workmanship standard: l-3 gcs finished material · 2016-06-17 · 1000-0100-01 rev c may 19, 2016...

WORKMANSHIP STANDARD

L-3 GCS FINISHED MATERIAL

1000-0100-01 REV C

MAY 19, 2016

L-3 GCS, 7640 Omnitech Place, Victor, NY 14564

Use or disclosure of the data contained in this document is prohibited without prior written approval from L-3 GCS

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WORKMANSHIP STANDARD: L-3 GCS FINISHED MATERIAL

1.0 SCOPE:

To define the inspection characteristics, viewing/cosmetic criteria, and

acceptability of parts with applied finishes.

2.0 ORDER OF PRECEDENCE:

In the event of a conflict between the text of this document and the references

cited herein, the text of this document takes precedence. Nothing in this

document, however, supersedes applicable laws and regulations unless a specific

exemption has been obtained.

3.0 RELEVANT DEPARTMENTS:

This document applies to the Engineering, Purchasing, Receiving, Receiving

Inspection, Supplier QA and Production QA departments.

4.0 RESPONSIBILITY:

4.1 Engineering is responsible for selecting the appropriate finish for

purchased material. Applies to L-3, GCS custom designed material and

COTS material with custom or specific finishing requirements.

4.2 Quality is responsible for inspection of material to comply with the

engineering documentation and this document.

5.0 GENERAL GUIDELINES:

Finish can be for cosmetic purposes, corrosion protection, specific engineering

purpose (i.e.: electrical conductivity), or a combination thereof.

5.1 Plating or painting should be applied after all processing of the metal, such

as machining, brazing, welding, and forming.

5.2 Unless otherwise specified on the engineering drawings:

Part must be coated 100% on all surfaces, except where indicated.

Areas purposely left unfinished (masked) will be defined on the

drawing.

“Overspray” is not allowed except where indicated on the

engineering drawing.

Finish specifications may include L-3/GCS documents, military

specifications, or industry standard specifications (i.e.; ASTM).

Deviations from the engineering documentation must be approved

by engineering and quality in advance, in writing.



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6.0 TERMS AND DEFINITIONS:

6.1 PLATING

Plating is usually used for an engineering purpose, not for cosmetics.

Certain platings serve both an engineering purpose and double as a

cosmetic finish.

Chromate on aluminum (“iridite”, “alodine”) can be clear/colorless

or a shade of yellow. It is used for corrosion protection of the

aluminum and as a pretreatment for paint. Usually specified by a

mil spec which should include type and class. Presence of

chromate can be checked using a two part chemical test.

Black Oxide usually used on stainless steel. Only provides a minor

amount of corrosion protection, used more to make a part black in

color. The black color should not come off excessively when

handling parts. May sometimes have an oil post treatment, but

should not have an excess of oil. Can vary from brown to gray to

black. May be mottled and non-uniform in color.

Anodize is a non-conductive plating for aluminum which can be

dyed various colors (typically black). Provides corrosion

protection, cosmetics, and can be a wear resistant surface.

Zinc plating usually used as a corrosion protection for steel. Can be

dyed green (OD), blue or black for cosmetic uses.

Cadmium is a better corrosion protection for steel, however is

considered a hazardous substance and is heavily regulated. Can be

dyed black or green (OD) for cosmetics. Used on aluminum also,

typically on connector shells.

6.2 PAINT

Applied as a liquid, applied by spray, brush, or dip.

Color should be specified using a FED-STD-595 color number.

FED-STD-595 colors are sequential except for the first

digit which indicates gloss (1XXXXX is high gloss,

2XXXXX is semi gloss, and 3XXXXX is flat or

“lusterless”).

Use the approved sample color paint chips as a visual, if

not available please request.

Requires a primer – first refer to the notes on the print.

Color of primer may affect the final color or hue of the top

coat of paint.



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Metal substrates require a pretreatment before primer is

applied (i.e.: iridite on aluminum).

6.3 POWDER COAT

Similar to paint, but is a dry powder instead of a liquid.

More difficult to mask than “wet” paint.

May not require a primer.

Baked at a high temperature to cure.

6.4 E-COAT

Liquid paint, but applied using electricity similar to powder coat.

