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BOEING is a trademark of Boeing Management Company.
Copyright © 2010 Boeing. All rights reserved.
Finish Appearance Challenges and Opportunities at Boeing Bruce Davis Boeing Research &Technology
April 12, 2011
COPYRIGHT © 2010 THE BOEING COMPANY
Earlier developments in aviation history have driven dramatic changes in finish requirements
Boeing Model C
1916
Boeing 247
1933
Boeing 707
1957 - 1978
Linen fabric, wood, and wire:
Nitrocellulose lacquer
Aluminum pigment
Aluminum Construction:
Epoxy and polyurethane enamels
Hexavalent chromium
Chemical and corrosion resistance
COPYRIGHT © 2010 THE BOEING COMPANY
• Environmentally compliant coatings
• Extensive use of composite structure
• Globally distributed supplier base
The 787 Dreamliner has placed a new set of demands on aircraft finishes
COPYRIGHT © 2010 THE BOEING COMPANY
Extensive use of composite structures delivers benefits and drives new challenges
• Lighter
• More durable
• Negligible corrosion
and fatigue
• Reduced scheduled
maintenance
• Opens new design
possibilities
• Presents new finishing
challenges
Carbon laminate
Carbon sandwich
Other composites
Aluminum
Titanium
Titanium/steel/aluminum
Aluminum
20%
Titanium
15%
Steel
10%
Other
5%
Composites
50%
COPYRIGHT © 2010 THE BOEING COMPANY
Boeing has addressed a range of 787 composite finishing challenges
• Composite fuselage design
• Epoxy impregnated carbon fibers are
wrapped onto smooth tool surface which
after curing becomes interior of fuselage
• Caul sheets used to create smooth exterior
surface
• “Weave” texture can contribute to orange
peel-like appearance
• Challenge is to achieve acceptable finish
quality without resorting to fillers and
surfacers, which add weight and can lead to
cracking problems
COPYRIGHT © 2010 THE BOEING COMPANY
Final exterior appearance development for composites requires consideration of many factors
Final Exterior
Appearance
Mold Release
Agents
Cleanliness
Detection
Surface
Preparation
Caul Sheet
Development
Part Design
Appearance
Inspection/
Expectation
Coating
Optimization
Surfacing Film
Development
Durability
COPYRIGHT © 2010 THE BOEING COMPANY
Asia Fuji
Mitsubishi
Kawasaki
KAL-ASD
Canada Boeing
Messier-Dowty
Australia Boeing
U.S. Boeing
Spirit
GE
Goodrich
Europe Messier-Dowty
Rolls-Royce
Latécoère
Alenia
Saab
Wing tips Seoul, Korea
Moveable trailing edge Melbourne, Australia
Fixed trailing edge Nagoya, Japan
Wing Nagoya, Japan
Nacelles Chula Vista, CA
Tail fin Frederickson, WA
Horizontal stabilizer Foggia, Italy
Aft fuselage Charleston, SC
Passenger entry doors Toulouse, France
Center fuselage Grottaglie, Italy
Mid forward fuselage Nagoya, Japan Forward fuselage
Wichita, KS
Cargo access doors Linköping, Sweden
Wing/body fairing
Landing gear doors Winnipeg, Canada
Engines
GE – Evandale, Ohio
Rolls Royce – Derby, UK
Fixed and moveable
leading edge Tulsa, OK
Landing gear Gloucester, UK
Center wing box Nagoya, Japan
Main landing gear
wheel well Nagoya, Japan
48
47
46
44
43
41
11 45
Partners Across the Globe are Bringing the 787 Together
COPYRIGHT © 2010 THE BOEING COMPANY
Distributed supplier base introduces additional challenges for exterior finishes
• Some sections come fully painted from supplier
• Wings, engine pylons, horizontal stabilizer
• Final assembly of these sections accomplished in Everett,
WA
• Requires approximately 25,000 pre-painted fasteners (heads
only) for assembly
• Over 20 different suppliers applying paint prior to assembly
• Color match issues led to establishment of requirement for
quantitative color match to standard Hide over representative substrates
0
0.5
1
1.5
2
2.5
3
3.5
0 1 2 3 4
Topcoat dry film thickness (mils)
delt
a E
SD Wing-Copper/BMS10-118
SD Wing-Blk/BMS10-118
SD Wing-Copper/BMS10-118
SD Wing-Blk/BMS10-118
SD Metlbond/BMS10-103A
SD Metlbond/BMS10-103A
SD Glass/BMS10-21/BMS103A
SD Glass/BMS10-21/BMS103A
Diel Top(BMS5-45)
Wing BMS8/276/BMS10-118
COPYRIGHT © 2010 THE BOEING COMPANY
Large aircraft painting introduces more challenges
787 Dreamliner Premiere 07.08.07
• Surface preparation and paint application in same hangar
• Manual application of coatings
COPYRIGHT © 2010 THE BOEING COMPANY
Numerous factors contribute to final paint appearance
• Substrate
• Layup, surfacer type, caul plate
type, etc.
