May 2003

1
May 2003

• 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

2
3M Aerospace Materials
Structural Non Structural
Adhesives Structural Film adhesives Primers
Core splice films Low Density Void fillers
(Potting Compounds) Coatings PPT Paint
Replacement film
Chromated Primers Adhesion Promoters
Aerospace Materials
3
3M Aerospace Materials
3M Structural Bonding films
Positioning of existing Bonding films
120/120
175/135
175/175
175/230
Curing/In-service temperature
Today AF163-2 AF3109-2 AF191 AF30 AF126-2 AF311
3-5 AF147 AF10
Applications
Metal/metal bonding Composite surfacing Composite
bonding
Composite cocure
Metal/composite bonding Metal/Metal
bonding Composite/composite
Metal / Metal bonding
4
3M Aerospace Materials
Only Silan primer
Epoxy Silan primer
Silan based Adhesion Promotors
Phenolic based
3M Primers
Epoxy based
Epoxy / Phenolic based
With Corrosion inhibitor
Solvant diluated adhesive
Solvent based
Low VOC
5
3M Aerospace Materials
3M Low Density Void Filler Applications
Core splicing
Abradable layer for jet engines
Low Density Void Fillers
Core edge sealing
Insert Bonding
Fuel tank inside coating
Core reinforcement
6
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 3439 HS AF Fire,
smoke, toxicity products 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
7
3M Aerospace Materials

• Edge finishing
• Honeycomb assemblage
• Principe 1K epoxy film containing foaming
  agents and glass bubbles for assembling of light
  weight structures.

3M Core splice films
Film Expansion range () AF 3002 125 - 160 AF
3024 170 - 350 AF 3030 FST 170 - 250 Expansion
Final Thickness / Initial Thickness
8
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
9
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

10
3M Aerospace Materials
Existing structural 3M 2K epoxy systems
Mono component
Bi - component
RT cure
Heat cure
Mild heat cure

• Bulk
• EC 2214
• EC 9360

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

• 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

11
Films and Primer Technology Migration
AF-163-2 repl. R.T. stable
120C Curing Films
AF 500
120/175C Curing
Very High Peel
AF 600
175C Curing Films
Composite Bonding
Non-chromated 120C/175C
EW-5000
LowVOC Primers
EW-6000
12
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

Overall purpose film
13
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.

14
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

15
Ease of Use and Shop Handling

• Property AF-600
• Tack (0-10) 4
• Conforming (0-10) 8
• Out time at ambient 30 days
• Flow
  Controlled
• Reticulation Capable yes

16
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

17
Primer development programs

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

18
Primer development programs
Highlights
EW-5000 EW-5000NC EW-6000 Solvent Low
VOC water-borne primer Chemistry Epoxy Epoxy
Epoxy/Phenolic Inhibitor Chromate Non-Chro
mate Chromate Remarks Excellent
corrosion and mechanical perf.
User-friendly in shop
handling
Targeted for high productivity
19
Primer development programs
Key Properties
EW-5000 EW-5000NC EW-6000 Application
Spray gun application Handling MEK
Skydrol resistance VOC content 247 g/dm3 166
g/dm3 233 g/dm3 Thickess range
2,5 - 9,0 µm (cured) Remarks
1 box coat to obtain 5 µm
Quick flash dry
Visible thickness difference
prior to cure
20
Primer development programs
About Corrosion resistance
EW-5000NC
EW-5000
After 100 days in 5 salt spray
21
3M Aerospace Materials
Existing structural 3M 2K epoxy systems
Bi - component
RT cure
Mild heat cure

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

• 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

22
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 100µm 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

23
3M Structural 2K Paste Adhesives
SCOTCH-WELD? PRODUCT POSITIONNING
Overlap Shear Strength (MPa) Test conditions DP
760 SW 9323 B/A DP190 DP490 - 55 3C 17,4
(C) 29,0 (C) 10,3 (C) 27,5 (C)
23 2C 29,1 (C) 41,0
(C) 17,2 (C) 28,5 (C)
80 2C 24,2 (C) 23,5 (C) 2,8 (C) 11,9
(C) 120 2C 16,1 (C) 3,5 (C) 2,0 (C) 3,2
(C) 150 2C 11,9 (C) 2,5 (C) 1,4 (C) 1,7
(C) 175 3C 7,3 (C) 1,2 (C) 1,4 (C) 205
3C 5,2 (C) 230 3C 3,0 (C)
Tg midpoint (2nd DSC Scan) Fully cured
product 145-150C 80-90C 13-25C 60-65C
24
3M Structural 2K Paste Adhesives
SCOTCH-WELD? PRODUCT POSITIONNING
25
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
0.15 mm (6mil) Smooth Surfaces lt100µinch
Roughness For Smooth Surfaces
(Not Suitable For
Aircraft Exterior) 4805 Paint Replacement
Tape 0.23 mm (9mil) Rough Surfaces gt
100µinch Roughness For Rough
Surfaces (Not
Suitable For Aircraft Exterior) 5004 Paint
Replacement Tape 0.14 mm (5.5mil)
Aircraft Top-Coat Paint Replacement
For Aircraft Exterior
Paint Replacement (Applique) Technology Support
Products
Product Description
Application
4881 Adhesion Test Strip For 5004
Indicates Adhesion Above and Below
40oz/in width per ASTM D3330 4882 Sealing
Film
Used with DP190 or DP460 Provides Color Matched
Edge Seal 4883 Support Kit
Tools to Support
Installation/Repair of Paint Replacement Tapes

26
High Performance Surface Coating
Protection Benefits of Fluoropolymer Film Coating
Technology Paint By The Roll
Features Attributes
Benefits

• Low Surface Energy
• Low WVTR
• Chemical/Fluid Resistance
• UV / Color Stability
• Conformability
• Flame Retardant

• Reduced Dirt Collection
• Reduced Corrosion
• Expanded Durability
• Expanded Longevity
• Expanded Coverage Areas
• Non-Flammable, low Smoke

• Reduced Cleaning Requirement
• Reduced Repairs, Extended
• Service Life
• Extended Service Life
• Extended Service Life
• Enhanced Substrate Protection
• Improved Safety

27
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)

28
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

29
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

30
Cleaning methods

• The following cleaning methods are suggested for
  common surfacess

• 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).
• 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

31
Cleaning methods

• 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

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

• Rubbers
• Solvent wipe with Methyl Ethyl Ketone (MEK)
• Abrade using clean fine grit abrasives
• Wipe again with MEK

32
Cleaning methods

• Glass
• 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