Applied in a dipping process

6.5 HYDROGRAPHIC

Pattern/color of ink applied through a proprietary process.

Process follows a clean/surface prep, primer application, ink stage,

then a top polyurethane coat for protection.

Typically used to apply a pattern, such as camouflage, to a surface.

See section 8.0 for surface definitions and allowable overwrap.

7.0 QUALITY/WORKMANSHIP REQUIREMENTS:

7.1 The base metal should be free from scratches, grind marks, inclusions,

pits, die or tool marks that will adversely affect the appearance and

performance of the applied coating (see Table 1).

7.2 Inspection, especially of blind holes, shall be done for residual plating

salts, excess paint, or other foreign material.

7.3 Finish shall have good adhesion:

7.3.01 A paint adhesion test shall be conducted and evaluated to ASTM

test method D3359‐B to a minimum score of 4B, unless otherwise

specified.

7.3.02 A tape adhesion test shall be conducted and evaluated to IPC-TM-

650, Test Method 2.4.28.1. All loose and non-adhering material

needs to be removed. See IPC-A-600

7.3.03 Tape Test - Can be inspected by applying a piece of 3M™ #2020

masking tape to the surface. Clean the surface as per L-3 GCS

standard 1000-0204-01, apply the tape, rub to remove any air

pockets, let stand for 30 seconds then remove tape by pulling back

on itself at an angle greater than 90⁰.



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7.3.04 Tape Test - Supplier shall perform tape adhesion test per lot.

Sample coupon should be noted with date code information for

traceability. Each batch should include coupon with shipment.

7.4 Free from visible imperfections:

7.4.01 Blisters/delamination in the form of a localized swelling and

separation between any of the layers of the coating.

7.4.02 Coating blisters/scratches/voids allow coating to flake in critical

assemblies after a tape test.

7.4.03 Pits, nodules, porosity, burning, excessive build up in holes or

edges, corrosive salts or other contaminants that expose base

material and are visible from a distance of 3 feet / arms length,

perpendicular to the finished surface. Use a 5 second viewing time.

7.4.04 Color should be inspected by comparison to a standard color

sample. If there is a question regarding color, take a part out doors

to view in natural sunlight.

7.4.05 Cosmetic finish on areas of the part or product that are in direct

view to the customer while operating, should be viewed from a

distance of 3 feet / arms length, perpendicular to the finished

surface. Use a 5 second viewing time.

7.4.06 Any defect or suspected defect seen can then be viewed at a closer

distance.

7.4.07 Racking marks are normal and allowed unless specified otherwise

on the drawing.

7.4.08 Care shall be taken to allow paint to be fully cured or packaged in

breathable material to allow it to cure in transit. Reference specific

paint specification for packaging.

8.0 SURFACE TYPE DEFINITIONS AND REQUIREMENTS:

8.1 “A” SURFACE:

8.1.01 No overspray/overwrap allowed. Primary viewing surface.

8.2 “B” SURFACE:

8.2.01 Minimal overspray/overwrap allowed. Secondary viewing surface.

8.3 “C” SURFACE:

8.3.01 Overspray/overwrap allowed. Surface is not in direct view.

Note: section 13 goes over Hydrographic related imperfections and per surface

allowances.



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9.0 VISUAL CRITERIA AND LIMITS:

As a general rule, the photos and descriptions in this document represent quality

requirements to be used on general product, with the exception being front panels,

indicator panels and switch panels as noted. Panels are to be viewed at a normal

operating position of a minimum of three feet. All visual outside surfaces such as

doors, doorframes, holding panels, skins and covers shall not exceed the

limitations of Table 1.

Painted surfaces shall comply with the color chip including other requirements

and have full paint coverage. Surfaces that, due to their position (inside, under or

on top of assemblies), are obscured or hidden from view while in normal

operating position shall not exceed the limitations of Table 1.

Table 1: Paint Flaw Limitations

Pits up to .04 in.

Diameter X .005 Deep

Foreign Particles up to

.03 High X .03 Long

Front panels, indicator

panels, switch panels, etc.

0

per square foot

2

per square foot

Doors, doorframes, holding

panels, skins, covers, etc.

