May 2003

1. 2.
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

3. 4. 5. 6.

3Aerospace

3M Aerospace Materials

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

Structural

Aerospace Materials

3Aerospace

3M Aerospace Materials
3M Structural Bonding films Positioning of existing Bonding films
Curing/In-service temperature

120/120
AF163-2 AF126-2

175/135
AF3109-2 AF3113-5 Applications

175/175
AF191 AF147

175/230
AF30 AF10

Today :

Metal/metal bonding

Composite cocure

Metal/composite bonding

Composite surfacing
Composite bonding

Metal/Metal bonding
Composite/composite

Metal / Metal bonding

3Aerospace

3M Aerospace Materials
Only Silan primer Epoxy Silan primer

Silan based
Adhesion Promotors

Phenolic based

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

Low Density Void Fillers

Insert Bonding

Core reinforcement

Fuel tank inside coating

3Aerospace

5 families of Low Density Void Fillers

Cold curing High temp. resistance products H.T. curing 3500 B/A 3500-2 B/A

3439 HT
3439 HT AF High Strength products Fire, smoke, toxicity products Low density products 3524 B/A FST 3524 B/A 3524 B/A AF 3439 HS AF 3439 HS FST 3439-2 HS FST

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
AF 3002 AF 3024 AF 3030 FST

Expansion range (%)

125 - 160 170 - 350 170 - 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
Bulk
EC 2214 EC 9360

RT cure
Bulk
SW 9323 B/A SW 9323-2 B/A EC 2216 B/A SW 7240 B/A FR SW 7260 B/A (FC) SW 7236 B/A SW 7838 B/A

Mild heat cure

EPX
DP 1xx series DP 4xx series DP 7xx series

3Aerospace

Films and Primer Technology Migration

120C Curing Films AF 500 AF-163-2 repl. R.T. stable

120/175C Curing

175C Curing Films

Very High Peel AF 600 Composite Bonding

LowVOC Primers

EW-5000 EW-6000

Non-chromated 120C/175C

3Aerospace

AF-500 - New 120C 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

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 175C 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

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 175C adhesives 90% of performance targets have been achieved

Pilot Plant stage: evaluations and feedback to be commenced

3Aerospace

Primer development programs

EW-5000 - 120C In service Primer EW-5000NC - 120C In service Primer EW-6000 - 175C In service Primer

3Aerospace

Primer development programs

Highlights :
EW-5000 Solvent Chemistry Inhibitor EW-5000NC EW-6000 Low VOC water-borne primer Epoxy Epoxy Epoxy/Phenolic

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
Handling

Spray gun application

MEK & Skydrol resistance

VOC content
Thickess range Remarks

247 g/dm3

166 g/dm3

233 g/dm3

2,5 - 9,0 m (cured) 1 box coat to obtain 5 m 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 Bulk
SW 9323 B/A SW 9323-2 B/A EC 2216 B/A SW 7240 B/A FR SW 7260 B/A (FC) SW 7236 B/A SW 7838 B/A

Mild heat cure EPX

DP 1xx series DP 4xx series DP 7xx series

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 -55C to 80C Best mechanical performance with 100m bondline thickness Optimal cure 2h at 65C 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
- 55 3C +23 2C +80 2C +120 2C +150 2C +175 3C +205 3C +230 3C

DP 760
17,4 (C) 29,1 (C) 24,2 (C) 16,1 (C) 11,9 (C) 7,3 (C) 5,2 (C) 3,0 (C)

SW 9323 B/A
29,0 (C) 41,0 (C) 23,5 (C) 3,5 (C) 2,5 (C)

DP190
10,3 (C) 17,2 (C) 2,8 (C) 2,0 (C) 1,4 (C) 1,2 (C)

DP490
27,5 (C) 28,5 (C) 11,9 (C) 3,2 (C) 1,7 (C) 1,4 (C)

Tg midpoint (2nd DSC Scan)

Fully cured product 145-150C
80-90C 13-25C 60-65C

3Aerospace

3M Structural 2K Paste Adhesives

SCOTCH-WELD : PRODUCT POSITIONNING
45 40

Overlap Shear Strength (MPa)

35 30 25 20 15 10 5 0 -100 -50 0 50 100 Temperature 150

DP 760 SW 9323 DP 190 DP 490

200

250

3Aerospace

High Performance Surface Coating & Protection Technology

Fluoropolymer Paint Replacement (Applique) Tapes & Film Currently Available
Product Description
3951 4804 Film (no adhesive) Paint Replacement Tape For Smooth Surfaces Paint Replacement Tape For Rough Surfaces Paint Replacement Tape For Aircraft Exterior

Thickness
0.1 mm (4mil) 0.15 mm (6mil)

Application
Co-cure In Process, Bonding w/Alt Adhesives

Smooth Surfaces <100inch Roughness

(Not Suitable For Aircraft Exterior)

4805

0.23 mm (9mil)

Rough Surfaces > 100inch Roughness

(Not Suitable For Aircraft Exterior)

5004

0.14 mm (5.5mil)

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
Low Surface Energy Low WVTR

Attributes
Reduced Dirt Collection Reduced Corrosion

Benefits
Reduced Cleaning Requirement Reduced Repairs, Extended Service Life Extended Service Life Extended Service Life Enhanced Substrate Protection

Chemical/Fluid Resistance Expanded Durability UV / Color Stability Conformability Flame Retardant Expanded Longevity Expanded Coverage Areas

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 360F (182C) at 100 psi (Possibly Higher)
VACUUM BAG
SURFACE PROTECTION FILM OR PAINT REPLACEMENT TAPE CAN BE APPLIED TO EITHER OR BOTH SURFACES

BREATHER

TOOL BAG SEAL AROUND PERIMETER

COMPOSITE PLIES AND/OR CORE

VACUUM PORT

3Aerospace

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 / 180C curing Little or no resin intermingling Readily sanded and painted

3Aerospace

Lightning Strike/EMI Protection - Surface Films

AF 163-2 LS
Excellent wet-out Flexible cures from 105 to 180C 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

1. 2. 3.

Aluminium
Vapor Degrease Percholorethylene condensing vapors for 5-10 minutes.* 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. Acid etch Place pannels in the following solution for 10 minutes at 150F+/- 5F (66C +/- 2C).*

1. 2. 3. 4.

Sodium Dichromate Sulfuric Acid, 66 2024-T3 aluminum (dissolved) Tap water

4.1-4.9 oz./gallon 38.5-41.5 oz./gallon 0.2 oz./gallon minimum Balance of volume

4. 5. 6.

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

1. 2. 3.

Steel
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

1. 2. 3.

Plastics
Solvent wipe with Isopropyl Alcohol * Abrade using clean fine grit abrasives Solvent wipe again with Isopropyl Alcohol *

1. 2. 3.

Rubbers
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 manufacturers precautions and directions for use when handling such materials

3Aerospace