e a k s and l o o s e conn e c t i o n s , t i g h t e n i n g o r r e p l a c i n g as necessary. G a s c y l i n d e r s s h a l l be s e c u r e d t o keep them from f a l l i n g . C y l i n d e r s i n u s e s h a l l be k e p t away from t h e t h e r m a l If t h i s is s p r a y o p e r a t i o n s o t h a t molten s p r a y o r flame w i l l n o t r e a c h them. n o t p o s s i b l e , f i r e r e s i s t a n t s h i e l d s s h a l l be provided. When n o t i n u s e , s h u t o f f gas and p l a c e valve c a p s on c y l i n d e r s .
21
=t
NIL-STD-3687A NF
7 9 9 7 9 3 3 0088343
I m
M I L S ' I . W 1 6 8 7 A ( CH) 11 February 1987 5.4.8.4 When abrasive blasting in semi-confined spaces, use face shields with dust hoods or helmets with forced fed purified air, to protect the eyes, face, chin and neck from flying particles. Personnel near blasting operations shall wear protective safety eyewear. 5.4.8.5 Maintain thermal spray guns in accordance with manufacturer's recommendations. Do not light the wire gun without wire in the nozzle as flames may shoot back into the gun causing equipment damage and operator injury. When lighting the gun, use a friction lighter; do not use matches. 5.4.8.6 Both abrasive blasting and thermal spraying generate dusts and fumes, posing a respiratory hazard. Adequate ventilation combined with use of proper personal protection equipment normally provide satisfactory protection. In closed areas, a water wash booth with a positive exhaust system shall be used to minimize the hazardous concentrations of dusts and fumes. Appropriate personal respiratory protection shall be worn during spraying and sealing operations. If operator discomfort such as dizziness or nausea develops, stop spraying. Determine the cause for the discomfort and correct the cause before resuming the spraying process. Noise levels generated by the thermal spray process are sufficient 5.4.8.7 to cause temporary deafness or permanent loss of hearing, and fatigue. Ear muffs and properly fitted soft rubber ear plugs shall be worn by thermal spray operators and personnel in the immediate spray vicinity to reduce the high intensity noise levels to acceptable conditions. Use of cotton wads is specifically prohibited. 5.4.8.8 Infrared, visible and ultraviolet radiation from the thermal spray process can cause eye discomfort and damage. When spraying, a suitable filter plate shall be used with the helmet, face shield or goggles as follows: (a)
('b)
(c)
(d)
WARNING:
Wire flame spraying: Powder flame spraying : Plasma spraying: Wire arc spraying :
Shades Shades Shades Shades
2
3
9 9
-4 - 6 - 12
12
Covers shall be placed over windows of the thermal spray facility when spraying to protect the eyes of personnel working outside or passing by.
5.4.8.9 Flame-resistant clothing and leather or rubber gauntlets shall be worn during thermal spraying to keep harmful flying particles from thermal sprayed materials from skin contact. Aluminized clothing may be used, taking care radiation and ultraviolet light are not reflected onto unprotected skin areas. Care shall also be taken as aluminized clothing may present a danger from electric shock. 5.4.8.10 Operators shall wear protective equipment as specified in 5.2.4.
5.4.8.11 Two persons shall be present at all times during the spraying operation; one inside the spray booth and one outside.
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---
MIL-STD-l687A(SH) 11 February 1987 Thermal s p r a -y applications. General.

_ I -
5.5
5.5.1
Thermal s p r a y c o a t i n g s can be a p p l i e d t o buildup worn o r m i s 5.5.1.1 machined p a r t s and t o improve a b r a s i o n r e s i s t a n c e . Thermal s p r a y c o a t i n g s are n o t intended t o f i l l gouges o r similar l o c a l i z e d damage w i t h o u t b u i l d i n g up t h e e n t i r e area. Thermal s p r a y d e p o s i t s do not r e s t o r e p r o p e r t i e s such as t e n s i l e s t r e n g t h o r r e s i s t a n c e t o f a t i g u e stresses. 5.5.1.2 Information contained i n t h i s s e c t i o n i s p r e s e n t e d f o r the purpose of a s s i s t i n g i n the s e l e c t i o n of a c o a t i n g which would be a p p r o p r i a t e f o r t h e i n t e n d e d a p p l i c a t i o n and also s u i t a b l e t o the c a p a b i l i t i e s of the performing f a c i l i t y . S e l e c t i o n s h a l l be made from t h e p r e s e n t e d l i s t i n g s i n t a b l e s I and II whenever p o s s i b l e . Thermal s p r a y a p p l i c a t i o n s and c o a t i n g s n o t s p e c i f i e d i n tables I and II and 5.5.2 s h a l l r e c e i v e NAVSEA approval on a case-by-case b a s i s b e f o r e spraying.
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---
23
MIL-STD-Lb7A
MF
7 9 7 7 9 3 3 OO343 5 H
MIL-STD- 1687A( SH) 11 February 1987
TABLE II
Recommended s p r a y procedures .L/

