May 2003
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6.
Overview of 3M Aerospace product line
Presentation of new material development
programs
3M 9323 B/A
Cocure of fluoropolymer film.
Surfacing Products Update
Cleaning methods
3Aerospace
3M Aerospace Materials
Aerospace Materials
Structural
Adhesives
Non Structural
Structural Film adhesives
Chromated Primers
Primers
Adhesion Promoters
Core splice films
Low Density Void fillers (Potting Compounds)
Coatings
PPT
Paint Replacement film
3Aerospace
3M Aerospace Materials
3M Structural Bonding films
Positioning of existing Bonding films
Curing/In-service
temperature
120/120
Today :
175/135
175/175
175/230
AF163-2
AF3109-2
AF191
AF30
AF126-2
AF3113-5
AF147
AF10
Applications
Metal/metal bonding
Composite cocure
Metal/composite bonding
Composite surfacing
Metal/Metal bonding
Composite bonding
Composite/composite
Metal /
Metal
bonding
3Aerospace
3M Aerospace Materials
Only Silan primer
Epoxy Silan primer
Silan based
Phenolic
based
Adhesion Promotors
3M Primers
Epoxy
based
With Corrosion inhibitor
Solvent based
Epoxy /
Phenolic based
Solvant diluated adhesive
Low VOC
3Aerospace
3M Aerospace Materials
3M Low Density Void Filler
Applications
Core splicing
Abradable layer
for jet engines
Core edge
sealing
Core reinforcement
Low Density Void
Fillers
Insert
Bonding
Fuel tank inside
coating
3Aerospace
5 families of Low Density Void Fillers
Cold curing
H.T. curing
High temp. resistance products
3500 B/A
3500-2 B/A
3439 HT
3439 HT AF
High Strength products
Fire, smoke, toxicity products
3439 HS AF
3524 B/A FST
3439 HS FST
3439-2 HS FST
Low density products
3524 B/A
3524 B/A AF
3534 B/A
Lowest density products
3584 B/A
3Aerospace
3M Aerospace Materials
3M Core splice films
• Edge finishing
• Honeycomb assemblage
Principe : 1K epoxy film containing
foaming agents and glass bubbles
for assembling of light weight
structures.
Film
Expansion range (%)
AF 3002
125 - 160
AF 3024
170 - 350
AF 3030 FST
170 - 250
Expansion = Final Thickness / Initial Thickness
3Aerospace
3M Aerospace Materials
3M Polyurethane Protective Tape & Boots