• Surface prep method
• Any repairs
• Painter
• Experience
• Training
• Preferred technique (gun
triggering, gun distance to part,
cross coating, etc.)
• Equipment
• Type (AA, Electrostatic,
Conventional, HVLP, etc.)
• Settings (fluid flow rate, air
settings, etc.)
• Equipment maintenance
practices
• Environmental Conditions
• Temperature and humidity
• Process
• Paint thickness (target and
actual)
• Overcoat times
• Cure conditions
• Paint
• Rheology
• Cure profile
• Batch to batch color
consistency
• Hide
• Facility
• Air quality and flow patterns
• Booth contamination
• Painter access to part
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Lab studies of application parameters may or may not correlate with production
• Charts showing orange peel at
different gun to part distance, spray
gun type and paint mix age
0
10
20
30
40
50
60
70
80
90
100
du dullness Wa 0,1-0,3mm Wb 0,3-1,0mm Wc 1-3mm Wd 3-10mm We 10-30mm
Wavescan Data as a Function of Paint Gun Type and Paint Mix Age
HVLP Gravity as Mix
HVLP Gravity Pot Life
HVLP Pressure as mix
HVLP Pressure Pot Life
Airspray Pressure as Mix
Airspray Pressure Pot Life
Airless, Air Assist as Mix
Airless, Air Assist Pot Life
Tension vs Spray Distance (36 in & 18 in.)
13.02
9.8810.09
8.39
7
8
9
10
11
12
13
14
18 inches 36 inches
Distance From Gun to Panel
Te
ns
ion Topcoat
Tension
PrimerTension
COPYRIGHT © 2010 THE BOEING COMPANY
Customers and industry continue to demand more quantitative measurement of appearance quality
• Currently most requirements are qualitative:
• “The film shall be uniform in appearance…”
• “It is acceptable to have a slight color variation…”
• “Cosmetic defects and features shall not detract from the
overall appearance of the detail part or assembly…”
• Some quantitative appearance requirements exist:
• 60° Gloss
• Waviness
• Color match to standard (“non-decorative” areas)
• Currently studying additional quantitative measurements:
• Orange peel
• Color (decorative areas and special effects coatings)
• 20° gloss (more sensitive for high gloss coatings)
COPYRIGHT © 2010 THE BOEING COMPANY
Each layer of exterior paint system requires unique appearance quality controls
• Need measurement and control at all levels of part
completion
• Substrate (metal or composite)
• Fillers and surfacers
• Primers and other undercoats
• Final topcoat (urethane monocoats, special effects coatings,
clear coats)
• Potential defects specific to layer
• Composite: pits, pinholes, roughness, waviness, resin
starvation…
• Primers and topcoats: blisters, contamination, cracking,
craters, crazing, drips, fish eyes, runs, sags, scratches,
seeding, solvent pop, wrinkles, overspray, dry spray, mottling,
orange peel…
COPYRIGHT © 2010 THE BOEING COMPANY
Future challenges require on-going development commitment – Wish List
• Measurement of composite texture (“weave”)
prior to paint application
• Local shape measurement (depressions,
waviness)
• Quantitative measurement of pits and pinholes in
composites (unpainted, primed and enameled)
• Quantitative measurement of particle
contamination in enamels and primers
COPYRIGHT © 2010 THE BOEING COMPANY
Wish List Continued • Wish List:
• Orange peel measurements on
very “peely” surfaces
• Mica and special effect coatings appearance characterization
• Strategy for establishing orange peel requirements for huge palette (hundreds) of customer colors
• What combination of Wavescan parameters best correlates with customer perception of quality finish?
• Paint thickness measurement on composites
• Stand off measurements of color and gloss
COPYRIGHT © 2010 THE BOEING COMPANY
Questions Questions ?
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