Customer Training – Defect Identification

Cessna
January 18, 2006
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 CESSNA CITATION VII / X / EXCEL

CITATION VII

CITATION EXCEL

CITATION X

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 Defect Identification

Note: Photographs of defects included in this guide are

for reference only and are not specific to Cessna
aircraft windshields.

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 Defect Identification
Typical Ageing Windshield Failure Sequence

4 Moisture Seal Failure

4 Moisture Ingress
4 Urethane Interlayer Degradation
4 Delamination
4 Additional Moisture Ingression
4 Bus bar to heating Film Junction Deterioration
4 Bus Bar/Conductive Film Interface Arcing
4 Outboard Glass Ply Fracture
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Moisture Seal

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Defect Identification – Moisture Seal

4 WEATHER SEAL IS THE PRIMARY BARRIER TO PREVENT

MOISTURE FROM ENTERING THE LAMINATE

4 WEATHER SEAL DEGRADATION IS DUE PRIMARILY TO

WIND/RAIN EROSION OF THE SEALANT MATERIAL

4 WHILE NOT A STRUCTURAL ISSUE, IF MOISTURE INGRESS IS

IS PRESENT, DELAMINATION, AND ELECTRIC HEATING
SYSTEM DAMAGE/FAILURE CAN OCCUR REDUCING SERVICE
LIFE OF THE WINDSHIELD

4 INSPECT AND REPAIR THE MOISTURE/HUMP SEAL PER

APPLICABLE AMM PROCEDURE

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Moisture Seal – Cessna Citation VII / X / Excel

PR-1425 Moisture Seal

Main Windshield

PR-1425 Moisture Seal

Side Window

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Defect Identification – Moisture Seal Erosion

PR-1425 MOISTURE SEAL

MOISTURE SEAL
EROSION
SEALANT CRACK
OUTBOARD GLASS SURFACE DLO

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Windshield Defect Identification
Moisture Seal Erosion

PR-1425 Sealant

Interlayer Cracking

Moisture Ingress

Moisture Seal Erosion

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Moisture Ingress

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Windshield Defect Identification
Moisture Ingress

• Occurs due to degradation of the outboard

moisture seal or the vertical edge seal
• Evidenced by change in appearance of
interlayer from optically clear to hazy,
milky condition
• Ultimately causes degradation of urethane
interlayer and heating system bus bar

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Windshield Defect Identification
Moisture Ingress

Moisture Ingress

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Windshield Defect Identification
Moisture Ingress

Moisture Ingress

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Interlayer Degradation

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Windshield Defect Identification
Interlayer Degradation

Interlayer Degradation - General

4 Degradation of the interlayer may

occur due to failure of the outboard
moisture seal allowing moisture to
interact with the urethane and vinyl
interlayer.

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Windshield Defect Identification
Urethane Interlayer Degradation
Interlayer Degradation –
PPG 112 Urethane
4 Urethane interlayer appearance may
change from optically clear to a white,
milky, translucence due to moisture ingress.

4 Continued exposure to moisture will cause

degradation of the urethane creating a
“mud-cracking” appearance.
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Defect Identification – Interlayer Degradation

INTERLAYER
DEGRADATION

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Windshield Defect Identification
Urethane Interlayer Degradation

Urethane Interlayer
Degradation
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Windshield Defect Identification
Urethane Interlayer Degradation

Vision Area

Urethane Degradation

Bus Bar

Moisture Seal (PR-1425)

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Windshield Defect Identification
Urethane Interlayer Degradation

Vision Area

Moisture Ingress
Urethane
Degradation

Moisture Seal (PR-1425)

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Windshield Defect Identification
Urethane Interlayer Degradation

Bus Bar

Urethane Degradation

Moisture Ingress

Moisture Seal PR-1425

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Windshield Defect Identification
Vinyl Interlayer Degradation
Interlayer Degradation – PVB/AG Vinyl

4 PVB / AG vinyl interlayer may also

change from optically clear to a milky /
cloudy appearance due to moisture
ingress.

4 Delamination or debonding may also occur.

4 Cracking through thickness of vinyl

interlayer section may occur.