Highly Durable, Long Service Life

Very High Elongation & Toughness

Puncture Resistant

Conformable to Curvatures

Solvent Free Technology

Transparent or Limited Color Matching

Easy and Fast Application

Specialized Capabilities
Extremely tough puncture
resistant thermoplastic
elastomer coated with an
acrylic adhesive
3Aerospace
3M Aerospace Materials
3M Paint Replacement Tape (Applique)
• Low Surface Energy
• Low WVTR
• Chemical / Fluid Resistance
• UV / Color Stability
• Conformability
• Flame Retardant
• Solvent Free Coating
• Simple Installation
• Wide Application Environment
• Coating Consistency
• Enhanced Performance
3Aerospace
3M Aerospace Materials
Existing structural 3M 2K epoxy systems
Mono component
Bi - component
Heat cure
RT cure
Mild heat cure
Bulk
Bulk
EPX
• EC 2214
• EC 9360
• SW 9323 B/A
• SW 9323-2 B/A
• EC 2216 B/A
• SW 7240 B/A FR
• DP 1xx series
• DP 4xx series
• DP 7xx series
• SW 7260 B/A (FC)
• SW 7236 B/A
• SW 7838 B/A
3Aerospace
Films and Primer Technology Migration
120°C Curing
Films
AF 500
AF-163-2 repl.
R.T. stable
120/175°C Curing
175°C Curing
Films
LowVOC Primers
Very High Peel
AF 600
Composite
Bonding
EW-5000
EW-6000
Non-chromated
120°C/175°C
3Aerospace
AF-500 - New 120°C curing film development
Development effort :
• Composite bonding film adhesive
• Surfacing capabilities
• General purpose metal bonding
• Excellent out time (minimum 30 days) with
good tack and handling characteristics
• New manufacturing process and system
3Aerospace
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Status
30 days out time shows no change in viscosity and is
expected to be adequate.
Composite bonding,metal bonding, and potentially
surfacing may be possible.
Excellent control of cure rheology, need to optimize to
composite and metal bonding performance
Optimization of film adhesive in process.
3Aerospace
AF-600 - New 175oC curing film development
Development Effort:
• Targeting Broad Performance capability with high
shear/service temperature applications to excellent
toughness requirements with a single film adhesive
•
Shop friendly handling
•
Excellent Durability
•
Significant property and handling increase of current
175°C systems
3Aerospace
Ease of Use and Shop Handling
Property
AF-600
Tack (0-10)
Conforming (0-10)
Out time at ambient
Flow
Reticulation Capable
4
8
30 days
Controlled
yes
3Aerospace
Status
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New film adhesive will provide significant advancement in
service temperature with toughness over current epoxy
film systems
Shop handling characteristics and out time significantly
improved over current 175°C adhesives
90% of performance targets have been achieved
Pilot Plant stage: evaluations and feedback to be
commenced
3Aerospace
Primer development programs
 EW-5000 - 120°C In service Primer
 EW-5000NC - 120°C In service Primer
 EW-6000 - 175°C In service Primer
3Aerospace
Primer development programs
Highlights :
EW-5000
Solvent
EW-5000NC
EW-6000
Low VOC water-borne primer
Chemistry
Epoxy
Epoxy
Epoxy/Phenolic
Inhibitor
Chromate Non-Chromate Chromate
Remarks
Excellent corrosion and mechanical perf.
User-friendly in shop handling
Targeted for high productivity
3Aerospace
Primer development programs
Key Properties:
EW-5000
EW-5000NC
EW-6000
Application
Spray gun application
Handling
MEK & Skydrol resistance
VOC content
Thickess range
Remarks
247 g/dm3
166 g/dm3
233 g/dm3
2,5 - 9,0 µm (cured)
1 box coat to obtain 5 µm
Quick flash dry
Visible thickness difference prior to cure
3Aerospace
Primer development programs
About Corrosion resistance :
EW-5000
EW-5000NC
After 100 days in 5% salt spray
3Aerospace
3M Aerospace Materials
Existing structural 3M 2K epoxy systems
Bi - component
RT cure
Mild heat cure
Bulk
EPX
• SW 9323 B/A
• SW 9323-2 B/A
• EC 2216 B/A
• SW 7240 B/A FR
• DP 1xx series
• DP 4xx series
• DP 7xx series
• SW 7260 B/A (FC)
• SW 7236 B/A
• SW 7838 B/A
3Aerospace
3M Structural 2K Paste Adhesives
2K Paste adhesives in Bulk
SW 9323 B/A
• Very high performance (Probably best RT performance of all 3M 2K
paste adhesives)
• Very tough adhesive
• Salmon pink colour (colour changes during storage)
• Temperature range from -55°C to 80°C
• Best mechanical performance with 100µm bondline thickness
• Optimal cure 2h at 65°C and 1kg/cm2
• Qualified and used all over Europe by Aerospace manufacturers
(Eurocopter, Agusta- Westland, Eurofighter, Fairchild Dornier, Ministry
of Defence UK, SAAB Military….)
• Worklife of 90 min. minimum for 20g of mix
3Aerospace
3M Structural 2K Paste Adhesives
SCOTCH-WELD : PRODUCT POSITIONNING
Overlap Shear Strength (MPa)
Test conditions
DP 760
SW 9323 B/A
DP190
DP490
- 55 ±3°C
+23 ±2°C
+80 ± 2°C
+120 ± 2°C
+150 ± 2°C
+175 ± 3°C
+205 ± 3°C
+230 ± 3°C
17,4 (C)
29,1 (C)
24,2 (C)
16,1 (C)
11,9 (C)
7,3 (C)
5,2 (C)
3,0 (C)
29,0 (C)
41,0 (C)
23,5 (C)
3,5 (C)
2,5 (C)
10,3 (C)
17,2 (C)
2,8 (C)
2,0 (C)
1,4 (C)
1,2 (C)
27,5 (C)
28,5 (C)
11,9 (C)
3,2 (C)
1,7 (C)
1,4 (C)
13-25°C