I -
S u b s t r a te Carbon, low a l l o y , and stainless steel; Cast i r o n Nickel base alloys
Application Fit
Spray process, 21
Spray mat e r i a 1 code?/
Spray category-4 1
PP FI? FWI F W PPIPP FPI FP PP

FP
P1 P1 Wl/W2 PllP2 PllP2 P3 P3 w 3 P3 1P2 P3lP2 P4 P4 WllW4 P4lP2 P4lP2
4.1 4.1 2.1 214.llt3.1 4.1/8.1 6.1 6.1 6.2
ll_-.l__
Wear, s e a l , erosion
Fit
Fw Wear, s e a l , erosion Bronze Fit
PP/ PP FP/ FP PP FP FW/ F W PPI PP FPI PP
2 1 6.11 8.1
6.118.1 5.1 5.1 5.2
>/5.1/8.1 5.118.1
erosion i/
Wear, s e a l ,
These procedures a r e recommended f o r t h e l i s t e d a p p l i c a t i o n s and s u b s t r a t e s ( o p e r a t o r s must be q u a l i f i e d i n accordance w i t h 4.4.3). Other procedures may be used i f t h e procedures and o p e r a t o r s are q u a l i i e d i n accordance w i t h 4.3 and 4.4.3, r e s p e c t i v e l y . 31 See t a b l e III f o r powder and wire c h e m i s t r i e s . 4 1 Spray c a t e g o r i e s and a s s o c i a t e d bond s t r e n g t h , p o r o s i t y , o x i d e and t h i c k n e s s requirements are g i v e n i n t a b l e I, 5 / The bond s t r e n g t h requirements f o r t h e ceramic t o p c o a t apply ( s p r a y c a t e g o r y 8.1 from t a b l e I).
I
24
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NIL-STD-Lb87A NF
77777LL 0088144 7
MIL-STD-l687A(,SH) 11 February 1987
u
(6
e)
w
d
e)
1 1
c13
al P
$4
5 O
m U
al
al
al
d d
Q
[A
O O LI rl % I
5
H
H
H
Y 8
(d
rl
d
s
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c:
O
Li
.rl
4
[A
a
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& U
25
MIL-STD-1b87A
VF W 9797711 0 0 8 8 1 4 5 9
5.5.2 5.5.2.1
Approved a p p l i c a t i o n s . Machinery. Thermal s p r a y i s approved f o r machinery a p p l i c a t i o n s
on s u r f a c e s h i p s w i t h t h e following e x c e p t i o n s :
(a) (b) (c) (d) (e) Primary and secondary n u c l e a r systems. Main p r o p u l s i o n t u r b i n e s . Ships s e r v i c e t u r b i n e generators. Reduction g e a r s . L i n e s h a f t s and l i n e s h a f t bearings.
5.5.2.1.1 Equipment. P e r m i t t e d a p p l i c a t i o n s on s u r f a c e s h i p s i n c l u d e main feed pumps, f o r c e d d r a f t blowers, and equipment of e q u a l o r lesser c r i t i c a l i t y . Permitted r e p a i r s on t h e s e equipments are: (a) (b) (c) (d) (e) (f) Repair of s t a t i c f i t areas t o r e s t o r e o r i g i n a l dimensions, f i n i s h , and alignment. Repair of seal ( i n c l u d i n g packing) areas t o r e s t o r e o r i g i n a l dimensions and f i n i s h . Repair of f i t areas on s h a f t s t o r e s t o r e o r i g i n a l dimensions and f i n i s h (except f o r motor g e n e r a t o r s e t s ) . Buildup of pump s h a f t s l e e v e s and wear r i n g s t o r e s t o r e o r i g i n a l dimensions. Repair of b e a r i n g s h a f t j o u r n a l s t o r e s t o r e o r i g i n a l dimensions. B a b b i t t b e a r i n g s f o r a u x i l i a r y equipment. Requests f o r
Thermal s p r a y i s not approved f o r r e p a i r of submarine components. d e v i a t i o n s t o t h i s e x c l u s i o n should be addressed t o NAVSEA.
5.5.2.2 Proposed a p p l i c a t i o n s . A p p l i c a t i o n s t h a t are not s p e c i f i e d i n 5.5.2.1 r e q u i r e s p e c i f i c NAVSEA approval. This approval w i l l be based on t h e r e s u l t s of a l a b o r a t o r y o r s e r v i c e t e s t t o determine t h e adequacy of t h e c o a t i n g i n t h e proposed a p p l i c a t i o n .
6.
NOTES
