Process specification

PCS-2800
Issue: 4
Date: 11th February 2008

TEMPORARY CORROSION AND DAMAGE

PROTECTION OF PARTS

PROTECTION TEMPORAIRE DES PIÈCES CONTRE LA

CORROSION
ET LES DÉTÉRIORATIONS

Issue N° Date Changes

1 09/00 Original issue.

2 08/01 Addition of other products.
3 08/02 Inclusion of new products and Toronto in the Approval List.
4 02/08 General revision with updating of specification references.

P. GREGORY: Materials and Processes Laboratory Engineer approved on file

Compiled by
(UK) approuvé sur dossier
approved on file
F. PESTEL: Materials and Processes Laboratory Engineer (F) approuvé sur dossier
Agreed by
approved on file
R. RAININGER: Materials Engineer (C)
approuvé sur dossier

Specification prime P. TAYLOR: Materials and Processes Laboratory Manager (F) approved on file
owner approuvé sur dossier

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Process specification
PCS-2800
Issue: 4
Date: 11th February 2087

INDEX

Page

1. INTRODUCTION 3

2. SCOPE 3

3. RESTRICTIONS ON USE 4

4. ASSOCIATED SPECIFICATIONS 4

5. DEFINITIONS 5

6. HEALTH AND SAFETY 5

7. SECTION 1: PROTECTION OF PARTS. SHORT-TERM PROTECTION

PRODUCTS 6

8. SECTION 2: PROTECTION OF PARTS. LONG-TERM PROTECTION

PRODUCTS 7

9. SECTION 3: PROTECTION OF PARTS. PACKAGING AND DAMAGE

PROTECTION 9

10. RECEIPT, STORAGE AND EXPIRY DATE 10

APPENDICES

APPENDIX A 11

APPENDIX B 12

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 Process specification
PCS-2800
Issue: 4
Date: 11th February 2008

PCS-2800
Temporary Corrosion and Damage Protection of Parts

1. Introduction

A. This specification covers the selection and use of temporary anti-corrosion products, wrappings and
protective sleeves, which can be applied for the storage and inter-operational protection of parts.

B. Their application is essential to all unprotected or partially protected metallic parts, which are subject
to the risk of corrosion, or impacts, whilst awaiting action between operations and during their
storage, their transit or transfer to other manufacturing sites.

C. This specification supersedes PCS-2800 Issue 3. It shall be implemented within 12 months of the
publication of Issue 4.

2. Scope

A. This specification is divided into three sections.

(1) Section 1: Short-term Protection Products

(a) This section contains the procedures for using de-watering fluids, which deposit soft, thin
films of preservative for the corrosion protection of parts, between machining operations,
and for short-term indoor storage periods of up to 3 months.

(2) Section 2: Long-term Protection Products

(a) This section contains procedures using liquids forming wax-like, or dry films, for long-term
temporary protection during storage under normal indoor conditions. This section also
describes the longer term protection of forgings and castings during transit, or transfer,
between sites and short periods of storage out of doors, but shielded from the weather.
Where necessary, these fluids may be applied over anti-corrosion surface treatments,
such as chromated magnesium.

(3) Section 3: Packaging and Damage Protection Products

(a) This section contains procedures for protecting items from damage due to dirt and han-
dling hazards. It also deals with protecting the soft protective films, produced by Section 1
and Section 2, from handling damage.

B. Temporary anti-corrosion products consist of organic products dissolved in a volatile hydrocarbon

solvent. On evaporation of the solvent, they deposit an oily, wax-like or dry anti-corrosion protective
film, which can be removed with hydrocarbon solvents.

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 Process specification
PCS-2800
Issue: 4
Date: 11th February 2008
C. The fluids described in this specification contain flammable solvents and care shall be exercised in
their use to avoid ignition.

D. The choice of protection will depend on:

(1) The length of the delay between operations

(2) The storage period

(3) The environmental conditions (temperature, relative humidity, atmospheric pollution, etc)

(4) The degree of susceptibility to corrosion of the metals and alloys treated

(5) The type of packaging

E. The storage durations given are mean values for sheltered conditions. These durations may be
doubled, or reduced by half, depending on the environmental conditions.

3. Restriction On Use

A. All elastomer materials, which can possibly be present on parts, or equipment, such as seals, collars
and sleeves, shall not be put in direct contact with these products, because of the risk of damage by
chemical incompatibility.