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Delamination

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Windshield Defect Identification
Delamination

Delamination
4 Types
• Clear - complete separation / de-bonding
• Cloudy - moisture present

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Defect Identification - Delamination

4 DELAMINATION WITHIN SPECIFIC

LIMITS DOES NOT EFFECT STRUCTURAL
INTEGRITY OF THE WINDSHIELD

4 DELAMINATION MAY IMPAIR VISIBILITY OR

ELECTRICAL HEATING SYSTEM OPERATION

NOTE: GLASS-FACED WINDSHIELDS SHOULD BE

REPLACED WHENEVER DELAMINATION
EXCEEDS LIMITS SPECIFIED IN AIRCRAFT
MAINTENANCE MANUAL

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 Defect Identification – Delamination
ALLOWABLE DELAMINATION LIMITS

Cessna Citation VII / X / Excel Main Windshield

4 1.0 inch from the edge of the daylight opening (vision area)
along the center post, top, and aft edges.

4 3.0 inches along the bottom edge.

4 Delamination is permissible in the non-critical vision area as

defined per the aircraft maintenance manual.

4 Delamination is not permitted in the semi-critical and critical

vision areas as defined per the aircraft maintenance manual.

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Defect Identification – Delamination

DELAMINATION

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Windshield Defect Identification
Delamination

Delamination

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Windshield Defect Identification
Delamination

Delamination
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Discoloration

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 Defect Identification – Interlayer Discoloration
DEFECT IDENTIFICATION - DISCOLORATION
4 AN AMBER/BROWN DISCOLORATION/STAIN, CAUSED
BY A MINOR REACTION BETWEEN THE POLYSULFIDE
WEATHER/MOISTURE SEAL AND THE URETHANE
INTERLAYER, MAY BE SEEN AROUND THE
PERIPHERY OF OLDER WINDSHIELDS

4 STAINING OF THE INTERLAYER DUE TO MOISTURE

INGRESS IS NOT A STRUCTURAL ISSUE, DOES NOT
AFFECT THE FUNCTIONALITY OF THE WINDSHIELD
AND IS NOT A CAUSE FOR REMOVAL

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Defect Identification – Bus Bar Discoloration
DEFECT IDENTIFICATION - DISCOLORATION
4 A BLACK OR BROWN DISCOLORATION MAY BE VISIBLE
ALONG THE INSIDE EDGE OF THE HEATING SYSTEM BUS
BAR, INTERNALLY VISIBLE LEAD WIRES, OR ANYWHERE
ON THE ELECTRICALLY CONDUCTIVE HEATING FILM

4 BLACK OR BROWN DISCOLORATION ALONG THE

ELECTRICAL BUS BARS, LEAD WIRES, OR HEATING FILM
IS AN INDICATION OF ARCING AND IS REGARDED AS A
POSSIBLE REASON FOR WINDSHIELD REMOVAL

4 CHECK THE HEATING ELEMENT (BUS TO BUS) RESISTANCE

IF THE RESISTANCE MEASURES BEYOND THE ALLOWABLE
TOLERANCE SPECIFIED IN THE AMM, THE WINDSHIELD
SHOULD BE REPLACED

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Defect Identification
Bus Bar/Interlayer Discoloration
DEFECT IDENTIFICATION - DISCOLORATION

BUS BAR

BUS BAR ARCING

MOISTURE INGRESS

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Heating System

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 Defect Identification – Heating System
ELECTRICAL ARCING
4 May occur along the top or bottom bus bar at the bus
bar/conductive film interface. It may also occur in the
vision area. Continued arcing will likely result in outboard
(outer) glass ply fracture. The windshield should be
replaced at the earliest opportunity.

HEATING SYSTEM FAILURE

4 The windshield may not heat. Check bus to bus
resistance of windshield per Aircraft Maintenance
Manual instructions. Remove windshield if resistance is
not within required resistance range.

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Defect Identification – Heating System
DEFECT IDENTIFICATION - ELECTRICAL HEATING SYSTEM

SENSING ELEMENT FAILURE

4 A sensing element has failed when its resistance is
beyond specified range or exhibits an open circuit.

WINDSHIELD HEAT CONTROLLER:

4 If the power and sensing element circuits check to be
acceptable, the heat problem could be caused by the
windshield heat controller. Consult the Aircraft
Maintenance Manual for procedure on required method
of checking the controller.