6.1 Intended use. T h i s s t a n d a r d d e f i n e s t h e q u a l i f i c a t i o n , procedure approval, and documentation requirements, and approved a p p l i c a t i o n s f o r thermal s p r a y processes used f o r machinery repair and c o r r o s i o n p r o t e c t i o n ( e x c e p t thermal s p r a y i n g of aluminum f o r c o r r o s i o n p r o t e c t i o n ) of Naval machinery. 6.2 General requirements. (a) (b) (c) (d) (e)
A l l s p r a y i n g a c t i v i t i e s should:
Prepare a w r i t t e n q u a l i t y a s s u r a n c e system document ( s e e 4.1). Obtain NAVSEA c e r t i f i c a t i o n of t h e q u a l i t y a s s u r a n c e system and thermal s p r a y f a c i l i t i e s ( s e e 4.2.1 and 4.2.2). T r a i n and q u a l i f y a l l s p r a y o p e r a t o r s and i n s p e c t o r s ( s e e 4.4). Obtain NAVSEA approval of s p r a y procedures o r demonstrate a b i l i t y t o u s e p r e v i o u s l y approved procedures (see 4.2.3, 4.3.1, and 4.3.4). P r e p a r e and submit sprayed component r e c o r d forms ( s e e 4.1.3, 4.1.4, and 4.1.5).
26
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---
MIL-STD-l687A(SH) 11 February 1987 6.3 Data requirements. When t h i s s t a n d a r d i s used i n a n a c q u i s i t i o n which i n c o r p o r a t e s a DD Form 1423, C o n t r a c t Data Requirements L i s t (CDRL), t h e d a t a requirements i d e n t i f i e d below s h a l l be developed as s p e c i f i e d by an approved Data I t e m D e s c r i p t i o n (DD Form 1664) and d e l i v e r e d i n a c c o r d a n c e w i t h t h e approved CDRL i n c o r p o r a t e d i n t o t h e c o n t r a c t . When t h e p r o v i s i o n s of DoD FAR Supplement, P a r t 27, Sub-Part 27.410-6 (DD Form 1423) are invoked and t h e DD Form 1423 i s n o t used, the d a t a s p e c i f i e d below s h a l l be d e l i v e r e d by the c o n t r a c t o r i n accordance w i t h t h e c o n t r a c t o r purchase o r d e r requirements. D e l i v e r a b l e d a t a r e q u i r e d by t h i s s t a n d a r d are c i t e d i n t h e f o l l o w i n g paragraphs. Paragraph no. 4.1 and 4.2.2 4.2.2.2, 4.3.1.1, and 4.3.3.5 Data requirement t i t l e Plan, q u a l i t y assurance program Certification data/report A p p l i c a b l e D I D no. UDI-R-21374 UDI-A-23264 Option
---I -
(Data i t e m d e s c r i p t i o n s r e l a t e d t o t h i s s t a n d a r d , and i d e n t i f i e d i n s e c t i o n 6 w i l l be approved and l i s t e d as such i n DoD 5010.12-L, AMSDL. Copies of d a t a i t e m d e s c r i p t i o n s r e q u i r e d by t h e c o n t r a c t o r s i n c o n n e c t i o n w i t h s p e c i f i c a c q u i s i t i o n f u n c t i o n s should be o b t a i n e d from the Naval P u b l i c a t i o n s and Forms C e n t e r o r as d i r e c t e d by t h e c o n t r a c t i n g o f f i c e r . )
6.4
S u b j e c t t e r m (key word) l i s t i n g .
Electric a r c Plasma Powder flame Spray Thermal Wire flame
6.5 Changes from p r e v i o u s i s s u e . A s t e r i s k s o r v e r t i c a l l i n e s are n o t used i n t h i s r e v i s i o n t o i d e n t i f y changes w i t h respect t o t h e p r e v i o u s i s s u e due t o t h e e x t e n s i v e n e s s of t h e changes. Preparing a c t i v i t y : Navy SH ( P r o j e c t MFFP-N346)
27
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---
I ~
HIL-STD-Lb87A
HF
~-
7777711 00881117 2
MIL-STD- 1687A( SH) 11 February 1987
I I _ . -
A.
Materials ( M i l i t a r y s p e c i f i c a t i o n and t r a d e names)
Lot no.
B.
Preparation Method of c l e a n i n g Masking information Fixturing type
D.
Coating parameters Pounds/hour
_ _ I _ -
---_ . -
Gun t o work d i s t a n c e i n . -- Surface f e e t per minute Preheat temperature

