Straight Up Paint: MRO Links Digital Extra

Let Robots Handle It

Aviolanda, an MRO cluster located in The Netherlands, engaged with with the Dutch company Large Robotic (LR) Systems in 2015. LR Systems is creating the world's largest robot that removes paint from commercial and military aircraft. Construction for the system is to end in 2016, and production will start at the end of the third quarter 2017. A preproduction version of the high-powered laser stripping system is located at LR Systems' testlab in San Antonio, Texas. The first series model will be demonstrated at the beginning of 2017.

Dip Into The Process

PPG Aerospace introduced Aerocron electrocoat primer this year. The primer, SAE AMS3144 qualified, is a water based, chrome-free primer system for aircraft that reduces waste of excess paint. The process includes two rinse tanks and an electrocoat dip tank. This process is used to coat parts, which eventually reduces the weight of aircraft by reducing the excess material.

Weight Reduction Means Savings

Aerocron has a transfer efficiency of 95%, whereas typical transfer efficiencies can hover between 30-70%. The electorcoat process provides a uniform film thickness across the entire aircraft, evens holes and reduces weight savings by up to 75%. For example, a narrowbody aircraft can see a 300-650 lb. reduction in weight.

Non-Agressive Blasting Of Surfaces

Aerolyte equipment and facilities, manufactured by Clemco Industries, is used by commercial operations to non-aggressively remove aircraft coatings, specialized paint, plastics and adhesives. The technology uses plastic, starch, baking soda or even walnut shells to remove coatings in a safe way, avoiding toxic substances or hazardous material to chemically remove the existing coating or paint. The equipment within the system includes dry strip cabinets, pre-assembed dry strip rooms or upgrades to existing rooms for the dry strip process.

Curing Technology

AeroWing infrared emitters use wide spectrum infrared emissions and work at lower temperatures, making it safer for operators and other materials around the curing area. The technology fully penetrates through the material surface, unlike heat lamps and hot air curing methods that create trapped bubbles, and cures up to 40 times faster than ambient light. Including fully automated cure cycles, temperature regulation, data export and safety monitoring from a touch screen interface, electric emitters come in various shapes of mounts and fixtures for portable and stationed productions.

It’s All In The Decals

Color Craft creates, designs and manufactures decals, graphics and labeling products for many industries, including aerospace. Color Craft President Doug Stewart says that there’s been an increasing demand from Boeing and other air carriers to directly use its products for broader marketing initiatives.

Recent projects include an ANA Boeing 787-9 that had a contact to installation timeline of less than two weeks, the largest decal installation to date of a Boeing 747-8 Freighter for Cargolux's 45th anniversary of operations, and a continued delivery of aircraft with unique and vibrant tail art for Air India Express.

Set Up For Success

During Aviation Week's MRO Americas in April, Sherwin Williams announced a new product: JCX Polyester Urethane. The coating, designed for commercial aircraft, features faster drying times and comes in a 2:1:1 pre-packed kit. It meets AMS-3095 performance requirements, provides chemical resistance to Skydrol and other hydraulic fluids, is lead-free and contains less than 3.5 lb./gal. VOC (volatile organic compound).

Sherwin Williams has been working with Dean Baldwin and Leading Edge through the testing process. Julie Voisin, global product manager for aerospace coatings and Sherwin Williams, says that working with customers to approve the process can take up to two years. During the testing, small panels then small areas of the aircraft are painted before an complete paint process is complete. The chemists and technical service representatives are in constant communication to understand the conditions and factors that weigh into the right application process.

The Paint Job In A Different Light

Logo lights exist to illuminate the aircraft company’s logo and make the airplane more visible. Lufthansa Technik developed a logo light protector that helps prevent GFRP (glass-fiber reinforced plastic) surface layer damage that can occur during removal of the sealant, as well as minimize erosion. The protector is a metal ring that is installed in and around the logo light cut-out, sitting between the cover of the light and protector without contact to the stabilizer. Already part of on Lufthansa Cargo’s 777 fleet maintenance, Lufthansa Technik’s Original Equipment Innovation Div. now offers the product to all 777 operators.

The Glossy Truth

A freshly painted Boeing 767 cagro aircraft is painted at Dean Baldwin's Roswell facility in New Mexico. According to Smith, vice president of business development for Dean Baldwin, "The photo illustrates the gloss values achieved when coatings are properly applied."

Dean Baldwin has five separate locations including corporate offices in Bulverde, Texas and in San Antonio; as well as facilities at Phoenix Goodyear airport location in Arizona, a new facility in Peru, Indiana, and one in Roswell, New Mexico. The Arizona, Indiana and New Mexico facilities offer full service operations and are approve FAA repair stations.

Sand, Wash, Continue

A Boeing 757 is wrapped and undergoes a composite sanding at Dean Baldwin's Indiana facility. After the sanding io remove unwanted materials is complete, the aircraft is washed and continues the coating process.

Ditching Pre-Treatment And Primer

AkzoNobel manufactures, develops and supplies coatings for commercial airline, general aviation and air defense markets. It developed its base coat/clear coat system with a focus on reducing drying times and bringing operational efficiency during the painting process. In February, KLM's Boeing 787-9 Dreamliner featured the base coat/clear coat in blue and white hues.