PROCESS AND MATERIAL SPECIFICATION

Printed in Germany

PROCESS SPECIFICATION

01-01-09

Cleaning of Aircraft Structural Plastic Transparencies

PROCESS AND MATERIAL SPECIFICATION

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LIST OF EFFECTIVE PAGES

SUBJECT PAGE DATE

RECORD OF REVISION LIST OF EFFECTIVE PAGES TABLE OF CONTENTS 01-01-09 01-01-09 01-01-09 01-01-09 01-01-09 01-01-09 01-01-09 01-01-09

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PROCESS AND MATERIAL SPECIFICATION

AIPS09-01-007 01-01-09

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Printed in Germany

AIPS Airbus Process Specification

Cleaning of Aircraft Structural Plastic Transparencies

Published and distributed by : AIRBUS S.A.S.

ENGINEERING DIRECTORATE 31707 BLAGNAC Cedex

FRANCE

Copyright reserved

Ref. no.AIPS09-01-007

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Contents

1 Scope3

2 Normative references 3

3 Definition, applicability and limitations 3

4 Requirements 4

5 Process qualification 6

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1 Scope This Airbus Process Specification defines the requirement for cleaning of aircraft structural plastic transparencies. The purpose of this specification is to give design and quality requirements to manufacturers. Although the essential requirements of a process are defined, the specification does not give complete in house process instructions, these shall be given in the manufacturers detailed process instruction and supporting work instructions.

This specification shall not be used as an inspection document unless parts or assemblies have been manufactured according to this specification.

It shall be applied when mentioned in the relevant standard, material specification or drawing.

2 Normative references This Airbus specification incorporates by dated or undated reference provisions from other publications. All normative references cited at the appropriate places in the text are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this Airbus specification only when incorporated in it by amendment of revision. For undated references, the latest issue of the publication referred to shall be applied.

National standards should be applied if Airbus standards are not available.

AIMS 09-03-000 Technical specification - Liquid non-aqueous cleaning agents AITM 1-0015 Liquid cleaning agents: Determination of the effect of liquid cleaning agents upon

the peel strength of polysulphide sealants AITM 1-0021 Liquid cleaning agents: Determination of the effect of liquid cleaning agents upon

the properties of elastomeric materials AMS 1535C Cleaner for Plastic transparencies

AMS 3819 B Cloths, Cleaning for aircraft Primary and Secondary Structural surfaces

3 Definition, applicability and limitations

3.1 Definition This process specification shall be used for cleaning of aircraft structural plastic transparencies. The final process shall conform to the requirements defined in 4. The process specification shall be used on the following types of structural plastic transparencies:

Types of structural plastic transparencies: Type 1: uncoated Type 2: hard-coated

3.2 Applicability This Airbus specification is applicable when invoked by the drawing directly or through another document for the purpose given in the scope. When processing to AIPS09-01-007 is required, it shall be invoked on the drawing by the words "Cleaning of Aircraft Structural Plastic Transparencies to AIPS09-01-007". Process instructions shall not be called on drawing.

3.3 Limitations of the process

The cleaning process shall only be used for aircraft structural plastic transparencies.

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3.4 Definitions

Cleaning agent: Any compound or substance, suitable to remove all contaminants by chemical action, is called a cleaning agent

Soft cloth: Clean, lint-free wipes according to AMS 3819

Pits: Surface indentations caused, for example, when hard particles hit the surface

Scratch: Linear marks on a surface

Orange Peel: Surface texture reminiscent of the surface of an orange

Crazing: A network of small cracks usually restricted to near the surface

Delamination: Lamellar separation of the material

Chipping: Damage of the edge of a part

Refinishing the surface : Removal of scratches from the surface

4 Requirements

4.1 Technical requirements

4.1.1 Prior to cleaning -Only qualified cleaning agents according to AMS 1535C shall be used. -The cleaning agent and equipment shall not contain any particles that could damage the surface. -Dry cloths shall not be used for rubbing.

4.1.2 During cleaning -The surface shall be carefully wiped off wet (cloth and cleaning agent together). -The surfaces shall afterwards be free of any liquids and dried if necessary. -It shall be ensured that no water or cleaning agent shall have penetrated into the spaces between panes or into the window seals.

4.1.3 After cleaning -The cleaned surfaces, including areas difficult to access, shall be free from dirt, dust, particles, fingerprints, iridescence (coloured rings) or other contamination. If this is not the case, the cleaning procedure shall be repeated. -The surface shall not be changed or damaged by the cleaning procedure.