_--.
. --
---
Blast g r i t t y p e and s i z e
Nozzle t o work d i s t a n c e Nozzle s i z e

C.
--
Spray t i m e ( p e r p a s s ) T o t a l no. of passes Thickness p e r pass Method of c o o i n g :

Air
Gas
. I . I -
-_-_--
--
l . ^ p .
Spray equipment supplements Gun t-y l--l lp - -e - l .&

Gears t y p e -__-__._____-
I -
I _ -
A i r cap t y p e
L _
Forced
I _ -
Static
I__._---
Wire n o z z l e t y p e no.
Nozzle o r i f i c e s i z e -Type of g a s used ( 1 ) Type of g a s used ( 2 )
_ I -
Coating t h i c k n e s s : As-sprayed
,
--------1 _ 1 1 -
--------
After f i n i s h i n g
_ _ _ I
E.
S e a l e r type
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---
L i g h t i n g p r e s s u r e s (1) Lighting p r e s s u r e s ( 2 )
F.
1 -
F i n i s h i n g method
---~-
FIGURE 1.
Wire oxy-fuel -- s p r a y process and parameter r e c o r d .
28
& .~
-~
_
~~
_
~~
_
~~
~-
MIL-STD-Lb87A PIF W 77777L1 0088148 Y M
_ _ _ ~
~~
MIL-STD-l687A( SH) 11 February 1987 A . Materials (Military specification and trade names) Coating : bond coat Substrate Lot no.
B.
Finish coat
D .
Coating parameters Pounds/ hour Gun to work distance (in) Surface feet per minute Preheat temp. Spray time per pass Total no. of passes Thickness per pass
I
Preparation Method of cleaning Masking information Fixturing type Blast: grit type and size Nozzle to work distance
--
--
___I---p
C .
Spray equipment supplements Gun type Wire size Atomizing gas

-
---
Method of cooling:
~I
_--
Air Forced
Gas Static
Pressure
------------
Coating thickness :
As-s prayed .
Atomizing air lb/in2 -Volts

I L . -
After finishing
Amps
--
E .
_ I _ -
Sealer type Finishing method
Spray distance
--
F.
FIGURE 2.
Wire arc spray process and parameter record.
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---
MIL-STD-Lb87A
NP
MIL- STD-l687A( SH) 11 February 1987
99999LL 0088349 b
__
_ I L -
A .
Materials (Military specification and trade names)
Substrate Lot no. -.--_ ^ _ . I B.
. . -
Preparation Method of cleaning _ Masking information
E .
Powder feeder Type
____
Carrier gas
I -
Pressure
___
Fixturing type ---_-__--Blast grit type and size Nozzle to work distance
I -
Flow C.F.H. Wheel RPM
-___-
I. I
---.PressUre
-I-
Vibrator type Metering valve,
Nozzle size
C.
Spray equipment supplements Gun type __
Flow control clicks
1 1 1 -
-----"--
Nozzle type no, --------fir cap Type of used F .