4. Associated Specifications

A. Messier-Dowty Specifications

M-DL M-D SA M-D Inc Title

PCS-2620 Hot Degreasing

B. National Standards

AIR 3634 Corrosion Preventive Compound, Solvent Cut Back, Cold Application
AIR 8132 Corrosion Preventive Compound

DEF STAN 68-10 Corrosion Preventive Compound, Water Displacing

DEF STAN 80-83 Corrosion Protective, Hard Film, Transparent, Cold Application
DEF STAN 80-217 Protective PX-1(Dyed), Protective PX-1(Undyed)
MIL-PRF-16173 Corrosion Preventive Compound, Solvent Cut Back, Cold Application

MIL-PRF-81309 Corrosion Preventive Compounds, Water Displacing, Ultra Thin Film

(1) Where no issue number is given for the standards listed above, the current issue is to be applied.

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 Process specification
PCS-2800
Issue: 4
Date: 11th February 2008
5. Definitions

A. PVC: polyvinyl chloride.

6. Health and Safety

A. The materials called up in this specification contain substances that may be harmful to health. In
addition, they are flammable and shall be handled in a safe manner.

B. It is the Departmental Manager's responsibility to develop safe working practices for the use of these
materials and to take notice of the hazards detailed on the relevant Materials Health and Safety Data
Sheet.

C. In addition, the following general precautions should be considered when establishing a safe working
practice.

(1) Liquids, oils and packaging products contain flammable materials. Avoid exposure to flames,
hot wires and sparks. In case of fire, use carbon dioxide, dry powder or foam extinguishers.

(2) Handling techniques shall ensure their safe use. This means that it is necessary to avoid direct
contact with skin, ingestion or inhalation and to use or store products in well ventilated areas.
Food shall not be consumed in the presence of these products.

(3) Eye protection should be worn during products and parts handling operations. In case of eye
splashes, immediately flush the affected eye with water from an eyewash bottle or fountain, or
with low-pressure running water, for at least 5 minutes. Obtain immediate medical attention.

(4) In case of splashes to clothing, the contaminated clothing, including underclothing, should be
changed immediately and thoroughly cleansed before re-use. Medical advice should be sought
if skin trouble develops.

(5) In case of splashes to skin, thoroughly clean with lukewarm water and soap. The use of solvents
is to be avoided. Disposable paper towels, not cloth, should be used to dry the skin.

(6) Smoking, eating and drinking are forbidden in areas where these products are being used.

(7) If liquid is introduced into the lung, obtain medical attention immediately. If liquid is swallowed,
obtain immediate medical attention. Do not induce vomiting.

(8) Hands should be washed and outer protective clothing changed before eating.

(9) If leakage or spillages occur, then the product should be cleaned up with a non-combustible
absorbent material. The contaminated cleaning material shall be removed as soon as possible
from the work place to safe storage to await disposal.

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 Process specification
PCS-2800
Issue: 4
Date: 11th February 2008
(10) Contaminated cleaning material and other unwanted materials shall be disposed of in
accordance with the requirement of local legislation. Complete any relevant documents.

7. Section 1: Protection of Parts. Short-term Protection Products

A. These fluids are de-watering oils, some with fingerprint neutraliser agent. They are suitable for the
protection of parts between machining operations, and for short-term storage (maximum 3 months),
prior to assembly.

B. Applicability

(1) Aluminium, steel, magnesium and copper alloy parts may all be protected by this process.
Where possible, however, separate tanks should be provided for these four main classes of
metals, because contamination by swarf of dissimilar metals may promote corrosion despite the
presence of the temporary protective.

(2) If the part is not moving immediately to another operation that requires it to be degreased, it is
advisable to protect with de-watering oil.

(3) De-watering should be carried out immediately after operations that are known to leave the part
vulnerable to corrosion.

C. Equipment and Materials Required

(1) De-watering oil meeting:

(a) MIL-PRF-81309, AIR 3634,or DEF STAN 68-10 specifications

or

(b) Short time protection products listed in Appendix A.

(2) Galvanised steel tanks, or tanks made from an inert polymer such as polyethylene or
polypropylene, fitted with an inclined bottom, perforated draining shelf, a tap for draining settled
water and the option of a close fitting lid to restrict any evaporation and vapour emissions.

NOTE: If it is intended to stand the component in the de-watering fluid, a perforated shelf shall be
fitted in the bottom of the tank, above the anticipated water level.

D. Procedure

(1) Parts shall be as clean as possible before dipping in the de-watering fluid. Excess oil and swarf
should be removed before dipping.

(2) Immerse the components in the de-watering oil for at least 30 seconds. Ensure all surfaces
have been wetted with the oil, paying particular attention to blind bores.

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 Process specification
PCS-2800
Issue: 4
Date: 11th February 2008
(3) If immersion is impractical, such as when parts remain on a machine, it is permissible to apply
the fluids by brush or spray. Ensure all surfaces and blind bores are thoroughly wetted.

(4) Allow the part to drain. Some fluids contain higher boiling solvents than others and will,
therefore, require a longer period of drying before the deposited film can be handled.

(5) Replace lids on tanks if present, in order to restrict any evaporation and vapour emissions.