4.1.4 Refinishing of uncoated structural plastic transparencies after cleaning -For uncoated structural plastic transparencies (Type 1) refinishing can be performed using a qualified product and a qualified cloth to remove the scratches. -The refinishing process shall meet the requirements of the producer of the transparencies and also maintain the warranty of the material and product. -After refinishing a final cleaning shall be performed. -The final appearance of the structural plastic transparency shall be free from dirt, dust, particles, fingerprints, iridescence (coloured rings) or other contamination and shall meet the requirements of 4.3.3.

4.2 Quality requirements

4.2.1 Compressed air

Compressed air used for the cleaning process shall be free of oil.

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4.2.2 Effect of cleaning agent on sealants No influence of the cleaner on sealants is allowed. The individual material specification(s) shall be respected. The following minimum parameters shall be tested and shall meet the individual material specification: Shore hardness, volume change, peel strength. 4.2.3 Effect of cleaning agent on seals No influence of the cleaner on seals is allowed. The individual material specification(s) shall be respected. The following minimum paramters shall be tested and shall meet the individual material specification: Hardness, volume change. 4.2.4 Effect of cleaning agent on external paint systems No influence of the cleaner on adhesion and scratch resistance of the external paint system is allowed. The paint adhesion tests shall pass the requirement GT 0 at delivery state and GT 1 after immersion in cleaning agent for one hour. The scratch resistance shall be >1200g after immersion in cleaning agent for one hour at room temperature. 4.2.5 Visual inspection The surface inspection shall be carried out with the naked eye or up to 5 x magnification. It has to be taken into account that the local lighting conditions will affect the determination of defects. Therefore uniform lighting conditions shall be provided during inspection of structural plastic transparencies. 4.3 Quality requirements 4.3.1 General requirements The Quality Assurance authority shall:

- make sure that only qualified materials are used. - check the cleaned surface to demonstrate that the engineering requirements are met.

4.3.2 Visual inspection

The surface inspection shall be carried out with the naked eye or up to 5 x magnification. It has to be taken into account that the local lighting conditions will affect the determination of defects. Therefore uniform lighting conditions shall be provided during inspection of structural plastic transparencies. 4.3.3 Inspection criteria for defects on window panes

Unacceptable defects: - cracks - crazing - chipping - delaminations - blistering - any defect caused by chemical influence - varnish and paint residues/overspray of any form (e.g. of the exterior paint) - damage of the structural plastic transparency sealing - deformation of the structural plastic transparency variation in colour or partial removal of

optical/wear-resistant coatings (as determined by visual inspection)

Unacceptable defects between cabin inner and outer pane: - insects and other particles - accumulation of dust particles - any type of liquid - debris, fibres/fluff (e. g. from cleaning cloths) or other contamination

Acceptable defects: Pits and cleaning/polish marks of the following quantities and sizes: - Maximum of 3 pits having a maximum diameter of 1,2mm each or 3 cleaning/polish marks

covering a surface of maximum 3mm2

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Orange peel: These surface irregularities are acceptable provided that the view from inside to outside is not impeded by optical distortions.

Scratches a) Geometry of scratches: Scratches on structural plastic transparency surfaces can have the following cross-sections:

TYPE A is a crack and therefore not acceptable. TYPE B is a scratch and acceptable provided that the width of the scratch is equal to or greater than 10 times the scratch depth. A scratch width smaller than 10 times the depth scratch is not acceptable. b) Test criteria/defect limit for scratches: On each side of the structural plastic transparency a maximum of 6 scratches with a maximum depth of 5m a width of 50|j.m and a maximum length of 15mm each is allowable. - Scratches having smaller dimensions than 0,5|j.m depth, 5|j.m width and 15mm length are not counted provided that their quantity is limited (maximum of 3 scratches on any surface of 50mm x 50mm). - Scratches having a depth of 0,5|j.m up to 5|j.m, a width of 5|j.m up to 50|j.m and a length of max. 15mm are not allowable in greater quantities (maximum of 6 scratches uniformly distributed on the surface of the structural plastic transparency).

5 Process qualification 5.1 Process Qualification Procedure For technical qualification: Refer to AIRBUS qualification procedure for Manufacturing Process.

