Chloe Zhang
Painting an aircraft is a complex process that requires specialised equipment and technical knowledge. Before applying any paint, the aircraft's surface must be thoroughly prepared to ensure proper adhesion and a smooth finish. This includes assessing and repairing any visible damage, wear and tear, and sanding or stripping the aircraft's existing coatings. Once the surface is ready, several layers of specialised coatings are applied, including a primer, a basecoat, and a topcoat. Each layer serves a specific function, such as protecting against corrosion or adding aesthetic livery. The painting process is time-consuming and requires precision to ensure the safety and efficiency of the aircraft.
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What You'll Learn
Sanding and stripping
To prepare plastic for painting, it is important to sand and strip the surface to ensure the paint adheres properly and the final product is long-lasting.
Firstly, it is crucial to clean the plastic thoroughly. This involves washing the plastic with soapy water and a sponge to remove any dirt or residue. For set-in stains, you can use rubbing alcohol, which should be left on the stain for 10 to 20 minutes before scrubbing and rinsing it away. After rinsing, the plastic should be dried completely for at least an hour.
Once the plastic is clean and dry, the sanding process can begin. Sanding is necessary to create a rough surface for the paint to adhere to, especially if the plastic has a shiny or glossy finish. It is recommended to use fine-grit sandpaper or a sanding block with light to medium pressure to sand down the entire surface, paying extra attention to shiny areas. If the plastic has curved surfaces or small crevices, sandpaper may be easier to manoeuvre than a sanding block. It is important to avoid using coarse or aggressive sandpaper, as this can damage the plastic. A better alternative is to use a grey abrasive pad with sanding paste, specifically designed for plastic scuffing. This will help lubricate the pad, prolong its life, and keep the surface clean during the process.
After sanding, it is essential to remove any dust or sand particles by washing the surface with water and a sponge. Any remaining particles can cause unwanted bumps in the final paint job. The plastic should then be dried again, either naturally or with the assistance of a fan in a well-ventilated area.
The final step in the sanding and stripping process is to apply an anti-static agent to the sanded surface, as plastic can easily accumulate static electricity, which attracts dust. This will help ensure a clean surface for painting.
By following these steps for sanding and stripping, you will effectively prepare the plastic surface for a successful paint job.
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Masking and sealing
The first step is to assess the aircraft's bodywork for any visible damage or wear and tear that needs to be repaired. All ducts are closed, and safety-sensitive equipment is protected before the entire craft is sealed up. This process can take up to two days for large carrier aircraft.
The aircraft is then stripped of its existing coatings. This can be done through sanding or using solvents. The aircraft's metal surfaces are sanded by hand using an electric orbital sander, such as Mirka's dust-free sanding system. This step ensures that the surface is smooth and ready for the new paint.
Once the aircraft is back to bare metal, a second inspection is performed to finalise any repair requirements, and the necessary repairs are made. All exposed fibreglass and plastic components are sanded smooth to ensure a uniform surface for the paint.
The next step is to mask and protect the aircraft's composite parts, such as windows, antennas, wheel fairings, and wingtips. A suitable protection film is applied to these areas to prevent any paint from getting on them. Fragile wing components also need heavy-duty protection, especially when the team climbs onto them to paint the fuselage above.
After the masking and sealing process is complete, the aircraft is ready for the painting process to begin.
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Applying primer bonding coat
Applying a primer bonding coat is a crucial step in the painting process, especially for aerospace applications. It is important to select the right type of primer for the specific project and materials being used.
Before applying the primer bonding coat, it is essential to prepare the surface thoroughly. This includes cleaning the aircraft components to remove any mould release, debris, or contaminants from the fabrication process. This can be done through a solvent bath and manual wiping. Additional pre-primer steps may include chemical etching and plasma treatment to further enhance the adhesion of the primer.
The application method of the primer bonding coat will depend on the specific project and surface being treated. Common application methods include brushing, spraying, and dipping.
- Brushing: Use a clean, soft-bristle brush to apply an even coat of primer. This method is suitable for small or intricate surfaces.