E. The water that will collect in the bottom of the tanks containing de-watering fluids shall be regularly
drained off to avoid contact with the part and to maintain the oil de-watering efficiency.

F. Operators of de-watering baths shall check the de-watering efficiency of their temporary protection
fluid at regular intervals. This shall be done using, either a method recommended by the fluid
supplier, or one given by a written procedure.

G. The frequency of the checks should be such that they ensure that the fluid is always capable of de-
watering parts.

H. If the de-watering efficiency of the fluid is impaired, the manufacturer shall be consulted as to what
corrective action is required to recover de-watering efficiency.

I. Dewatering fluids that have become heavily soiled, or are incapable of being recovered, should be
disposed of in accordance with local legislation, and the tank refilled with new fluid which is within its
shelf life.

J. Films may be removed by vapour degreasing in accordance with PCS-2620, by power washing with a
hydrocarbon based solvent, or by swabbing in accordance with PCS-2622.

8. Section 2: Protection of Parts. Long-term Protection Products

A. The two types of fluid included in this section offer storage times equal to or greater than Section 1
products.

(1) Type 1. Long-term Protection Products

(a) A soft wax-like, undyed film forming product, with de-watering properties which may be
applied to wet components.

or

(2) Type 2. Long-term Protection Products

(a) A wax-like or dry film forming product. These fluids are not de-watering products, and,
therefore, the part shall be clean and dry before application of the fluid. These materials are
suitable for the protection of forgings and castings during transport and storage. Some of
these fluids are transparent and, therefore, they should be used when it is desirable to read
markings on the underlying metal.

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Process specification
PCS-2800
Issue: 4
Date: 11th February 2008
B. The choice of product and the duration of its effectiveness will depend on the conditions listed in para
2.D.

C. Equipment and Materials Required

(1) Type 1. Long-term Protection Fluids

(a) These fluids offer protection indoor of approximately 6 months and meet:

1 MIL-PRF-16173, Grade 3 (undyed) or DEF STAN 80-217 (Undyed)

or

2 Selected from the long-term products list referenced in Appendix A.

(2) Type 2. Long-term Protection Fluids

(a) These fluids offer indoors protection from at least 6 months up to 10 years, depending on
the grade. Protection outdoors can be up to 1 year. These fluids meet:

1 MIL-PRF-16173, Grade 1,2 or 4, AIR 8132, or DEF STAN 80-83.

or

2 Selected from the long-term products list referenced in Appendix A.

(3) The equipment required for dipping parts are identical to the ones indicated in short time
protection products, see para 7.C.(2).

D. Procedure

(1) Cleaned parts, which are to be treated with Type 1 fluids, should be immersed in the fluid in the
same manner as described in para 7.D of short-term protection products. Because clean parts
are being immersed in this fluid, there should be no excess contamination of the fluid. However,
every precaution should be taken to ensure the fluid is kept in good condition and that parts
immersed in it are not lowered deep enough to pick up any sediment which may have settled in
the lower part of the tank. The soft films deposited from these fluids need to be protected from
damage by wrapping as described in para 9.

(2) Parts to be treated with Type 2 fluids shall be clean and dry. Cleaning should be carried out by
immersing in hydrocarbon solvents, such as white spirit, odourless kerosene or similar. Care
shall be taken to ensure all surfaces, especially blind bores are thoroughly cleaned. Spray
washing and pressure jet washing systems may also be used. The cleaned units should then be
dried by wiping with clean, lint-free wipers, or by blasting with clean, dry air.

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 Process specification
PCS-2800
Issue: 4
Date: 11th February 2008

(3) Application of Type 2 coatings is best done by spraying, preferably using airless spraying. The
coatings should be applied to give a uniform coating approximately 0.05 mm (0.002 in) thick.
Small areas may be coated by brushing, but care shall be exercised to ensure that a coating of
at least 0.05 mm (0.002 in) is produced and no thin areas are produced due to brushing out.

(4) Type 2 coatings are transparent and may be handled with care after eight hours. After 24
hours, the coatings are tack free.

(5) Regular density checks of the fluid should be made to confirm that the product conforms to the
requirements of the suppliers technical data sheet. Any adjustment necessary should be made
by the addition of white spirit.

(6) Fluid that has become unsuitable for use should be disposed of in accordance with local
legislation and replaced with new fluid that is within its shelf life.

(7) Films deposited from Type 1 and Type 2 fluids may be removed when necessary, by either
power washing with odourless kerosene, or swabbing with white spirit, or immersion in a
hydrocarbon based solvent.

9. Section 3: Protection of Parts, Packaging and Damage Protection

A. This section lists some methods and gives some guidance, on the prevention of damage caused by
moisture, or dirt contamination, and by mechanical damage commonly caused in transit.

B. It is stressed that it is usually a false economy to omit to pack, or protect, components in transit
between operations, or between sites.

