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Home | Update | LATEST ISSUE | Gallery | FR Profile | Datafiles | FR 1/98 PROTECTIVE FILMS TO REPLACE PAINT? by Karl Schwarz Together with 3M, Boeing and Lockheed Martin are evaluating the potential of replacing paint by adhesive films. Up to 90 percent of all dangerous materials that are generated in the service-life on an aircraft, come from painting or stripping the fuselage. Furthermore, while painting or stripping the paint, it is not possible to accomplish other work on the aircraft and, paint jobs have the tendency to become heavier over the time due to permanent repairs. The use of adhesive films would omit these disadvantages. They can be applied by hand and are possibly lighter and more durable than paint. They are supposed to even offer a better corrosion protection than paint does. Once weared out, they can simply be pulled off. The question remains open, however, if the films are able to cope with the permanent strain from harsh flight operations. They need to withstand high speeds, enormous temperature fluctuations, sun radiation, salt water, oil and fuel residues, as well as scratches. Before possibly using the films with future programs, such as the Joint Strike Fighter, Boeing and Lockheed Martin are running test programs. Both companies are working together with 3M. The money for the tests comes from the JSF paintless aircraft programme (Boeing) and from the National Institute of Standards (Lockheed Martin). Following some preliminary work in the laboratory, several of the coatings were already tested in-flight. Boeing, for example, covered 95 percent of an F-18D of the Naval Air Test Center in Patuxent River in the fall of 1996. More than 400 pieces of film were applied. These can be cut individually from existing CATIA data. Meanwhile, the Hornet has accomplished more than 100 flight hours, some of which were in the supersonic speed region. According to Boeing, the experiences were good, the maintenance effort is being reduced. The F-18D is supposed to fly for a total of two years with the foil, including some aircraft carrier operations. Lockheed Martin has used a variety of aircraft for its applique trials, among them: a S-3 Viking of the VS-32 Navy squadron form Cecil Field (Florida) which is flying with the films since April of 1997. Approximately the aft third of the aircraft is covered with the films and they have already been changed once. a F-16 Fighting Falcon, the tail of which is partially covered with films. The aircraft has so far accomplished 35 flight hours, partially supersonic. another F-16 that was covered with plastic film on its entire upper surface. The aircraft was flight tested at Edwards AFB. a third F-16 which uses a external fuel tank that is covered with the appliques. a US Air Force C-130E Hercules. The forward fuselage area of this aircraft was covered with approximately 150 square meters of film. It is the first test with an aircraft that has a pressurized fuselage. An entirely film covered Hercules is scheduled for flight tests beginning in February of 1998. If the adhesives demonstrate their reliability in the difficult military flight operations, Lockheed does see some civil applications. Possibly at the end of 1998 or at the beginning of 1999, the company plans to apply the films to an airliner. From page 56 of FLUG REVUE 1/98 Home | Update | LATEST ISSUE | Gallery | FR Profile | Datafiles | FR 1/98 Copyright 1997/98 by Motor-Presse Stuttgart. All rights reserved. Last updated December 5, 1997 FLUG REVUE, Ubierstr. 83, 53173 Bonn, Germany