60-65°C
Tg midpoint (2nd DSC Scan)
Fully cured product 145-150°C
80-90°C
3Aerospace
3M Structural 2K Paste Adhesives
SCOTCH-WELD : PRODUCT POSITIONNING
45
Overlap Shear Strength
(MPa)
40
DP 760
SW 9323
DP 190
DP 490
35
30
25
20
15
10
5
0
-100
-50
0
50
100
Temperature
150
200
3Aerospace
250
High Performance Surface Coating & Protection Technology
Fluoropolymer Paint Replacement (Applique) Tapes & Film Currently Available
Product Description
Thickness
Application
3951
Film (no adhesive)
0.1 mm (4mil)
Co-cure In Process, Bonding w/Alt Adhesives
4804
Paint Replacement Tape
For Smooth Surfaces
0.15 mm (6mil)
Smooth Surfaces <100µinch Roughness
Paint Replacement Tape
For Rough Surfaces
0.23 mm (9mil)
Paint Replacement Tape
For Aircraft Exterior
0.14 mm (5.5mil)
4805
5004
(Not Suitable For Aircraft Exterior)
Rough Surfaces > 100µinch Roughness
(Not Suitable For Aircraft Exterior)
Aircraft Top-Coat Paint Replacement
Paint Replacement (Applique) Technology Support Products
Product
4881
4882
4883
Description
Adhesion Test Strip For 5004
Sealing Film
Support Kit
Application
Indicates Adhesion Above and Below 40oz/in width per ASTM D3330
Used with DP190 or DP460 Provides Color Matched Edge Seal
Tools to Support Installation/Repair of Paint Replacement Tapes
3Aerospace
High Performance Surface Coating & Protection
Benefits of Fluoropolymer Film Coating Technology: “Paint By The Roll”
Features
Attributes
Benefits
• Low Surface Energy
• Reduced Dirt Collection
• Reduced Cleaning Requirement
• Low WVTR
• Reduced Corrosion
• Reduced Repairs, Extended
Service Life
• Chemical/Fluid Resistance • Expanded Durability
• Extended Service Life
• UV / Color Stability
• Expanded Longevity
• Extended Service Life
• Conformability
• Expanded Coverage Areas
• Enhanced Substrate Protection
• Flame Retardant
• Non-Flammable, low Smoke • Improved Safety
3Aerospace
High Performance Surface Coating & Protection
Surface Protection Film Co-cured With Composite Parts
•Incorporate Surface Protection Film into the Parts During Cure
Colored, Cleanable, Moisture Barrier, Chemical/Fluid Resistant, UV Stable
•Eliminates Finishing, Priming, Coating
•Curing temperatures to 360°F (182°C) at 100 psi (Possibly Higher)
SURFACE PROTECTION FILM OR PAINT
REPLACEMENT TAPE CAN BE APPLIED TO
EITHER OR BOTH SURFACES
VACUUM BAG
BREATHER
TOOL
BAG SEAL AROUND
PERIMETER
COMPOSITE PLIES
AND/OR CORE
3Aerospace
VACUUM PORT
3M Low Density Surfacing Film
AF 325
• New Carrier
• Excellent surfacing with minimal
pinholes
• Low flow and customized tack
• Co-curing with most prepregs
• 120° / 180°C curing
• Little or no resin intermingling
• Readily sanded and painted
3Aerospace
Lightning Strike/EMI Protection - Surface Films
AF 163-2 LS
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Excellent wet-out
Flexible cures from 105° to 180°C
Minimal Preparation for paint
Excellent surface and fill
.45wt: .30wt film/.15 wt grid
.60 wt: .30wt film/.29 wt grid
3Aerospace
Cleaning methods
The following cleaning methods are suggested for common surfacess
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Aluminium
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2.
Vapor Degrease – Percholorethylene condensing vapors for 5-10 minutes.*
3.
Acid etch – Place pannels in the following solution for 10 minutes at 150F+/- 5F (66C
+/- 2C).*
Alkaline Degrease – Oakite 164 solution (9-11 oz./gallon water) at 190F+/- 10F (88C
+/- 5C) for 10-20 minutes. Rinse immediately in large quantities of cold running water.
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Sodium Dichromate
4.1-4.9 oz./gallon
Sulfuric Acid, 66
38.5-41.5 oz./gallon
2024-T3 aluminum (dissolved)
0.2 oz./gallon minimum
Tap water
Balance of volume
Rinse – Rinse panels in clear running tap water.
Dry – Air dry 15 minutes; force dry 10 minutes at 150F +/- 10F (66C +/- 5C)
If primer is to be used, it should be applied within 4 hours after surface preparation
3Aerospace
Cleaning methods
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Steel
1.
2.
3.
Wipe free of dust with oil-free solvent such as Methyl Ethyl Ketone (MEK)*
Sandblast or abrade using clean fine grit abrasives
Wipe again with solvents to remove loose particles
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Plastics
1.
2.
3.
Solvent wipe with Isopropyl Alcohol *
Abrade using clean fine grit abrasives
Solvent wipe again with Isopropyl Alcohol *
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Rubbers
1.
2.
3.
Solvent wipe with Methyl Ethyl Ketone (MEK)*
Abrade using clean fine grit abrasives
Wipe again with MEK *
3Aerospace
Cleaning methods
 Glass
1.Solvent wipe with Acetone or Methyl Ethyl Ketone (MEK)*
For glass applications which will be subjected to high moisture/humidity conditions, a primer
should be used to prime the glass
* Note: When using solvents or chemicals, be shure to extinguish all ignition sources
and follow the manufacturer’s precautions and directions for use when handling such
materials
3Aerospace