2

per square foot

6

per square foot

Surfaces obscured from view

in normal operating position.

6

per square foot

12

per square foot

Table 2: Measurable Paint Criteria

Gloss Level For gloss requirements, reference the mil spec. or other specified

gloss requirement.

Paint Color Standard: ± 5% off the FED-STD-595 color chip or other specified

color requirement, as measured by the Spectrophotometer.

10.0 TARGET QUALITY/WORKMANSHIP:

The following are objectives for finished material:

Smooth, uniform, continuous film free of blisters, chips, fisheyes,

pinholes, runs, sags, scratches, wrinkling or foreign particles.

Color matches specified color chip.

Paint meets specified gloss requirements.

Sample objective finishes:



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11.0 ACCEPTABLE IMPERFECTIONS:

Acceptable

Impressions in the paint

that have not

compromised the finish

(paint is firm and does

not lift from the

substrate) are acceptable

except on front panels.

Acceptable

A visible texture, unlike

wrinkling and orange

peel.



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Acceptable

A color difference within the

acceptable range measured by the

Spectrophotometer, though visible to

the naked eye. See Table 2.

Acceptable

Marring and surface lightening due

to handling is, characteristic of

Chemical Agent Resistant Coatings.



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Acceptable

Paint on moving parts (handles,

hinges, etc) made of stainless steel or

other non-corrosive material may be

scraped or chipped.

Acceptable

See Table 1 for acceptable FOD

criteria.



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Acceptable

Marking may be built up

outside the line of a

character providing the

character is legible.

Missing marking is not

more than 10% of the

character.

Lines of a number or letter

may be broken (or thin

over a portion of the

character).



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12.0 UNACCEPTABLE IMPERFECTIONS:

Defect

Paint peeled or chipped

away from the substrate.

Defect

A raised area of paint that

resembles a small bubble

or blister.



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Defect

Chipped paint exposing

primer or substrate

material.

Defect

Where final paint film is

required, primer or bare

substrate material is

exposed.



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Defect

Fisheyes or crater-like

circular areas that may vary

in size and sometimes

expose the underlying

substrate.

Defect

Excessive FOD, See criteria

in Table 1.



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Defect

Fingerprints, bubblewrap, and other

impressions when visible on front panels.

`

Defect

A uniform rippled appearance that resembles

the peel of an orange.

(Photo also shows pinholes,reference criteria

in Table 1.)



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Defect

Paint film is rough and uneven,

possibly with tiny specks of color

other than the appropriate finish as a

result of overspray.

Defect

Pinholes in the paint that appear as

small craters or holes. Bottom of

crater not visible.



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Defect

Runs that appear as drips or tears of

paint mainly on vertical surfaces.

Defect

A sag in the paint that appears draped

onto the surface, like curtains.



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Defect

Surface scratches on a front

panel or similar item that do

not expose the underlying

substrate.

Defect

Scratches or marks in the

paint that expose the

underlying substrate.



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Defect

Solvent popping or bubbles that are

generally clear and appear on the

surface of the paint film.

Defect

Uncured paint is tacky and malleable

and may contain impressions.

NOTE: The difference between

uncured paint and simple impressions

is that uncured paint will not be firm to

the touch.



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Defect

Multiple images.



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13.0 HYDROGRAPHIC ACCEPTABLE/UNACCEPTABLE IMPERFECTIONS

Imperfection Type

Pattern overwrap.

Surface A:

Unacceptable

Surface B:

Small amount (shown)

acceptable

Surface C:

Acceptable

Imperfection Type

Cracked pattern.

Surface A:

Unacceptable

Surface B:

Unacceptable

Surface C:

Unacceptable



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Imperfection Type

Inconsistent pattern.

Surface A:

Unacceptable

Surface B:

Unacceptable

Surface C:


acceptable

Imperfection Type

Areas of minimal pattern

coverage.

Surface A:

Unacceptable

Surface B:


acceptable in areas expected

to not get sufficient coverage,

such as a heatsink.

Surface C:

Acceptable

workmanship standard: l-3 gcs finished material · 2016-06-17 · 1000-0100-01 rev c may 19, 2016...

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