_ I
Transport valve setting -.---Powder valve setting Coating parameters Gun to work distance in,
__I.____--
Type of gas used (2) Auxiliary equipment
D.
Arc gas settings
Surface feet per minute --Preheat temperature
Regulator (1) lb/in2 Regulator (2) lb/in2 Console flow C.F.H.
----
Spray time (per pass) Pounds per hour

__l-.-_l----
FIGURE 3 .
-Powder
oxygen
parameter record.
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---
MIL-STD-16878( SH) 11 February 1987

Total no. of passes
Coating thickness per pass Method of cooling: Air Forced

*
---
Gas
Cross
Static
^ I _ -
Air jets:
Pressure
--
Coating thickness: As sprayed
-----___--
After finishing
G.
--
H .
FIGURE 3 .
Powder _ I & -
oxygen - fuel spray process and parameter record. - Continued
--
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---

L
MIL- STD-16 8 7A( SH) 11 February 1987

A.
Materials (Military specification and trade names) Coating : bond coat Substrate Lot no.
. I I . -
--
B.
Preparation Method of cleaning Masking information
E .
Powder feeder
I I _
Fixturing type
I I _
Blast grit type and size

I -
Nozzle to work distance Nozzle size
Powder gas orifice

_ I -
. . -
C.
Spray equipment supplements Thermal spray gun type Nozzle type no.
L_--
Air vibrator
Pressure --
I I _ _ .
A -
Spray rate
G.
_ _ _ _
Type of gas used ( 1 ) Type of gas used ( 2 )
Coating parameters Gun to work distance in. Surface feet per minute Preheat temperature -__-.Pounds per hour
-_I.__--___
_ . I
D .
Arc gas settings Regulator ( 1 ) lb/in2 --.------Regulator ( 2 ) lb/in2 Console flow C.F.H.
_ _ I _ ^ -
Spray time (per pass)

L _ -
E .
Power Voltage dc operating Amperes dc operating

I _ _ I -
Total no. of passes ._ Coating thicknesslpass

I _ I I -
Method of cooling:
*Adjust gas flow as necessary t o obtain the voltage range required. FIGURE 4 .
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---
Plasma spray process and parameter record.

---l__l__ll____l__-__--
32
MIL-STD-l687A( SH) 11 February 1987

Coating thickness:
A s sprayed
A s finished
H .
I.
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---
FIGURE 4 .
Plasma spray process and parameter record.
Continued
Licensee=Delta Airlines/1310000101, User=Vaughan, Paul Not for Resale, 02/04/2013 06:41:38 MST . . . .- .
b -
MIL-ST-
77llO153
MIL-STD- 1 6 8 7 A( SH)
11 February 1987
7
i
. .
O
e
i
O
r
b
b
a
0
*e
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---
Oa25o / '
0
. . . *
6'
O 50 O/O
'
o
* .
* e
i
* .
e r
...
*@
a
2o .
O / O
1 . 0
O10
SH 13203134
FIGURE 5,
comparison chart -Oxide, - - . - ~ - -porosity ---~-
(ZOOX). -
34
MIL-STD- 1687A( SH)
11 February 1987
4, O o / *
0o .
O10
IOrO0/0
I 2. O
O / O
SH 13203134
FIGURE 5.
Oxide '
porosity comparison chart (200X).

A
Continued
35
--`,,,,,,``,`,,,,,`,`,``,,``,,-`-`,,`,,`,`,,`---

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MIL-STD-l687A(SH) 11 F e b r a r y 1987 SUPERSEDING MIL-STD-l687(SH) 24 November 1 9 8 0 ( S e e 6.5)

Provided by IHS No reproduction or networking permitted without license from IHS

AREA MFFP A p p r o v e d for p u b l i c release; d i s t r i b u t i o n u n l i m i t e d

THIS DOCUMENT CONTAINS

MIL-STD-l687A(SH) 11 February 1987

Provided by IHS No reproduction or networking permitted without license from IHS

Thermal Spray Processes f o r Naval Ship Machinery A p p l i c a t i o n s

Provided by IHS No reproduction or networking permitted without license from IHS

MIL-STD-l687A(SH) 11 February 1987

CONTENTS Page Paragraph 1 1 . 1 1 . 2

4.1.1 4.1.2 4.1.3

2 2.1 2.1.1 2.1.2 2 02 2.3

5.1 5.1.1 5.1.1.1 5 . 1 . 1 . 2 5 . 1 01.3 5.1.1.4 5 . 1 . 1 5 5.1.2 5.1.2.1 5.1.3

. ., . A i r . d No reproduction2 or.c networking without license from IHS . *permitted .