5.1.1 General The general process qualification, the qualification of industrial facilities and Airbus quality assurance are described in prevailing procedure documents. The process qualification is given and maintained only on condition that the qualified workshop complies with the cleaning and inspection documents formally approved by Airbus. The qualification is limited to a specific issue of any process specification of the developer. Any modification needs re-approval or re-qualification. Users need to be qualified in accordance with the relevant Airbus quality requirements. Airbus reserves the right to audit the use of qualified processes to check conformity with the agreements.

5.1.2 Start of qualification The process qualification shall be done by qualified and authorized personal. The process qualification shall be performed using the materials (cleaning agents and components (material) and cleaning procedures/equipment to be used in serial production. All affected materials (seals), all surface coatings (painting), all kind of parts and assemblies shall be tested with the cleaning process. The production shop must use its facilities under serial production conditions during the qualification tests. The process qualification shall be done with a qualified cleaning agent according to AMS1535.

5.2 Standard qualification test program (QTP) This chapter provides the details of the standard test program, which shall be taken into account for the definition of the specific qualification test program (QTP) for the technical qualification of a shop. The QTP shall show the compliance with the engineering, technical and quality requirements defined in this AIPS (chapter 4). In addition to

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the acceptance criteria, specific test requirements are defined as amendment and/or deviation. This means the qualification test program (QTP) includes the standard qualification test defined by this AIPS hereinafter (chapter 5.4) as well as any amendment or deviation.

Any change to the cleaning process/cleaning agent shall be submitted for technical assessment to the appropriate AIRBUS authority, which shall decide whether new verification tests are required.

5.3 Verification during qualification testing of the required performance and quality level All verification tests named in table 1 shall be done. The test methods are applicable. If another test method is used only specified and qualified test methods are allowed and the reason for changing the test method shall be explained.

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Table 1 - Test selection for the standard qualification test program

Test results of the qualification test program of the process qualification shall be recorded in a qualification test report (QTR), which may include results from the sub-contractors.

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5.4 Qualification test report (QTR) The basis of the qualification/approval of a specific process to the AIPS is a detailed test report about all tests and procedures that have been performed (adding details and values). Prior to any production cleaning run the complete test report shall be submitted and approved by Engineering. The test report has to be established and signed by the developer and its quality assurance department. The test report shall give at least all the following information:

- Name and address of the production shop - Description of all used specifications and test methods - Description of the type of cleaning agent - Detailed description of process steps with all methods of cleaning and description of the work

instruction sequence - Discussion of the results with respect to the qualification test program (QTP) and achievement of

the requirements - Any incident that may have affected the results and any deviation from this AIPS

Process instruction

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RECORD OF REVISIONS

Front PagesTitle PageRevision Transmittal SheetHighlightsRecord of Revisions

IntroductionCross Reference ListAlphabetical IndexAlphanumerical IndexChapter 01 - ProcessesList of Effective Pages01-01..01-01-0101-01-0201-01-0301-01-0401-01-0501-01-0601-01-0701-01-0801-01-0901-01-1001-01-1101-01-1201-01-1301-01-14-101-01-14-201-01-1501-01-1601-01-1701-01-1801-01-1901-01-2001-01-2101-01-2201-01-2401-01-2501-01-2701-01-28

01-02..01-02-0101-02-0201-02-0401-02-0501-02-0701-02-0801-02-0901-02-1001-02-1101-02-1201-02-1301-02-1601-02-2101-02-2201-02-2301-02-2401-02-2501-02-2701-02-2901-02-3001-02-3101-02-3201-02-3501-02-3601-02-3701-02-3801-02-3901-02-4001-02-4101-02-4201-02-4301-02-4401-02-4501-02-4701-02-4801-02-5301-02-10001-02-10101-02-10201-02-10301-02-10401-02-105

01-03..01-03-0201-03-0301-03-0401-03-0501-03-0601-03-0701-03-0801-03-0901-03-1001-03-1101-03-1201-03-1301-03-1401-03-1501-03-1601-03-1701-03-1801-03-1901-03-2001-03-2101-03-2201-03-2301-03-2401-03-2501-03-2701-03-2901-03-3101-03-3301-03-3401-03-3501-03-36

01-04..01-04-0101-04-0201-04-0801-04-0901-04-1701-04-1801-04-1901-04-2001-04-2101-04-2301-04-2401-04-2501-04-2601-04-2801-04-2901-04-3001-04-3101-04-3201-04-3301-04-3401-04-3601-04-3701-04-3801-04-4001-04-4501-04-4601-04-4801-04-5001-04-5101-04-5301-04-5401-04-5501-04-5601-04-5701-04-58

