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WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 1 of 18 REV A
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.
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 2 of 18 REV A
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.
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 3 of 18 REV A
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.
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 tape to the surface, rub to remove any air pockets, and remove tape by pulling back on itself at 180⁰.
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
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 4 of 18 REV A
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 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
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 5 of 18 REV A
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.
9.0 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:
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 6 of 18 REV A
10.0 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.
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 7 of 18 REV A
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.
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 8 of 18 REV A
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.
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 9 of 18 REV A
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).
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 10 of 18 REV A
11.0 UNACCEPTABLE IMPERFECTIONS:
Defect Paint peeled or chipped away from the substrate.
Defect A raised area of paint that resembles a small bubble or blister.
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 11 of 18 REV A
Defect Chipped paint exposing primer or substrate material.
Defect
Where final paint film is required, primer or bare substrate material is exposed.
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 12 of 18 REV A
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.
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 13 of 18 REV A
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.)
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 14 of 18 REV A
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.
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 15 of 18 REV A
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.
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 16 of 18 REV A
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.
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 17 of 18 REV A
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.
WORKMANSHIP STANDARD L-3 GCS FINISHED MATERIAL
1000-0100-01 REV A AUG 19, 2013
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
1000-0100-01 Page 18 of 18 REV A
Defect Multiple images.