C. Protection against mechanical damage as described in this section is complementary to protection

against corrosion afforded by Section 1 and Section 2.

D. Forgings, castings and parts treated with Type 2 fluids for transport shall be protected from damage
by packing in suitable containers, such as wooden boxes. Care shall be taken to ensure that treated
items cannot rub against each other and are firmly supported to prevent distortion.

E. Wrappings for military equipment shall be in accordance with the appropriate military specification.

F. Work not destined for a military application may be protected by any other wrapping, which has been
shown to be suitable for the particular application.

G. Application of a polyurethane foam resin, such as Instapak, in accordance with the manufacturer’s
instructions is permitted, provided individual components are pre-wrapped in such a way that they are
protected from direct contact with the foam.

H. Procedure

(1) Components protected by a soft wax-like preservative film should be left to allow the solvent to
evaporate before being wrapped in paper. Further damage protection can then be applied,
dependent upon the size of the unit.

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 Process specification
PCS-2800
Issue: 4
Date: 11th February 2008

(2) Small items can be packed in polyethylene bags, or polyethylene sheeting made especially for
the part. The use of white cloth bags, or corrugated paper, is not recommended for primary
wrapping.

(3) Components will be more easily handled, and better protected, if packed in boxes during transit
between operations. Prior to packing, parts should be cleaned free of swarf, loose dirt and the
residues of chemical processing solutions.

(4) Delicate components and large items in transit may be protected from mechanical damage by
the use of special fixtures, or boxes, whichever is the most appropriate.

(5) The use of a PVC Plastisol provides a relatively easy and inexpensive means of manufacturing
rubber-like mouldings for the mechanical protection of delicate parts. The mouldings are quite
strong and re-usable. See Appendix B for method of manufacture.

(6) Adhesive tape should be used to cover delicate splines in order to prevent damage between
operations.

10. Receipt, Storage and Expiry Date

A. Receipt

(1) On receipt of the product:

(a) Check the presence of Certificate of Conformance

(b) Check manufacturing date and expiry date, which shall be indicated on the identification
label

(c) Check that expiry date allows at least 12 months of storage

(d) Sanction: refusal to accept non-conforming deliveries, or products with a remaining shelf life
of less than 12 months

B. Storage

(1) Store unopened drums in an area which is frost-free, under cover and ventilated and, as far as
possible, at a temperature between 15 °C and 25 °C (59 °C to 77 °F), remote from any source
of ignition and oxidising products.

(2) Inspect drums regularly for signs of corrosion or leakage and put it right if necessary.

C. Expiry Date

(1) For all the products: 24 months.

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 Process specification
PCS-2800
Issue: 4
Date: 11th February 2008

Appendix A

A.1. Messier-Dowty Approved Short-term Protection Products Not Meeting a National Standard

PRODUCT SUPPLIER
Ardrox 396/1 E8 Chemetall
Ardrox 3968 Chemetall
Rustilo DWX 30 Castrol
Rustilo DW 924 Castrol Canada
Synergen 718 Agma Plc
AGIR 66 AGIR
PROTEX GM3 SPCA
Tectyl 275 Valvoline Oil Co

A.2. Messier-Dowty Approved Long-term Protection Products Not Meeting a National Standard

PRODUCT SUPPLIER

TYPE 1 TYPE 2
Chemetall
Ardrox 3140
Ardrox AV 100D * Chemetall

Protex CS 39 SPCA

Ferrocoat N5818 HF Quaker Chemical BV

Wadis 24/60 Socomor

Aerospec Protect Rocol

NOTE: * Ardrox AV 100D is a replacement for Dinitrol AV 100

A.3. Packaging and Damage Protection Products

PRODUCT SUPPLIER
Plastisol Hydro-Coatings
Instapak Foam Sealed Air Corporation

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Process specification
PCS-2800
Issue: 4
Date: 11th February 2008

Appendix B

B.1 Method of Manufacture of Plastisol Mouldings

A. To make a PVC Plastisol moulding, a light alloy mould should be made with a polished finish
on the mould surface. The design of the mould should be such that it can be easily filled by
pouring the viscous PVC paste into it. The filled mould is then placed in the oven and
brought up to a temperature specified by the manufacturer. It shall be kept at this
temperature for at least 30 minutes. PVC Plastisol will emit hazardous fumes if overheated
and care shall be taken to avoid this happening. The mould is then taken from the oven,
cooled in cold water and the moulding extracted.

B. Protective fixtures may be manufactured by coating a heated (120 ºC) (248 ºF) light alloy
mould with the PVC paste, by dipping. The surplus paste is allowed to drain, and then the
coating is cured by heating. The mould is taken from the oven, cooled in cold water and the
moulding peeled off. The same technique may be employed for producing a flexible coating
on racks and wire baskets

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