MIL-STD-l687A(SH) 11 February 1987

Provided by IHS No reproduction or networking permitted without license from IHS

MIL-STD-Lb7A MF W 7777733 OOLL7 - __ -~~

MIL-STD-l687A(SH) 11 Februasy 1987

NOTES . . . . . . . . . . . . . . . . . . . . o o o o o o o o o o o * o o o * o o . o o o o o o o Intended u s e General r e q u i r e m e n t s Data r e q u i r e m e n t s S u b j e c t term (key word) l i s t i n g Changes from p r e v i o u s i s s u e

...................................... .............................. ................................. ................... .......................

... ........ ............................................ .......... ............

Thermal s p r a y c o a t i n g p r o p e r t i e s Recommended s p r a y procedures Spray material compositions

MIL-STD-1687A MF___W 9799913 O088320 4 I ___-~~~ ~ ~~ ~ ~~ ~~ ~

MIL-STD-l687A( SH) 11 February 1987

MIL-STD-l687A(SH) 11 February 1987

Sprayed Coating Systems f o r Corrosion P r o t e c t i o n Aboard Naval Ships. (Metric)

( A p p l i c a t i o n f o r copies should be addressed t o t h e American S o c i e t y f o r T e s t i n g and Materials, 1916 Race S t r e e t , P h i l a d e l p h i a , PA 19103.)

Provided by IHS No reproduction or networking permitted without license from IHS

MIL-STD-Lb7A MF W _ 7777733 0088322 _ W _ _ _ _ _ ~ _ ~~~ ~ ~ ~

MIL-STD-16 87A( SH) 11 February 1987

---- -MIL-STD-Lb7A I F 7777733 OO323 T

MIL-STD-1687A(SH) 11 February 1987

Provided by IHS No reproduction or networking permitted without license from IHS

MIL-STD-l687A(SH) 1 1 February 1987

Qualification and certification requirements.

Thermal spray procedures shall

Thermal spray procedures shall be approved by

Thermal spray pro-

Provided by IHS No reproduction or networking permitted without license from IHS

Blisters Cracks. Chips o r l o o s e l y a d h e r i n g p a r t i c l e s . Evidence of o i l o r o t h e r contaminants. P i t s exposing t h e u n d e r c o a t o r s u b s t r a t e . Coating s e p a r a t i o n . S p a t t e r , o r ummelted p a r t i c l e s .

MIL-STD-l687A(SH) 11 February 1987

EIL-STD-l687A( SH) 11 February 1987

Provided by IHS No reproduction or networking permitted without license from IHS

MIL-STD-Lb87A NF W 7777733 008330 7 m

MIL-STD-l687A(SH) 11 February 1987 4.4 Personnel t r a i n i n g , q u a l i f i c a t i o n , and c e r t i f i c a t i o n .

Training t i m e (hours) Coating p r o c e s s Flame Electric arc Plasma

Provided by IHS No reproduction or networking permitted without license from IHS

4.4.5.1 Visual examination. meet t h e requirements of 4.3.3.1.

4.4.5.6.2 Operators whose c e r t i f i c a t i o n has l a p s e d may be r e q u a l i f i e d by s a t i s f a c t o r i l y completing t h e q u a l i f i c a t i o n t e s t s of 4.4.3.

Provided by IHS No reproduction or networking permitted without license from IHS

Provided by IHS No reproduction or networking permitted without license from IHS

4.6.1.3 Specimens f o r bond t e s t . i n accordance w i t h ASTM C 633.

Specimens s h a l l be machined and tested

Equipment, Spraying systems.

MIL-STD-l687A(SH) 11 February 1987

sary t o roughen areas which are t o be t h e r m a l sprayed.

MIL-STD-1687A MF_W 9799913 O088320 4 I _-~~~ ~ ~~ ~ ~