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Windshield Defect Identification
Heating System

Heating System Failure

4 Bus bar / heating film arcing
4 Sensing element failure
4 Windshield heat controller failure

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 Windshield Defect Identification
Discoloration – Bus Bar
Discoloration
4 Bus Bar
• Black or dark brown discoloration along the
inside edge of the heating system bus bar,
internally visible power lead wires, or on the
electrically conductive heating film is an
indication of arcing and should be regarded
as a potential removal for replacement.

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Defect Identification – Bus Bar Arcing

BUS BAR

BUS BAR ARCING

CONDUCTIVE FILM ARC

INTERLAYER DISCOLORATION

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Defect Identification – Conductive Film Arcing

CONDUCTIVE FILM ARC/BURN

GLASS FRACTURE

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Defect Identification - Electrical Heating System

Power Lead / Terminal Block Arcing

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Windshield Defect Identification
Bus Bar / Conductive Film Arcing

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Windshield Defect Identification
Bus Bar / Conductive Film Arcing

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Windshield Defect Identification
Bus Bar / Conductive Film Arcing

Vision Area / DLO

Interlayer Discoloration /
Degradation

Bus Bar

Bus Bar / Conductive Film

Arcing

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Windshield Defect Identification
Bus Bar / Conductive Film Arcing

Moisture Ingress

Bus Bar / Conductive

Film Arcing

Bus Bar Degradation

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Windshield Defect Identification
Bus Bar / Conductive Film Arcing

Outboard Metal Retainer

Bus Bar

Moisture Ingress
Bus Bar / Conductive Film Arcing

Vision Area

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Windshield Defect Identification
Bus Bar / Conductive Film Arcing

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Interlayer Bubbling

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Windshield Defect Identification
Interlayer Bubbling

Cause:
• Overheat condition

• Over torque of windshield fasteners

• Clamping pressure

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Windshield Defect Identification
Interlayer Bubbling

4 Small bubbles may form within the interlayer.

4 Bubbles in the interlayer are not considered to
be a structural issue.
4 Bubbles may be an indication of a problem with the
electrical heating system of the windshield or the
windshield heat controller.
4 If interlayer bubbling is believed to be due to a
heating system problem, check/measure the
heating system bus to bus resistance and
temperature sensing element resistance for an
out-of tolerance condition.
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Windshield Defect Identification
Interlayer Bubbling – Overheat Condition

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Windshield Defect Identification Interlayer
Bubbling – Clamping Pressure
4 Bubbles in the interlayer may also be
caused by clamping pressure. This type of
bubbling typically occurs near the edge of
the vision area and is the result of
localized clamping pressure or over
torque of the mounting fasteners around
the periphery of the windshield.

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Windshield Defect Identification Interlayer
Bubbling – Clamping Pressure

MOISTURE SEAL

1.5” - 2.0”

VISION AREA (DLO)

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Temperature Sensing Element

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Windshield Defect Identification Temperature
Sensing Element
Temperature Sensing Element

• Controls power applied to windshield

• Typical control temperature is 110º F. (anti-ice)

• Typical failure modes include:

4 Open circuit
4 Cracking / crazing (not a cause for removal)

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Windshield Defect Identification Temperature
Sensing Element

Cracking / Crazing

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Terminal Block

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Windshield Defect Identification
Terminal Block/Power Lead Wire Arcing
Power Lead Wire/
Terminal Block Arcing

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Terminal Block Arcing

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Glass Fracture

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Windshield Defect Identification
Glass Fracture
Glass Fracture
4 Glass fracturing or cracking can occur
on any of the glass plies.
4 Glass fracture can result from foreign
object damage (FOD) impact /
impingement, surface scratches,
overheat condition, electrical arcing or
peel / adhesion chip.