- Spraying: Utilise a spray gun or aerosol can to achieve a consistent layer of primer. This method is ideal for larger surfaces or when a smooth, even coat is required.
- Dipping: Submerge the substrate in the primer and slowly remove it, allowing excess primer to drip off. This ensures complete coverage of complex or irregular shapes.
It is crucial to follow the manufacturer's instructions for the specific primer being used, including allowing the recommended drying time before proceeding to the next step. The drying time can vary based on factors such as temperature, humidity, and primer thickness.
After the primer bonding coat has been applied and dried, the surface may require additional treatment, such as light sanding, to enhance adhesion. This step ensures that the final paint coat will adhere properly and result in a strong, durable finish.
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Anti-corrosion basecoat
Aircraft manufacturers design aeroplanes to prevent corrosion through the careful selection of structural materials and coatings. However, as aircraft age, corrosion becomes an increasingly common problem. As any metal object is inherently prone to corrosion, it is important to have a planned corrosion-control program in place for the complete service life of the aircraft.
Corrosion is the process of Mother Nature bringing an airplane back to its natural state. It is primarily caused by hostile environmental factors and climatic conditions. For example, airplanes operating in polluted industrial or saline coastal environments are susceptible to severe corrosion of their exposed surfaces. Water vapour, either alone or in combination with acidic constituents such as salts, fumes, or industrial pollutants, can initiate electrochemical reactions on the metallic surfaces of the aircraft, leading to corrosive deterioration.
To prevent corrosion, it is recommended to base the aircraft in a dry location, such as the Arizona desert near Tucson, where the Air Force mothballs its aircraft. Other preventative measures include hangaring, frequent washing, and regular treatment with corrosion inhibitors like ACF-50 (Aircraft Corrosion Formula 50). Removing corrosion is the only sure fix once it's found; light surface corrosion can be removed through abrasion, followed by the application of a corrosion inhibitor, primer, and then paint.
Additionally, specific areas of the aircraft are more prone to corrosion and require special attention. For example, the landing gear and wheel well areas are susceptible to corrosion due to exposure to water, salt, chemicals, and other corrosive substances. Joint sealants, such as polysulfide sealants, can be used to minimise crevice corrosion at joints.
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Livery topcoat
Painting an aircraft is a complex and challenging process that requires specialized skills and precision. Aircraft livery painting is a valuable service that transforms these assets into works of art. The livery is the most visible representation of an airline's brand, so it is essential that it looks amazing. The paint must be hard-wearing and flexible to cope with the loads on the aircraft's structure and must also withstand huge swings in temperature, from -55°C at cruise altitude to 40°C on the ground in hot climates. It also has to protect the aircraft from harsh UV light in the upper atmosphere.
The painting process involves several steps, including graphic concept and design, chemical and mechanical stripping or sanding, surface inspection, pre-treatment, and primer application. The primer is soft and sticky and aids the adhesion of the other coats while smoothing out the contours of the composite weave. The next three layers are applied in the paint shop and consist of the basecoat, the Andaro layer, and the clear coat. The basecoat will be silver for the main fuselage or salmon pink for the red bits, such as the engine covers, wing tips, and tailfin. The Andaro layer is a red and aubergine colour with a silver Mica coat and can take three to four coats of paint. The clear coat is the finishing touch that protects the paint and gives the aircraft a polished look.
The temperature and humidity in the hangar have a significant impact on the painting process. To ensure a first-class output, technical teams carefully examine all parts for likely damages, corrosion, and cracks during the painting process. Aircraft livery painting is a highly specialized service that demands expertise, innovative techniques, and a keen eye for detail to bring visual ideas and concepts to life.
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Frequently asked questions
The first step in painting an aircraft is to assess the bodywork for any visible damage, wear and tear that will need repairing before painting begins.
After the initial assessment, the aircraft is stripped of its existing coatings. This can be done through sanding or stripping with solvents.
After the aircraft is stripped of its existing coatings, all exposed fibreglass and plastic components are sanded smooth using an orbital sander.