01-05..01-05-0101-05-0201-05-0301-05-0401-05-0501-05-0701-05-1001-05-1101-05-1701-05-2401-05-2601-05-2701-05-2801-05-2901-05-3601-05-3701-05-3901-05-4201-05-4301-05-4401-05-4501-05-4601-05-4701-05-5201-05-5301-05-5501-05-5801-05-6101-05-6201-05-6301-05-6401-05-6501-05-6601-05-6701-05-6801-05-6901-05-7001-05-7101-05-72

01-06..01-06-0101-06-0201-06-0301-06-0401-06-0501-06-0601-06-0701-06-0801-06-0901-06-1101-06-1201-06-1301-06-14

01-07..01-07-0101-07-0401-07-0501-07-0601-07-0701-07-0801-07-0901-07-1001-07-1101-07-1201-07-1301-07-1401-07-1501-07-1601-07-1701-07-1901-07-2001-07-2101-07-2201-07-2301-07-2401-07-2501-07-2601-07-2701-07-2801-07-2901-07-3001-07-3101-07-3201-07-3301-07-3401-07-3501-07-3601-07-3701-07-3801-07-3901-07-4001-07-4201-07-4401-07-4501-07-4601-07-4701-07-4801-07-4901-07-5001-07-5201-07-5301-07-5401-07-5501-07-5601-07-5701-07-5801-07-5901-07-6001-07-6201-07-6301-07-6401-07-6501-07-6701-07-6801-07-6901-07-7001-07-7101-07-7201-07-7301-07-7401-07-7501-07-7601-07-7701-07-7801-07-7901-07-8001-07-8101-07-8301-07-8401-07-8501-07-8601-07-8701-07-8801-07-8901-07-9001-07-9201-07-9301-07-9401-07-9501-07-9601-07-9701-07-9801-07-9901-07-10001-07-10101-07-10201-07-10301-07-104

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Chapter 02 - MaterialsList of Effective PagesTable of ContentsMaterial Cross Reference List02-00-0102-01-0002-02-0002-03..02-03-0002-03-0102-03-0202-03-0302-03-0402-03-0502-03-0602-03-0702-03-0802-03-0902-03-1002-03-1102-03-1202-03-1302-03-1402-03-1502-03-1602-03-1702-03-1802-03-1902-03-2002-03-2102-03-2202-03-2302-03-2402-03-2502-03-2602-03-2702-03-2802-03-2902-03-3002-03-3102-03-3202-03-33

02-04..02-04-0002-04-0102-04-0202-04-0302-04-0402-04-05

02-05..02-05-0002-05-0102-05-0202-05-0302-05-0402-05-0502-05-0602-05-0702-05-0802-05-0902-05-1002-05-1102-05-1202-05-1302-05-1402-05-1502-05-1602-05-1702-05-18

02-06..02-06-0002-06-0102-06-02

02-07..02-07-0002-07-0102-07-0202-07-0302-07-0402-07-0602-07-0702-07-0802-07-0902-07-1002-07-11

02-08..02-08-0002-08-0102-08-0202-08-0302-08-0402-08-0502-08-0602-08-0702-08-0802-08-0902-08-1002-08-1102-08-12

02-09..02-09-0002-09-0102-09-0202-09-0302-09-0402-09-05

02-10..02-10-0002-10-0102-10-0202-10-0302-10-0402-10-0502-10-06

02-11..02-11-0002-11-0102-11-0202-11-0302-11-0402-11-0502-11-0602-11-0702-11-0802-11-0902-11-1002-11-1102-11-1202-11-1302-11-1402-11-15

02-12..02-12-0002-12-0102-12-0202-12-0302-12-0402-12-0502-12-0602-12-0702-12-0802-12-0902-12-1002-12-1102-12-1202-12-1302-12-1402-12-1502-12-16

02-13..02-13-0002-13-0102-13-0202-13-03

02-14..02-14-0002-14-0102-14-0202-14-0302-14-0402-14-0502-14-0602-14-0702-14-0802-14-0902-14-1002-14-1102-14-1202-14-1302-14-14

02-15-0002-16-0002-17-0002-18..02-18-0002-18-01

02-19-0102-20-00