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Windshield Defect Identification
Glass Fracture – Impact Damage

Outboard Glass Surface

Fracture Face
Impact Damage

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Windshield Defect Identification
Glass Fracture – Impact Damage

OUTBOARD SURFACE
Surface Crush Damage

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Windshield Defect Identification
Glass Fracture – Conductive Film Arcing

Glass Fracture Origin - Overheat

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Scratches

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Windshield Defect Identification
Scratches - Types
• Superficial / Hairline / Sleek
4 Scratch can be seen under certain
lighting conditions (i.e. reflected light)
• Light
4 Scratch is typically less than 0.001 inch
(.025 mm) deep
4 ASTM Scratch Std. #6 or less
• Heavy
4 Scratch is typically greater than 0.002 inch
(.051 mm) deep
4 Greater than ASTM Scratch Std. #6
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Windshield Defect Identification

Scratches
4 Superficial / Hairline Scratches
• Caused by wiping glass with a dry cloth,
which has an effect similar to rubbing the
glass surface with a fine grade of
sandpaper.

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Windshield Defect Identification

Scratches
4 Light Scratches
• Usually results from improper handling,
contact of glass surface with rings,
watches, belt buckles.
• Improper cleaning using powdered
detergents and/or other abrasive
cleaners.

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Windshield Defect Identification
Scratches
Scratches
4 Heavy Scratches
• Caused by sharp edged tools usually
during windshield installation.
• Accidental contact of the inboard surface
by pilot’s notebooks, clipboards, flight
manuals.

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Windshield Defect Identification - Scratches

4ASTM Standard F 428

Standard Test Method for Intensity of Scratches
on Aerospace Glass Enclosures.

• PPG uses this standard for assessing scratch

intensity on many glass windows.
• Uses visual comparison to assess damage.
• Typical criteria for scratch on structural glass
ply:
If scratch is greater than ASTM F 428-6,
window replacement is required.
(Refer to ACMM or governing document.)

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Windshield Defect Identification - Scratches

4ASTM Standard F 428 Aerospace Scratch Standard

for Glass
4Standard Test Method for Intensity of Scratches on
Aerospace Glass Enclosures

inches

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Defect Identification - Scratch

SCRATCH - PERMISSIBLE LIMITS

Cessna Citation VII / X / Excel Main Windshield

4 Minor (light) scratch repair, which is limited to

scratches no more than 0.002 inch in depth, requires
that the windshield be removed and returned to the
manufacturer for repair.
There are no exceptions.

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Defect Identification - Scratch
SCRATCH REPAIR

METHODS
4Scratch Wheel
4 Handwork

CONCERNS
4Thickness Requirements
4Glass Strength
4Distortion
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Peel Chip

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 Peel Chip
DEFECT IDENTIFICATION - PEEL CHIP
4 INNER OR LAMINATED SURFACE PEEL/ADHESION CHIPS CAN
OCCUR ON THE SURFACE OF ANY OF THE GLASS PLIES

4 PEEL CHIPS USUALLY FORM IN COLD AREA(S) OF THE

WINDSHIELD

4 PEEL CHIPS EXHIBIT JAGGED PROGRESSION LINES AS THE

CHIP GROWS TO BECOME LARGER/WIDER

4 PEEL CHIPS WILL CONTINUE TO EXPAND PROPAGATE UNTIL

THE STRESS THAT CAUSED ITS INITIATION IS RELIEVED

4 BECAUSE THE STRENGTH OF THE GLASS STRUCTURAL PLY

IS REDUCED BY THIS TYPE DEFECT, WINDSHIELD REMOVAL
IS REQUIRED
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Windshield Defect Identification – Peel Chip

Peel Chip
4 Created by local
excessive adhesion
at the glass surface
or edge usually from
contraction of vinyl or
fiberglass resin Direction of
propagation
4 Creates sharp “V” Peel Chip
shaped chip at origin Origin

4 Chip propagates or
“peels” with thermal
and mechanical stress
until spontaneous fracture
occurs

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Defect Identification – Peel Chip

ORIGIN

PEEL CHIP

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Product Support Contacts
Ann Wommack - Account Manager
Telephone: (316) 689-4243 / FAX: (316) 689-4258
E-Mail: wommack@ppg.com
David Bohannan - Manager, Product Support
Telephone: (256) 859-2500 ext. 1029 / FAX: (256) 859-8155
E-Mail: bohannan@ppg.com

Rodney Mitchell - Product Support Engineer

Telephone: (256) 859-2500 ext. 2521 / FAX (256) 859-8155
E-Mail: ramitchell@ppg.com

David Allen - Technical Training Coordinator

Telephone: (256) 859-2500 ext. 2338 / FAX: (256) 859-8155
E-Mail: dcallen@ppg.com

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